1997 MAZDA MX-5 lock

Fig. 2: Prying Out Axle Shaft
Courtesy of MAZDA MOTORS CORP.
Installation
To install, reverse removal procedure. Install NEW clip. Measure outer diameter of clip after installing. See Fig.
3 . Replace clip if it exceeds specification. With the ends of clip facing upward, push axle shaft into deferential.
After installation, pull outward on double offset joint outer ring and verify that axle shaft is securely held by
clip. Install NEW locknut and stake it as shown. See Fig. 4
. Tighten all bolts and nuts to specification. See
TORQUE SPECIFICATIONS
.
CAUTION: Sharp edges of axle shaft snap ring can slice or puncture oil seal. Be
careful when installing axle shaft to differential.

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:37 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Installing Axle Shaft Locknut
Courtesy of MAZDA MOTORS CORP.
OVERHAUL
AXLE SHAFTS
Disassembly
1. Place axle shaft assembly in soft-jawed vise. Keep axle shaft assembly clean during disassembly and
reassembly. To remove boot bands, pry up locking clip by using a screwdriver, then raise end of band.
See Fig. 5
.
2. Mark axle shaft and outer ring with paint as shown. See Fig. 6
. Remove clip. Remove outer ring. Mark
axle shaft end and inner ring with paint as show. See Fig. 7
. Remove snap ring by using snap ring pliers.
3. Insert a screwdriver between inner ring and cage to remove balls. See Fig. 8
. Mark inner ring and cage
with paint. Turn cage approximately 30 degrees and pull it away from inner ring. See Fig. 9
. Wrap shaft
splines with tape and remove boot. See Fig. 10
.

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:37 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of MAZDA MOTORS CORP.
Reassembly
1. To reassemble, reverse disassembly procedure. Wrap tape around drive axle shaft ends before sliding CV
joint boots onto drive axle shaft. See Fig. 12
.
2. Align marks on cage and inner ring. Install balls to inner ring. Install cage, inner ring and ball assembly to
axle shaft in direction shown. See Fig. 14
. Larger diameter of cage should be facing snap ring groove.
3. Install a NEW snap ring in axle shaft snap ring groove. Apply specified amount of grease to joints and
boots. See LUBRICATION SPECIFICATION
table. Align marks and install NEW clip.
4. Ensure that boots are not dented or twisted. Set axle shaft to standard length. See AXLE SHAFT
LENGTH table. Release any trapped air from boots by carefully lifting up small end of each boot with a
cloth-wrapped screwdriver. Ensure that axle shaft length is within standard. If drive shaft length is not
within standard, repeat this step.
5. Fold NEW band back by pulling on end with pliers. See Fig. 15
. Band should be folded in direction
opposite forward revolving direction of axle shaft. Lock end of band by bending locking clips.
Fig. 12: Installing CV Joint Boot

Courtesy of MAZDA MOTORS CORP. NOTE: Inner and outer CV joint boots differ in design and/or diameter. CV joint boots
are stamped DOJ (wheel side) and BJ (differential side). Ensure correct boot is
installed at proper end when reassembling axle shaft. See REAR AXLE SHAFT
BOOT IDENTIFICATION table. See Fig. 13 .

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:37 PMPage 12 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Axle Shaft Lock Nut
1997160-216 (216-294)
1999-2001174-235 (236-318)
Brake Caliper Mounting Bolt37-50 (50-68)
Lower Control Arm Bolt/Nut47-54 (64-73)
Wheel Lug Nuts66-86 (89-117)

1997 Mazda MX-5 Miata
1997-2001 DRIVE AXLES Axle Shafts - MX-5 Miata
Microsoft
Sunday, July 05, 2009 1:51:38 PMPage 16 © 2005 Mitchell Repair Information Company, LLC.

BRAKE SYSTEM
1995-97 BRAKES Mazda - Disc & Drum
DESCRIPTION & OPERATION
All models use hydraulic-operated brake system with a tandem master cylinder, proportioning valve and a
power brake unit. All models are equipped with front disc brakes and either rear disc or rear drum brakes.
Rear Anti-lock System (RABS) is standard on B2300, B3000, B4000 and MPV models.
BLEEDING BRAKE SYSTEM
BRAKE LINE BLEEDING SEQUENCE
ADJUSTMENTS
MASTER CYLINDER PUSH ROD
Miata Without ABS, MPV, MX-6 M/T Without ABS & 626 M/T Without ABS
1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it
contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.
2. Invert adjuster gauge and place gauge on power brake unit. Adjust push rod on power brake unit until
there is no clearance between push rod and adjuster gauge screw.
B2300, B3000 & B4000
NOTE: For information on anti-lock brake systems, see appropriate ANTI-LOCK article
in BRAKES.
NOTE: If vehicle is equipped with anti-lock brakes, see appropriate ANTI-LOCK article
for brake bleeding procedure.
ApplicationSequence
B2300, B3000 & B4000(1) RR, LR, RF, LF
All Other ModelsLongest Line First
(1)Bleed master cylinder and RABS hydraulic unit before bleeding wheel cylinders and calipers.
NOTE: Push rod has an adjustment screw to maintain correct distance between
booster push rod and master cylinder piston. If push rod is adjusted too long, it
prevents master cylinder piston from completely releasing hydraulic pressure,
causing brakes to drag. If push rod is adjusted too short, it causes excessive
pedal travel and an undesirable clunk in booster area.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
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1. Raise and support rear of vehicle. Remove rear wheel assemblies. If drums are installed on vehicle,
remove cover from adjusting hole at bottom of brake backing plate. Turn adjusting screw with a brake
adjusting tool until shoes drag against brake drum and lock drum.
2. When shoes are against drum, loosen adjusting screw an additional 10-12 notches so drum rotates freely.
If drum does not rotate freely, remove wheel and drum and vacuum dust and dirt from linings. Use
sandpaper and remove rust from points where shoes touch backing plate. Apply a light coating of
molybdenum grease to brake shoe-to-backing plate contact points. Install wheel and drum and adjust
shoes.
3. To adjust brakes with rear drums removed, first clean all rust and dirt on points where shoes touch
backing plate and apply a small amount of molybdenum grease to those areas. Using a brake shoe
adjustment gauge, measure inside diameter of drum braking surface.
4. Reverse tool and adjust brake shoes until they touch gauge. Gauge contact points on shoes must be
parallel to vehicle with center line through center of axle. Hold automatic adjusting lever out of
engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates
freely.
MX-3, MX-6, Protege & 626
Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake. Remove brake drum.
Insert screwdriver between adjusting plate and quadrant. Twist screwdriver to disengage teeth. See Fig. 2
. Push
quadrant adjusting lever toward backing plate. Install brake drum. Operate parking brake a few times to reset
ad
juster. Adjust parking brake.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

