1997 MAZDA MX-5 Factory Repair Manual

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 19 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Checking Drive Pinion Installation & Position
Courtesy of MAZDA MOTORS CORP.
6. Install dial indicator on Pinion Height Gauge (49-0727-570). Place pinion height gauge on a flat surface
and zero dial indicator. Position gauge block on top of dummy drive pinion assembly. See GAUGE
BLOCK SELECTION table.
GAUGE BLOCK SELECTION
7. Place pinion height gauge on top of gauge block. Position dial indicator to measure distance to a point
where side bearing sits. Measure lowest point. See Fig. 12
. Measure both sides. Add both measurements
together and divide by 2.
8. If result is not zero, replace pinion spacer. Spacers are available in a range of .1213-.1366" (3.080-3.470
mm) in .001" (.03 mm) increments. Remove dummy drive pinion. Press rear bearing onto drive pinion.
9. Install drive pinion, spacer, front bearing, collapsible spacer and companion flange in differential carrier.
DO NOT install pinion oil seal yet. DO NOT exceed one-ton force; collapsible spacer will be damaged.
10. Install washer and drive pinion lock nut. Temporarily tighten drive pinion lock nut. Turn companion
flange by hand to seat bearing. Using torque wrench, tighten drive pinion lock nut to specification. See
TORQUE SPECIFICATIONS
. Check pinion bearing preload at drive pinion lock nut. See PINION
PRELOAD SPECIFICATIONS table. If pinion bearing preload is not as specified, replace collapsible
spacer and recheck preload.
PINION PRELOAD SPECIFICATIONS
11. Remove drive pinion lock nut, washer and companion flange. Install pinion oil seal. Lubricate oil seal lip
with differential oil. Install companion flange and washer. Install NEW drive pinion lock nut and tighten
to specification. See TORQUE SPECIFICATIONS
. Recheck pinion bearing preload. Lubricate end of
companion flange with grease.
12. Position differential assembly into differential carrier. Install side bearing adjusters. Position side bearing
caps. Align marks made during disassembly. Install side bearing cap bolts and hand-tighten bolts.
13. Ti
ghten side bearing adjusters equally until adjusters contact bearing races. Mark ring gear in 4 locations,
ApplicationGauge Block No.
Front Differential
MPV
4WD49-0305-555
Rear Differential
Miata49-0305-555
MPV49-0660-555
ApplicationINCH Lbs. (N.m)
Miata7.8-12.1 (0.9-1.3)
MPV 2WD11.3-15.6 (1.3-1.8)
MPV 4WD
Front7.8-12.2 (0.9-1.4)
Rear11.3-15.6 (1.3-1.8)

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 20 © 2005 Mitchell Repair Information Company, LLC.

90 degrees apart. Position dial indicator against ring gear to check ring gear backlash.
14. Check backlash at all 4 locations. Tighten side bearing adjusters equally until backlash is .0035-
.0043" (.09-.11 mm). Minimum backlash at any point is .002" (.05 mm). Difference between minimum
and maximum backlash should not exceed .0028" (.07 mm).
15. To set differential bearing preload, tighten adjusters equally until distance between measuring points on
carrier bearing caps is within specification. See Fig. 13
. See DIFFERENTIAL CARRIER
DIMENSIONS table.
16. Ensure backlash did not change when preload was set. Tighten side bearing cap bolts to specification. See
TORQUE SPECIFICATIONS. Check ring gear tooth patterns. See GEAR TOOTH CONTACT
PATTERNS article in GENERAL INFORMATION.
17. To complete reassembly, reverse disassembly procedure. Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS
.
DIFFERENTIAL CARRIER DIMENSIONS
Application(1) In. (mm)
Miata7.300-7.303 (185.43-185.50)
MPV 2WD8.022-8.050 (203.78-204.50)
MPV 4WD
Front7.275-7.303 (184.78-185.50)
Rear8.022-8.050 (203.78-204.50)
(1)See illustration for measuring point. See Fig. 13 .

