1997 MAZDA MX-5 Factory Repair Manual

Fig. 1: Connecting Pressure Gauge/Valve (Typical)
Courtesy of MAZDA MOTORS CORP.
Gear Fluid Pressure Test
1. Ensure steering pump pressure is within specification. See PUMP FLUID PRESSURE TEST . To
measure steering gear fluid pressure, open gauge valve completely. Increase engine speed to 1000-1500
RPM.
2. Turn steering wheel from lock to lock. Measure steering gear fluid pressure. Ensure gear pressure is
within specification. See HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
table. If
pressure is not within specification, replace gear.
HYDRAULIC SYSTEM FLUID PRESSURE SPECIFICATIONS
(1)
Applicationpsi (kg/cm2 )
Miata & MPV1102-1209 (77-85)
MX-31138-1152 (80-81)
Millenia, MX-6 & 6261209-1280 (85-90)
Protege1244-1350 (87-95)
RX71110-1209 (78-85)
9291066-1137 (75-80)
(1)Specifications are measured at 1000-1500 RPM, with fluid temperature at 122-140°F (50-60°C).

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

LUBRICATION
FLUID CAPACITY
POWER STEERING FLUID CAPACITY
FLUID TYPE
Dexron-II or Mazda M-III fluid is recommended for all models.
FLUID LEVEL CHECK
Check fluid level on oil pump dipstick (if equipped) or reservoir. Fluid should be between marks on level gauge
dipstick (if equipped) or reservoir. If fluid level is low, fill as necessary. Recheck fluid level. DO NOT overfill.
HYDRAULIC SYSTEM BLEEDING
1. Raise and support front of vehicle. With ignition off, turn steering wheel from lock to lock several times.
Check fluid level. Add fluid as necessary. Repeat procedure until fluid level no longer decreases.
2. Start engine and operate at idle. Turn steering wheel from lock to lock 5 times. Check fluid level. Add
fluid as necessary. Continue procedure until fluid is clear of air bubbles and does not decrease in level.
ADJUSTMENTS
PINION PRELOAD
Miata & Protege
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover to 43 INCH lbs. (4.9 N.m), then loosen adjusting cover. See Fig. 2
. Repeat loosening and
ti
ghtening procedure 3 times. After tightening adjusting cover the third time, loosen adjusting cover 25
ApplicationQts. (L)
Miata & Protege.85 (.80)
MPV.95 (.90)
MX-3
4-Cylinder.85 (.80)
V61.27 (1.20)
Millenia, MX-6 & 6261.32 (1.25)
RX71.01 (.96)
9291.80 (1.70)
NOTE: Pinion preload should be checked when steering gear assembly has been
disassembled or overhauled. Check preload after steering gear assembly has
been reassembled, but tie rods have not yet been installed.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

degrees.
2. Center steering rack. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure
pinion preload using spring scale. Pinion preload should be 2.2-2.6 lbs. (1.0-1.2 kg).
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to
adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 29-36 ft. lbs.
(39-49 N.m) on Protege or 44-54 ft. lbs. (60-73 N.m) on Miata.
Fig. 2: Tightening Adjusting Cover (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 3: Checking Pinion Preload (Miata Shown; Others Are Similar)
Courtesy of FORD MOTOR CO.
Millenia
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover 14-22 ft. lbs. (19-30 N.m), then loosen cover. Again, tighten adjusting cover to 15 ft. lbs.
(20 N.m), then loosen adjusting cover 25-35 degrees.
2. Apply thread sealant to exposed adjusting cover threads. Install and tighten adjusting cover lock nut 37-
50 ft. lbs. (50-68 N.m). Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure
pinion preload using spring scale. Pinion preload shoul d be 1.8-3.3 lbs. (.8-1.5 kg). If preload is not as
specified, repeat steps 1) and 2).
MPV
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover to 15 ft. lbs. (20 N.m), then loosen cover. Again, tighten adjusting cover to 15 ft. lbs. (20
N.m) then loosen cover.
2. Tighten adjusting cover 44-56 INCH lbs. (5.0-6.3 N.m), then loosen adjusting cover 35-45 degrees.
Apply thread sealant to exposed adjusting cover threads. Install and tighten adjusting cover lock nut 37-
43 ft. lbs. (50-58 N.m).

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.