929
1. Depress brake pedal several times. Depress parking brake pedal several times with a force of 44 lbs. (20
kg). If stroke is 5-7 notches, parking brake is properly adjusted. If stroke is not 5-7 notches, rotate
adjusting nut, located under parking brake pedal, until stroke is within specification.
2. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake pedal is
depressed one notch.
BRAKE PEDAL FREE PLAY
With engine off, depress pedal a few times to eliminate vacuum. Depress brake pedal by hand and check pedal
free play. See BRAKE PEDAL FREE PLAY SPECIFICATIONS
. Adjust play by loosening push rod lock
nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut to 18-25 ft. lbs. (24-34 N.m).
BRAKE PEDAL FREE PLAY SPECIFICATIONS
BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH
Miata, MPV, MX-3, MX-6, RX7, 626 & 929
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Rotate switch away
from pedal. Loosen push rod lock nut. Rotate push rod until correct pedal height is obtained. See
BRAKE PEDAL HEIGHT SPECIFICATIONS
.
2. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock nut to 18-25 ft. lbs.
(24-34 N.m).
3. Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut 10-13 ft. lbs. (14-18 N.m). Reconnect stoplight switch electrical connector.
4. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure.
5. Measure applied pedal hei
ght. See BRAKE PEDAL HEIGHT SPECIFICATIONS . If distance is not NOTE: On B2300, B3000 & B4000, brake pedal free play is built into pedal linkage and
is not adjustable.
ApplicationIn. (mm)
Miata, MPV & MX-3.16-.28 (4-7)
Millenia, MX-6, Protege & 626.16-.47 (4-12)
RX7.12-.31 (3-8)
929.12-.47 (8-12)
NOTE: B2300, B3000 & B4000 are equipped with dual brake master cylinder and
vacuum booster. System is designed to permit full stroke of master cylinder
when brake pedal is fully depressed. Brake pedal height adjustment is not
required.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 6 © 2005 Mitchell Repair Information Company, LLC.

as specified, check for air in system, rear brake adjustment (drum brakes) or worn shoes or pads.
BRAKE PEDAL HEIGHT SPECIFICATIONS
Millenia & Protege
1. Released pedal height is measured between brake pedal and stoplight switch mounting bracket. See Fig.
3 . Disconnect stoplight switch electrical connector and remove switch. Measure length "L" between
stoplight switch mounting bracket and brake pedal. See Fig. 3
. On Millenia, length should be .79-
.90" (20-23 mm). On Protege, length should be .71-.86" (18-22 mm).
2. On all models, if clearance is as specified, install stoplight switch. No adjustment is necessary. If
clearance is not as specified, loosen lock nut "B" and rotate self-locking nut "A" counterclockwise until it
does not contact brake pedal.
3. Loosen push rod lock nut and rotate push rod until correct clearance between brake pedal and stoplight
switch mounting bracket is obtained. Tighten push rod lock nut. Rotate self-locking nut "A" clockwise
until clearance between brake pedal and end of self-locking nut "A" is .004-.039 (.1-1.0 mm). See Fig. 3
.
Tighten lock nut "B".
4. Install NEW stoplight switch. Stoplight switch is automatically adjusted by pulling back on brake pedal
until stoplight switch click noise is heard. Reconnect stoplight switch electrical connector. Check
stoplight operation. Adjust pedal free play. See BRAKE PEDAL FREE PLAY
. Tighten push rod lock
nut to 18-25 ft. lbs. (24-34 N.m).
5. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132 lbs. (60 kg) pressure. On Millenia, distance should be 2.7" (70
mm). On Protege, distance should be 3.8" (95 mm). On all models, if distance is not as specified, check
ApplicationIn. (mm)
Pedal Released
Miata6.8-7.1 (171-181)
MPV7.5-7.9 (191-201)
MX-37.6-7.7 (193-196)
MX-6 & 6267.5-7.7 (191-196)
RX76.5-6.9 (165-176)
9297.4-7.7 (188-195)
Pedal Applied (1)
Miata3.7 (95)
MPV, MX-6 & 6263.3 (85)
MX-32.8 (70)
RX73.9 (100)
9291.6 (40)
(1)Minimum height.
NOTE: When adjusting brake pedal height, a NEW stoplight switch must be used.
Stoplight switch can only be adjusted one time.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
Sunday, July 05, 2009 1:51:02 PMPage 7 © 2005 Mitchell Repair Information Company, LLC.