1997 MAZDA MX-5 torque spec

Fig. 5: Exploded View Of Rear Axle Shaft (MPV)
Courtesy of MAZDA MOTORS CORP.
DIFFERENTIAL ASSEMBLY
Removal (Front MPV 4WD)
1. Raise and support vehicle. Remove engine skid plate. See Fig. 6 . Drain front differential fluid. Remove
tie rod ends and lower control arms. Remove front axle shafts. See AXLE SHAFTS
- FRONT article.
2. Mark drive shaft and differential carrier flanges for reassembly reference, and remove drive shaft from
differential carrier. See Fig. 6
. Disconnect Automatic Free Wheel (AFW) vacuum hoses and electrical
connector.
3. Place floor jack under differential assembly. Remove differential-to-chassis mounting bolts and AFW
extension housing mounting nuts. Remove differential and AFW extension housing from vehicle.
Remove AFW assembly from left side of differential housing. Pull drive coupler from 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.

1997 Mazda MX-5 Miata
1997-98 DRIVE AXLES Differentials & Drive Axles - MPV & MX-5 Miata
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Sunday, July 05, 2009 1:52:42 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.

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.

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. 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.

differential housing block.
2. Tighten PPF/differential mounting spacer bolts to 28-38 ft. lbs. (38-52 N.m). See Fig. 4
. Install PPF to
differential. Hand-tighten long bolts. Ensure PPF-to-differential large shank reamer bolt and spacer are
properly installed.
3. When PPF is properly aligned between transmission and differential, tighten all long mounting bolts to
specification. Install rear transmission-to-PPF bracket and tighten to specification. See TORQUE
SPECIFICATIONS . To complete installation, reverse removal procedure. Before installing M/T shift
lever, add gear oil to transmission through shifter hole. Fill all fluids to correct level. Prime fuel system
before attempting to start engine. See FUEL PRESSURE RELEASE & PRIMING. Bleed cooling system.
See COOLING SYSTEM BLEEDING.
Fig. 4: Locating PPF
-To-Differential Reamer Bolt, Sleeve & Spacer
NOTE: Reamer bolt is the front long bolt attaching PPF to differential. This bolt
aligns PPF with drive train.

1997 Mazda MX-5 Miata
1997-98 ENGINES 1.8L 4-Cylinder
Microsoft
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