MX-3 (4-Cylinder)
1. Install and temporarily tighten adjusting cover to 95 INCH lbs. (10.7 N.m). Move steering rack back and
forth about 3 times, then loosen adjusting cover. Tighten adjusting cover 40-47 INCH lbs (4.5-5.3 N.m)
then loosen adjusting cover 0-40 degrees. Apply thread sealant to adjusting cover lock nut. Install lock
nut. Holding adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m).
2. Center steering rack. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure
pinion preload using spring scale. With steering rack in center position, pinion preload should be 2.2-3.0
lbs. (1.0-1.4 kg). With steering rack in any other position, pinion preload should be a maximum of 3.7 lbs.
(1.7 kg). If preload is not as specified, repeat steps 1) and 2).
MX-3 (V6)
1. Center steering rack. Install and temporarily tighten adjusting cover to 100 INCH lbs. (11.3 N.m), then
loosen cover. Tighten adjusting cover 40-47 INCH lbs. (4.5-5.3 N.m), then loosen cover 45 degrees.
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. With steering rack in center position (plus or minus 90 degrees), preload should be 2.2-2.6
lbs. (1.0-1.2 kg). With steering rack in any other position, preload should be a maximum of 3.7 lbs. (1.7
kg).
3. If preload is as specified, apply thread sealant to adjusting cover lock nut. Install lock nut. Holding
adjusting cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m). If preload is not as specified, repeat
steps 1) and 2).
MX-6 & 626
1. Center steering rack. Install and temporarily tighten adjusting cover to 87 INCH lbs. (9.8 N.m), then
loosen adjusting cover. Tighten adjusting cover 39-48 INCH lbs (4.4-5.4 N.m) then loosen adjusting
cover 20 degrees. Apply thread sealant to adjusting cover lock nut. Install lock nut. Holding adjusting
cover in place, tighten lock nut 37-43 ft. lbs. (50-58 N.m).
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. With steering rack in center position (plus or minus 90 degrees), pinion preload should be
2.8-3.3 lbs. (1.3-1.5 kg). If preload is not as specified, repeat steps 1) and 2).
RX7
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten
adjusting cover 87 INCH lbs. (9.8 N.m), then loosen adjusting cover 20-25 degrees. See Fig. 2
.
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to
adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-50 ft. lbs.
(50-68 N.m).
929
1. Ensure steering rack is in center position. Using Protractor (49-D032-316 ) and a torque wrench, tighten

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

adjusting cover 15-21 ft. lbs. (20-28 N.m), then loosen adjusting cover 25 degrees. See Fig. 2.
2. Install Preload Adapter (49-0180-510B ) on pinion shaft. See Fig. 3
. Measure pinion preload using
spring scale. Pinion preload should be 3.3 lbs. (1.5 kg) maximum.
3. If preload is not as specified, repeat steps 1) and 2). If preload is as specified, apply thread sealant to
adjusting cover lock nut. Install lock nut. Holding adjusting cover in place, tighten lock nut 37-50 ft. lbs.
(50-68 N.m).
PINION SHAFT & VALVE HOUSING ASSEMBLY
Miata
1. With steering rack assembly secured in a vise, pull steering rack out until distance between end of rack
and end of rack housing is 2.38" (60.5 mm). See Fig. 4
.
2. If reusing original gear housing, pinion shaft and valve housing, install same number of shims that were
removed during disassembly procedure. If installing a NEW gear housing, pinion shaft and/or valve
housing, install same number of shims that were removed during disassembly procedure, and go to next
step.
3. Install and tighten valve housing bolts 15-21 ft. lbs. (20-28 N.m). Using a feeler gauge, measure clearance
between gear housing and valve housing. See Fig. 5
. Add or remove necessary shims until clearance is
zero.
Fig. 4: Centering Steering Rack (Miata Shown; Others Are Similar)

Courtesy of FORD MOTOR CO.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Measuring Gear Housing To Valve Housing Clearance (1996-97 Miata)
Courtesy of FORD MOTOR CO.
POWER STEERING PUMP BELT
BELT ADJUSTMENT SPECIFICATIONS
Application(1) Deflection In. (mm)
Miata & Protege
New Belt.31-.35 (8.0-9.0)
Used Belt.35-.39 (9.0-10.0)
Millenia
2.3L(2)
2.5L
New Belt.23-.27 (6.0-7.0)
Used Belt.27-.31 (7.0-8.0)
MPV
New Belt.27-.35 (7.0-7.5)

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
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Sunday, July 05, 2009 1:39:26 PMPage 8 © 2005 Mitchell Repair Information Company, LLC.

REMOVAL & INSTALLATION
STEERING GEAR
Removal & Installation (Miata & MPV)
1. Disconnect negative battery cable. Raise and support front of vehicle. Remove front wheel assemblies.
Remove cotter pins and castle nuts from tie rod ends.
2. Using Puller Set (49-T028-3A0 ), separate tie rod ends from steering knuckles. Mark steering column
intermediate shaft-to-steering column gear pinion for installation reference. Remove steering column
intermediate shaft-to-steering gear pinion shaft bolt. Place reference marks on steering gear and pressure
line fitting for reassembly.
3. Disconnect pressure and return line connections from steering gear. On Miata, remove steering gea
r-to-
Used Belt.35-.33 (7.5-8.2)
MX-3
4-Cylinder
New Belt.31-.35 (8.0-9.0)
Used Belt.35-.39 (9.0-10.0)
V6
New Belt.23-.27 (6.0-7.0)
Used Belt.27-.31 (7.0-8.0)
MX-6 & 626
4-Cylinder
New Belt.30-.35 (7.5-9.0)
Used Belt.32-.37 (8.1-9.4)
V6
New Belt.24-.27 (6.0-7.0)
Used Belt.27-.31 (7.0-8.0)
RX7
New Belt.14-.16 (3.5-4.0)
Used Belt.18-.20 (4.5-5.0)
929
New Belt.23-.25 (5.8-6.3)
Used Belt.27-.30 (6.9-7.7)
(1)Belt deflection is measured at midpoint between idler pulley and pump, with 22 lbs. (10 kg.) of
pressure applied.
(2)Serpentine belt with an automatic tensioner is used. No adjustment is necessary. If pointer on
tensioner is not within wear gauge limit, replace belt.
NOTE: Use a suitable container or rags to collect fluid when disconnecting pressure
and return lines.

1997 Mazda MX-5 Miata
STEERING SYSTEM - POWER RACK & PINION 1997 STEERING Mazda Power Rack & Pinion
Microsoft
Sunday, July 05, 2009 1:39:26 PMPage 9 © 2005 Mitchell Repair Information Company, LLC.