1994 MAZDA MX-5 Workshop Manual

FRONT SUSPENSION (DOUBLE-WISHBONE) R Disassembly I Inspection I Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of disassembly, referring to Assembly Note. 4. Tighten all nuts and bolts to the specified torques, referring to the figure. (FRONT ONLY) & 3 1. Sheet (front only) 2. Cap 3. Mounting plate 4. Bound stopper lnspect for damage 5. Coil spring .......... Disassembly Note page R-13 ............ Assembly Note page R-14 6. Shock absorber lnspect for oil leakage and abnormal noise Disassembly note Coil spring Warning Removing the coil spring nut is dangerous. The shock absorber and spring could fly off under tre- mendous pressure and cause serious injury or death. Secure the shock absorber in the SST before removing the coil spring nut. 1. Loosen the piston rod upper nut several turns, but do not remove the nut. 2. Assemble the SST. 3. Compress the coil spring with the SST, and remove the upper nut. 4. Remove the coil spring. Gartner Banana

I3 FRONT SUSPENSION (DOUBLE-WISHBONE) I t'- SHOCK ABSORBER 05UORX-02 Inspection Shock absorber Check the following and replace if necessary. 1. lnspect for damage and oil leakage. 2. lnspect the rubber bushing for deterioration and wear. 3. Compress and extend the shock piston at least three (3) times. Verify that the operational force does not change and that there is no unusual noise. 4. (1) Compress the shock absorber piston and release it. (2) Verify that the piston extends fully at a normal speed. Assembly note Coil spring and bound stopper 1. Set the shock absorber in a vise. 2. Install the bound stopper on the shock absorber as shown. 3. lnstall the compressed coil spring (compressed with SST). 4. Install the mounting plate. 5. Tighten the mounting plate nut, but do not torque it yet. 6. Remove the SST. 7. Secure the mounting plate in a vise. 8. Tighten the piston rod upper nut. Tightening torque: 30-36 N.m (3.0-3.7 kgf.m, 22-26 ftdbf) Disposal of shock absorber Caution The gas in the shock absorber is color less, order less, and non-toxic. Wear safety glasses as drilling chips may be expelled by the pressurized gas. 1. Lay the shock absorber flat. 2. Drill a hole in the shock absorber body. Drill size: 2-3mm (0.08-0.11 in). 3. Allow the gas to escape from the shock absorber. 4. Discard the shock absorber. Gartner Banana

FRONT SUSPENSION (DOUBLE-WISHBONE) LOWER ARM Removal / lnspection I Installation 1. Jack up the front of the vehicle and support it with safety stands. 2. Remove the undercover. 3. Remove in the order shown in the figure, referring to Removal Note. 4. lnspect all parts and repair or replace as necessary. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. Loosely tighten the lower arm, shock absorber, and stabilizer control link bolts. Tighten all other nuts and bolts to the specified torque with the vehicle unladen. 7. Lower the vehicle. 8. With the vehicle unloaded, tighten the lower arm, shock absorber, and stabilizer control link bolts to the - specified torques. 9. Adjust the front wheel alignment. (Refer to page R-6.) 1. Wheel and tire 15UORX-012 5. Ball joint dust boot 2. Stabilizer control link bolt emo oval ~ote ............. page R-16 3. Shock absorber bolt Installation Note ........... page R-16 u 4. Lower arm ball joint 6. Lower arm Removal Note ............. page R-16 Inspect for damage and cracks Inspection ................. page R-16 7. Lower arm bushing (front and rear) lnspect for deterioration and wear Gartner Banana

FRONT SUSPENSION (DOUBLE-WISHBONE) Removal note Lower arm ball joint Separate the ball joint from the knuckle with the SST. ./-' Ball joint dust boot Carefully remove the dust boot with a chisel. Installation note Ball joint dust boot 1. Wipe away the grease on the ball joint. 2. Liberally coat the inside of the new dust boot with grease. 3. Press the dust boot onto the ball joint with the SST. J 4. Wipe away any grease that has been expelled from the dust boot. Inspection Lower arm ball joint Ball joint rotation torque 1. Shake the ball joint stud 5 times. 2. Connect the SST to the ball stud, and measure the rota- tion torque with a pull scale. Rotation torque: 0.5-1.4 N.m (5--15 kgf.cm, 4.4--13 in-lbf) Pull scale reading: 5.b14.7 N (0.5-1.5 kgf, 1.1-3.3 Ibf) Gartner Banana

