1997 MAZDA MX-5 Factory Repair Manual

See REAR AXLE SHAFTS & BEARINGS.
2. Remove ABS wheel speed sensor. Mark drive shaft and differential carrier flanges for reassembly
reference and remove drive shaft from differential carrier. Remove differential carrier-to-housing bolts.
Remove differential carrier.
Installation
To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during
removal. Refill differential with lubricant. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS .
Removal (Miata)
1. Raise and support vehicle. Remove wheel and tire assembly. Drain differential. Remove differential
mounting pipe. Remove exhaust pipe. Mark drive shaft and differential carrier flanges for reassembly
reference and remove drive shaft from differential carrier. See Fig. 7
. Disconnect speedometer cable
from transmission. Notin
g locations, disconnect wiring harness from Power Plant Frame (PPF).

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 11 © 2005 Mitchell Repair Information Company, LLC.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 7: Exploded View Of Differential Components (Miata)
Courtesy of MAZDA MOTORS CORP.
2. Support transmission using a jack. Remove PPF bracket from rear transmission extension housing (M/T
only). Remove PPF-to-differential side bolts. Pry out spacer. Remove PPF/differential mounting spacer.
See Fig. 8
. Install bolt (M14 X 1.5) into sleeve. See Fig. 9 .
3. Twist bolt from side to side while pulling it downward. Install a metric bolt (M6 X 1) into hole in housing
block to hold sleeve and remove long bolt (M14 X 1.5). Remove short bolt (M6 X 1).
4. Remove PPF-to-transmission side bolts and remove PPF. Remove caliper assembly. Remove lower arm
bolt. Mark and disconnect CV joint axle shafts from differential assembly, and support aside.
5. Support differential assembly and remove differential-to-chassis mounting nuts. Remove differential from
vehicle. Remove drive axle output shafts from carrier. Remove differential carrier-to-housing bolts.
Remove differential carrier.
Fig. 8: View Of Power Plant Frame (PPF) Components (Miata)

Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Removing Reamer Bolt Sleeve (Miata)
Courtesy of MAZDA MOTORS CORP.
Installation
1. To install, reverse removal procedure. Apply sealant to carrier mating flange. Align marks made during
removal and install axle shafts. Install differential. Raise transmission until engine and transmission are
level.
2. Position Power Plant Frame (PPF) in place. Install PPF/differential mounting spacer. Tighten bolts to 27-
38 ft. lbs. (37-52 N.m). Install and tighten PPF-to-transmission side mounting bolts.
3. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed
into front hole and tighten bolt. See Fig. 8
.
4. Install transmission-to-PPF bracket (M/T only). Install remaining PPF bolts. Refill differential with
NOTE: Front PPF-to-differential side mounting bolt is reamer bolt which aligns
PPF. See Fig. 8
.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 14 © 2005 Mitchell Repair Information Company, LLC.

lubricant. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedure.
OVERHAUL
DIFFERENTIAL
Disassembly (Standard Type)
1. Mount carrier in Differential Carrier Hanger (49-M005-561). Mark side bearing caps for reassembly
reference. Remove adjuster lock plates (if equipped). See Fig. 10
.
2. Loosen side bearing cap bolts and slightly back off adjusters. Remove side bearing caps. Remove
differential assembly from carrier. Mark side bearing races for reassembly reference. Remove adjusters
and side bearing races from differential.
3. Remove drive pinion lock nut and washer. Remove companion flange using Puller (49-0839-425C).
Remove oil seal, spacer, front bearing and collapsible spacer from carrier. Remove drive pinion, spacer
and rear bearing assembly from carrier. Remove bearing races using a drift and hammer in slots provided
on inner lip (as necessary).
4. Remove ring gear retaining bolts. Separate ring gear from differential case. Mark side bearings for
reassembly reference. Using Puller (49-0839-425C), remove side bearings from differential case. Remove
knock pin. Remove pinion shaft, pinion
gears, thrust washers, and side gears. See Fig. 10. NOTE: Mark positions of all components before disassembly.
NOTE: Overhaul procedure for Limited Slip Differential (LSD) is not available.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Exploded View Of Standard Differential & Carrier Assembly
Courtesy of MAZDA MOTORS CORP.
Reassembly & Adjustment (Standard Type)
1. Install side gears, thrust washers, pinion gears and pinion shaft. Position dial indicator against pinion
gear. See Fig. 11 . Secure one side gear.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Measuring Side Gear & Pinion Gear Backlash
Courtesy of MAZDA MOTORS CORP.
2. Check side gear and pinion gear backlash. If backlash exceeds .004" (.10 mm), replace thrust washers.
See THRUST WASHER SPECIFICATIONS
table. Install and stake knock pin. Noting marks made
during disassembly, press side bearings onto differential assembly using Bearing Installer (49-G030-338
or 49-UB71-525) and Body (49-F401-331).
THRUST WASHER SPECIFICATIONS
3. Apply locking compound to rear face of ring gear. Install ring gear and tighten ring gear retaining bolts to
51-61 ft. lbs. (69-83 N.m). Using appropriate bearing installer set and press, install drive pinion bearing
races into differential carrier.
4. Put original spacer, rear bearing and Collar (49-H027-001) on Dummy Drive Pinion (49-8531-565). See
Fig. 12
. Secure collar with "O" ring. Install assembly into differential carrier.
Identifying MarkThickness - In. (mm)
0.0787 (2.000)
05.0807 (2.050)
1.0827 (2.100)
15.0846 (2.150)
2.0866 (2.200)

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:52:42 PMPage 17 © 2005 Mitchell Repair Information Company, LLC.

5. Install front bearing and collar on dummy drive pinion. See COLLAR SELECTION table. Install
companion flange, washer and original drive pinion lock nut. Tighten drive pinion lock nut so dummy
drive pinion assembly can be turned by hand.
COLLAR SELECTION
ApplicationCollar No.
Miata49-8531-567
MPV49-U027-001

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
Microsoft
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