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 21 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Measuring Carrier Case Spread
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (MIATA)
ApplicationFt. Lbs. (N.m)
Differential Carrier Bearings Cap Bolts28-38 (38-52)
Differential Carrier Bearings Lock Plate Bolt13-18 (18-25)
Differential Carrier-To-Housing Bolts17-19 (23-26)
Differential-To-Chassis Mount Nuts
Inner Nut61-72 (83-98)
Outer Nuts (2)13-20 (18-27)
Drive Axle Inner CV Joint Flange Nuts40-47 (54-64)
Drive Pinion Lock Nut94-209 (128-284)
Drive Shaft Companion Flange Nuts20-22 (27-30)
Exhaust Pipe Mount Nuts30-41 (40-55)
Filler Plug29-40 (39-54)
Power Plant Frame Bracket
To-Power Plant Frame Bolt (M/T)77-91 (104-123)
To-Transmission Bolts (M/T)27-40 (37-54)

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 22 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS (MPV)
Power Plant Frame-To-Differential
Side Mounting Bolts (Long)77-91 (104-123)
Spacer Bolt (Short)27-38 (37-52)
Power Plant Frame-To-Transmission Side Mounting Bolts (Long)77-91 (104-123)
Ring Gear Retaining Bolts51-61 (69-83)
Wheel Lug Nuts65-87 (88-118)
ApplicationFt. Lbs. (N.m)
AFW Extension Housing Mount Nut (4WD)49-72 (66-98)
Brake Pipe Union10-16 (14-22)
Differential Carrier Bearings Cap Bolts Front Differential27-38 (37-52)
Differential Carrier Bearings Cap Bolts Rear Differential54-78 (73-106)
Differential Carrier Bearings Lock Plate Bolt13-19 (18-26)
Differential Carrier-To-Housing Nuts/Bolts17-19 (23-26)
Differential-To-Chassis Mount Nuts (4WD)49-72 (66-98)
Drive Pinion Lock Nut94-210 (127-284)
Drive Shaft Companion Flange Nuts37-43 (50-58)
Filler Plug29-40 (39-54)
Lower Ball Joint-To-Control Arm Bolts (4WD)75-101 (102-137)
Lower Ball Joint-To-Control Arm Nut (4WD)94-127 (127-172)
Rear ABS Wheel Speed Sensor Bolt12-16 (16-22)
Rear Axle Shaft Assembly-To-Axle Shaft Housing Retaining Nuts40-49 (54-66)
Rear Brake Caliper Bolts37-43 (50-58)
Ring Gear Retaining Bolts51-61 (69-83)
Skid Plate Bolts (4WD)12-17 (16-23)
Tie Rod End Nut (4WD)43-58 (58-78)
Wheel Lug Nuts65-87 (88-118)

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 23 © 2005 Mitchell Repair Information Company, LLC.

1997 MAZDA
MX-5 Miata
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS
CIRCUIT PROTECTION DEVICES
CIRCUIT PROTECTION DEVICES
CONTROL UNITS
CONTROL UNITS
ComponentComponent Location
A/C RelayIn right front of engine compartment, near radiator. See Fig. 1 .
Condenser Fan RelayIn right front of engine compartment, near radiator. See Fig. 1 .
Cooling Fan RelayIn main fuse/relay block.
Flasher UnitBehind left side of dash. See Fig. 2 .
Fuel Pump RelayUnder left side of dash. See Fig. 2 .
Headlamp RelayOn left rear corner of front inner fender panel. See Fig. 1 .
Horn RelayOn left rear corner of front inner fender panel. See Fig. 1 .
INT RelayIntegral with windshield wiper & washer switch.
Main RelayIn left rear corner of engine compartment, in main fuse/relay block.
Power Antenna RelayIn right rear of vehicle, attached to power antenna.
Rear Window Defogger
RelayIn center rear of trunk compartment. See Fig. 3 .
Retractable Headlamp RelayBehind left side of dash.
TNS RelayIn left rear corner of engine compartment, on inner fender panel. See Fig.
1 .
Warning UnitBehind left side of dash. See Fig. 2 .
ComponentComponent Location
Fuse Block (Front)Behind left side of dash. See Fig. 2 .
Fuse Block (Rear)On right rear side of luggage compartment. See Fig. 3 .
Main Fuse BlockOn right rear corner of engine compartment, near firewall. See Fig. 1 .
ComponentComponent Location
ABS Control ModuleBehind passenger's seat. See Fig. 3 .
ABS Control UnitIn right rear corner of engine compartment.
Cruise Control ModuleUnder left side of dash above fuse block. See Fig. 2 .
Daytime Running Lamp (DRL) Control ModuleOn bracket, behind left side of dash. See Fig. 2 .
Engine Control Module (ECM)Behind passenger's seat. See Fig. 3 .