FRONT SUSPENSION (DOUBLE-WISHBONE) R UPPER ARM Removal I Inspection I Installation 1. Jack up the front of the vehicle and support it with safety stands. L/ 2. Remove the undercover. 3. Remove the band for the wheel speed sensor harness. 4. Remove in the order shown in the figure, referring to Removal Note. 5. lnspect all parts and repair or replace as necessary. 6. Install in the reverse order of removal, referring to Installation Note. 7. Loosely tighten the upper arm and shock absorber bolts. Tighten all other nuts and bolts to the specified torques. 8. Install the band for the wheel speed sensor harnes. 9. Lower the vehicle. 10. With the vehicle unloaded, tighten the upper arm and shock absorber bolts to the specified torques. 11. Adjust the front wheel alignment. (Refer to page R-6.) 25UORX-01 1. Wheel and tire 5, Ball ioint dust boot Upper arm ball joint demoval ~ote ............. page R-18 Removal Note ............. page R-18 Installation Note ........... page R-18 Shock absorber bolt 6. Upper arm bushing (front and rear) 4. Upper arm Inspect for deterioration and damage Inspect for damage and cracks Gartner Banana

R FRONT SUSPENSION (DOUBLE-WISHBONE) I0.04 in} Removal note Upper arm ball joint Separate the upper arm ball joint from the knuckle with the SST. Ball joint dust boot Carefully remove the dust boot with a chisel. Installation note Ball joint dust boot 1. Liberally coat the inside of the new dust boot with grease. 2. Press the dust boot on with a 30mm (1 118 in) socket until the dust boot contacts the seat. Caution Install the dust boot squarely and do not press excessively; the inner metal ring will be deformed if not done correctly. 3. Verify that the clearance between the boot and the seat is less than 1mm (0.04 in). Inspection Upper arm ball joint Ball joint rotation torque 1. Shake the ball joint stud 5 times. 2. Connect the SST to the ball stud, and measure the rota- tion torque with a pull scale. Rotation torque: O.4--1.7 N.m {&-I 8 kgf.cm, 3.5--15.6 in4 bf) Pull scale reading: 4.b17.6 N (0.4--1.8 kgf, 0.9--3.9 Ibf) Gartner Banana

FRONT SUSPENSION (DOUBLE-WISHBONE) R STABILIZER Removal / Inspection / installation 1. Jack up the front of the vehicle and support it with safety stands. - 2. Remove the undercover. 3. Remove in the order shown in the figure. 4. lnspect all parts and repair or replace as necessary. 5. Install in the reverse order of removal, referring to Installation Note. 6. Loosely tighten the stabilizer control link and bracket bolts. Tighten all other nuts and bolts to the speci- fied torques. - 7. Lower the vehicle. 8. With the vehicle unloaded, tighten the stabilizer control link and bolts to the specified torques. 1. Stabilizer bracket 3. Stabilizer 2. Stabilizer bushing Inspect for bending and damage Inspect for deterioration and wear 4. Stabilizer control link Installation Note . . . . . . . . . . . . . . . . R-19 Inspect for bending and damage Installation note Align the bushing with the installation mark on the stabi- lizer. Gartner Banana

FRONT SUSPENSION (DOUBLE-WISHBONE) CROSSMEMBER Removal I Inspection 1 lnstallation Note 4 Use a container or rags to collect the power steering fluid when disconnecting the power steering pipes. 1. Jack up the vehicle. 2. Remove the wheels and the undercover. 3. Support the engine with a hoist. 4. Lower the crossmember and other suspension parts as an assembly, and then separate the parts. 5. Remove in the order shown in the figure. 6. lnspect all parts and repair or replace as necessary. 7. Loosely tighten the stabilizer bracket, upper arm, and lower arm bolts. Tighten all other nuts and bolts to the specified torques. 8. Lower the vehicle. 9. With the vehicle unloaded, tighten the stabilizer bracket, upper arm, and lower arm bolts to the specified torques. 10. Adjust the front wheel alignment. (Refer to page R-6.) 11. Bleed the air from the brake system. (Refer to section P.) 12. Bleed the air from the Power Steering System. (Refer to section N.) Q - re-no ~L1.3--11.W, Okl-m} 94-1;2 (9.Cll.5,69--83) 1 &26 {1.&2.7,14--19) 1 S21 (1 3-- 1. Brake pipe Removal / lnstallation . . . . . . . . . Section P 2. Pinion shaft bolt Removal / lnstallation . . . . . . . . Section N 3. Power steering pipe Removal 1 lnstallation . . . . . . . . Section N 4. Shock absorber bolt 5. Stabilizer bracket bolt 6. Upper arm bolt 7. Performance rod 8. Adjusting cam bolt 9. Steering gear bracket bolt 10. Front crossmember assembly lnspect for damage Gartner Banana