1994 MAZDA MX-5 Workshop Manual

M DIFFERENTIAL 49 DO1 7 2A1 Installer set, bearing 49 F401 331 Body (Part of 49 DO17 2A1) 49 GO30 338 Attachment E (Part of 49 DO1 7 2A1) Puller set, bearing 49 0259 720 Wrench, differential side bearing adjusting nut For installation of bearing For installation of bearing inner race (rear bearing) For installation of bearing inner race (side bearing) For removal and installation of companion flange For adjustment of drive pinion and ring gear backlash 49 F401 337A Attachment C (Part of 49 DO17 2A1) Holder, main shaft Holder, coupling flange 49 U027 003 Installer, oil seal For installation of bearing inner race (rear bearing) For prevention of oil leakage For removal and installation of companion flange For installation of oil seal (companion flange) Gartner Banana

DIFFERENTIAL M DIFFERENTIAL OIL Inspection 1. Remove the filler plug. 2. Verify that the oil is at the bottom of the filler plug hole. If it is low, add the specified oil. 3. Install the filler plug. Tightening torque: 39-54 N.m (4.0-5.5 kgf.m, 29-40 ft4bf) Replacement 1. Remove the filler and drain plugs. 2. Drain the differential oil into a suitable container. 3. Wipe the plugs clean. 4. Install the drain plug and a new washer. Tightening torque: 39-54 N.m (4.0-5.5 kgf-m, 29-40 ft4bf) 5. Add the specified oil from the filler plug until the level reaches the bottom of the plug hole. Specified oil TY pe Above -18°C (0°F): API GL-5, SAE 90 Below -18°C (0°F): API GL-5, SAE 80 Capacity: 1 .OO L {I .06 US qt, 0.88 Imp qt) 6. lnstall the filler plug. Tightening torque: 39-54 N.m (4.0-5.5 kgf.m, 29--40 ft.lbf) OIL SEAL (OUTPUT SHAFT) Replacement 1. On level ground, Jack up the vehicle and support it on safety stands. 2. Drain the differential gear oil. 3. Mark the drive shaft and output shaft flanges for proper reassembly. 4. Remove the upper arm installation bolt and nut. Gartner Banana

M DIFFERENTIAL 5. Separate the driveshaft from the differential and sus- pend it. 6. Remove the output shaft by using two pry bars as shown in the figure. J 7. Remove the oil seal. 8. Apply lithium-based grease to the new oil seal lip and install it by using'the SST. 9. Install the new clips. 10. Install the output shaft into the side gears by lightly tap- ping with a plastic hammer. 11. Verify that the output shaft is hooked into the side gears by pulling it by hand. ./ 12. Align the marks and install the drive shaft. Tightening torque: 54-64 N.m (5.5--6.5 kgf.m, 40-47 ft-lbf) 13. Install the upper arm installation bolt and nut. Tightening torque: 46-67 N.m (4.7-6.8 kgf.m, 34--49 ftlbf) 14. Add the specified oil. 15. Adjust the rear wheel alignment. (Refer to section R.) I Gartner Banana

DIFFERENTIAL M DIFFERENTIAL, STANDARD; DIFFERENTIAL, TORQUE SENSING LIMITED SLIP ("TORSEN" LSD) Removal 1 lnstallation 1. Drain the differential oil. ,, 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Add the specified oil to the specified level. 1. Rear wheels 7. Drive shafts 2. Differential mounting pipe Removal Note ............. page M-29 3. Exhaust pipe 8. Differential 4. Propeller shaft Removal Note ............. page M-29 Service ..................... section L Installation Note ........... page M-30 ' 5. Speedometer cable Overhaul .................. page M-32 ,, 6. Power plant frame (PPF), Differential mounting spacer Removal Note ............. page M-28 Installation Note ........... page M-30 Gartner Banana

M DIFFERENTIAL SLEEVE BLOCK BOLT (MI 4 x 1.5) dl Removal note Power plant frame (PPF) 1. Disconnect the wire harness from the PPF. 2. Support the transmission with a jack. 3. Remove the power plant frame bracket. (Manual trans- mission) 4. Remove the differential-side bolts, and pry out the spacer. 5. Remove the differential mounting spacer. 6. Turn a bolt (MI4 x 1.5) into the sleeve. 7. Twist and pull the bolt downward. 8. Install a bolt (M6 x 1) into the hole in the block to hold the sleeve, and remove the long bolt (MI4 x 1.5). 9. Remove the bolt ,(M6 x 1). Gartner Banana

DIFFERENTIAL M t- 900mm (35.43 in) 10. Remove the transmission-side bolts, and remove the PPF. Do not remove the spacers from the PPF. If they are removed, replace the PPF as an assembly. Drive shaft Mark the drive shaft and output shaft for proper installa- tion. Differential 1. Support the differential with a jack. 2. Lower the differential and move it forward. Note If the drive shaft will not separate easily from the out- put shaft, remove a bolt and nut from one side of the upper arm. 3. Separate the driveshaft from the output shaft. 4. To prevent damaging the fire wall, crank angle sensor, and engine mount, support the transmission as follows. (1) Prepare a steel plate (as shown in the figure), a wooden block, bolts (M8 x 1.25), and washers. (2) Install the parts as shown in the figure. Gartner Banana

M DIFFERENTIAL Installation note Differential 1. Connect the drive shaft to the output shaft with the marks aligned. 2. Install the differential. - JOMX- Tightening torque 0: 83-98 N-m (8.5-10 kgf.m, 61-72 ft4bf) @I: 18-26 N.m (1.8-2.7 kgf.m, 13-20 ft.lbf) 3. Adjust the rear wheel alignment if the upper arm installa- tion bolt and nut were removed. (section R.) Power plant frame (PPF) 1. Install the differential mounting spacer. Tightening torque: 37-52 N-m (3.8-5.3 kgf.m, 27-38 ftdbf} .i 2. Support the transmission with a jack so that it is level. 3. Position the PPF and snugly tighten the transmission- side bolts by hand. 4. Verify that the sleeve is installed into the block. 5. Install the spacer and bolts and snugly tighten them. The reamer bolt should be installed in the forward hole. 6. Snugly install the power plant frame bracket. 7. Tighten the transmission-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft4bf) Gartner Banana

DIFFERENTIAL M 8. Tighten the differential-side bolts. Tightening torque: lO4--123 N.m (1 0.6-1 2.6 kgf.m, 77-91 ft~lbf) 9. Install the power plant frame bracket. (Manual transmis- sion) Tightening torque 0: 104-123 N-m (10.6-12.6 kgf.m, 77-91 ftlbf) 0: 36-54 N.m I3.7--5.5 kgf-m, 2740 ft-lbf) 10. Remove the jack, and connect the wire harness. Gartner Banana