1997 Mazda MX-5 Miata
1997 MAZDA MX-5 Miata

1997 Mazda MX-5 Miata
1997 MAZDA MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:54:00 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, July 05, 2009 1:54:09 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

MOTORS
MOTORS
SENDING UNITS & SENSORS
SENDING UNITS & SENSORS
Key Interlock UnitBehind left side of dash. See Fig. 2 .
SAS UnitBehind center of dash. See Fig. 2 .
Transmission Control Module (TCM)Under left side of dash, near fuse block. See Fig. 2 .
ComponentComponent Location
Blower MotorUnder right side of dash. See Fig. 2 .
Condenser Fan MotorIn front of engine compartment.
Cooling Fan MotorIn front of engine compartment.
Cruise Control ActuatorOn left side of engine compartment.
Fuel PumpIn fuel tank.
Power Antenna MotorIn right front of trunk.
Retractable Headlamp ActuatorsBehind respective headlamp.
Shift Lock ActuatorUnder center console, on base of gear selector.
Windshield Washer MotorOn bottom of washer fluid reservoir.
Windshield Wiper MotorOn right side of firewall.
ComponentComponent Location
ABS Wheel Speed Sensor (Left Front)On back of left front wheel spindle assembly. See Fig. 1 .
ABS Wheel Speed Sensor (Left Rear)On back of left rear wheel hub assembly. See Fig. 3 .
ABS Wheel Speed Sensor (Right Front)On back of right front wheel spindle assembly. See Fig. 1 .
ABS Wheel Speed Sensor (Right Rear)On back of right rear wheel hub assembly. See Fig. 3 .
Brake Fluid Level SensorIn brake fluid reservoir. See Fig. 1 .
Camshaft Position SensorIn center rear of engine compartment. See Fig. 1 .
Crankshaft Position SensorOn front of engine.
EGR Boost SensorOn right side of engine compartment.
EGR Valve Position SensorOn right side center, rear of engine compartment.
EGR Valve Position SensorOn right side center, rear of engine compartment. See Fig. 1 .
Engine Coolant Temperature SensorOn rear of engine. See Fig. 1 .
Fuel Gauge Sender UnitIn fuel tank.
Heated Oxygen Sensor (Front)In rear of engine compartment. See Fig. 1 .
Heated Oxygen Sensor (Rear)On underside of vehicle, on exhaust pipe.
Input/Turbine Speed SensorOn left side of transmission.
Mass Air Flow SensorOn top of air filter housing. See Fig. 1 .
Throttle Position (TP) SensorOn side of throttle body. See Fig. 1 .
Transmission Fluid Temperature SensorOn left side of transmission.

1997 Mazda MX-5 Miata
1997 MAZDA MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:54:00 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES
SWITCHES
SWITCHES
MISCELLANEOUS
MISCELLANEOUS
Vehicle Speed Sensor (VSS)On speedometer assembly.
Water Temperature Sender UnitOn center of engine. See Fig. 1 .
Washer Fluid Level SensorOn washer fluid reservoir. See Fig. 1 .
ComponentComponent Location
AT Interlock SolenoidIn steering column, near ignition switch. See Fig. 2 .
EC-AT Solenoid ValveOn left side of transmission.
EGR Solenoid Valve (Vacuum)On right side of engine compartment. See Fig. 1 .
EGR Solenoid Valve (Vent)On right side of engine compartment. See Fig. 1 .
Fourth Gear Solenoid ValveOn left side of transmission.
Idle Air Control ValveOn right side, front of engine compartment. See Fig. 1 .
PRC Solenoid ValveOn right side, front of engine. See Fig. 1 .
Purge Solenoid ValveOn right strut tower. See Fig. 1 .
ComponentComponent Location
Back-Up Lamp Switch (M/T)On right side of transmission. See Fig. 1 .
Brake SwitchOn bracket, above brake pedal. See Fig. 2 .
Buckle SwitchOn driver side seat belt buckle. See Fig. 3 .
Clutch Switch (M/T)On bracket, above clutch pedal. See Fig. 2 .
Hold SwitchUnder right side of center console.
Key Reminder SwitchIn steering column, near ignition switch.
Neutral Switch (M/T)On right side of transmission. See Fig. 1 .
Oil Pressure SwitchOn right side of engine. See Fig. 1 .
"P" Range SwitchUnder center console, on base of gear selector.
Parking Brake SwitchOn base of parking brake lever. See Fig. 4 .
Power Steering Pressure SwitchOn power steering pump assembly.
Refrigerant Pressure SwitchIn front of engine compartment, near radiator support. See Fig. 1 .
Starter Interlock Switch (M/T)On bracket, above clutch pedal. See Fig. 2 .
ThermoswitchUnder right side of dash.
Transmission Range SwitchOn left side of transmission.
ComponentComponent Location

1997 Mazda MX-5 Miata
1997 MAZDA MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:54:00 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.