1997 MAZDA MX-5 4WD

openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS. Remove remaining mounting
bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system.
FRONT BRAKE ROTOR
Removal & Installation (B2300, B3000 & B4000 2WD)
1. Raise and support vehicle. Remove front wheel assemblies and brake caliper. See FRONT DISC
BRAKE PADS . Remove grease cap, cotter pin, retainer, adjusting nut, washer and outer bearing.
Carefully remove hub and rotor assembly. Remove inner bearing and seal.
2. To install, reverse removal procedure. Adjust front wheel bearings. While rotating rotor, tighten adjusting
nut 17-25 ft. lbs. (23-34 N.m) to seat bearings. Back off adjusting nut 1/2 turn. Tighten adjusting nut to
18-20 INCH lbs. (2.0-2.3 N.m). Install bearing retainer and NEW cotter pin. DO NOT turn adjusting nut
to align cotter pin.
Removal (B2300, B3000 & B4000 4WD With Automatic Locking Hubs)
1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE
PADS . Remove retainer washers from lug nut studs. Remove automatic locking hub assembly from
spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 9
. Carefully pull cam
assembly off wheel bearing adjusting nut. If necessary, rotate adjusting nut slightly to relieve pressure on
locking key.
3. Using a magnet, remove locking key. Using 2 3/8" Hex Lock Nut Wrench (49-UN01-037), remove wheel
bearing adjusting nut. Remove outer wheel bearing and rotor.
Installation
When installing rotor, outer bearing and adjusting nut, tighten adjusting nut to 35 ft. lbs (47 N.m) to seat
bearings. Spin rotor, and back off adjusting nut 1/4 turn. Tighten adjusting nut to 16 INCH lbs. (1.8 N.m). To
install remaining components, reverse removal procedure. See Fig. 7
. After assembly is complete, wheel to
spindle end play should be .000-.003" (.00-.08 mm).
CAUTION: Extreme caution must be used when aligning adjusting nut lug with
spindle locking key slot to prevent damage to locking key.

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Fig. 9: Removing Front Rotor (B2300, B3000 & B4000 With Automatic Locking Hubs)
Courtesy of FORD MOTOR CO.
Removal (B2300, B3000 & B4000 4WD With Manual Locking Hubs)
1. Raise and support vehicle. Remove front wheel assemblies and caliper. See FRONT DISC BRAKE
PADS . Remove retainer washers from lug nut studs. Remove manual locking hub assembly from
spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacers. See Fig. 10
. Using Lock Nut Wrench
(49-UN01-042), remove outer wheel bearing lock nut. Remove lock washer. Using lock nut wrench,
remove inner wheel bearing lock nut. Remove outer wheel bearing, cup and rotor.
Installation
When installing rotor, outer bearing and inner lock nut, tighten inner lock nut to 35 ft. lbs. (47 N.m) to seat
bearings. Spin rotor, and back off inner lock nut 1/4 turn. Tighten inner lock nut to 16 INCH lbs. (1.8 N.m). To
install remaining components, reverse removal procedure. See Fig. 10
. After assembly is complete, wheel to
spindle end pla
y should be .000-.003" (.00-.08 mm).

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Submerge other end of hose in container of brake fluid.
2. Fill reservoir with DOT 3 brake fluid. Have an assistant press and release clutch pedal several times, then
hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.
3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate
clutch while inspecting for leaks. Check clutch and brake operation.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (B2300, B2500, B3000 & B4000)
1. Disconnect negative battery cable. Shift transmission into Neutral. Remove gearshift lever. Raise and
support vehicle. Mark drive shaft flanges for installation reference. Remove drive shaft. Using Clutch
Disconnect Tool (T88T-70522-A), disconnect hydraulic line at transmission. See Fig. 2
. Plug hydraulic
line to prevent contamination. Disconnect wiring at transmission.
2. Remove starter. Remove exhaust components as necessary for clearance. On 4WD models, remove skid
plate and transfer case. On all models, secure transmission jack under transmission. Remove transmission
mount-to-crossmember nuts and bolts.
3. Remove nuts securing crossmember to frame side rails, and remove crossmember. Lower transmission
enough to gain access to transmission-to-engine block bolts. Remove transmission-to-engine block bolts.
Remove transmission.
4. If clutch parts are going to be reused, mark clutch cover and flywheel for reassembly reference. Loosen
pressure plate bolts evenly in crisscross pattern until springs are not under tension. Remove clutch cover
and clutch disc.
Inspection (B2300, B2500, B3000 & B4000)
1. Inspect disc for loose rivets, worn or defective springs, excessive wear, or oil contamination. Inspect
flywheel and clutch cover for burns, scoring, or grooves.
2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond
specification. See CLUTCH RUNOUT (MAXIMUM)
table.
3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT
(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide
smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has
excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect
release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.
CLUTCH RUNOUT (MAXIMUM)
ApplicationIn. (mm)
Disc0.028 (0.7)
Flywheel0.008 (0.20)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
Microsoft
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Installation (B2300, B2500, B3000 & B4000)
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide
grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS
.
2. Raise transmission into position. Install and tighten transmission-to-engine block bolts. See TORQUE
SPECIFICATIONS . Install crossmember.
3. On 4WD models, install NEW transfer case gasket. Install transfer case. Tighten transfer case bolts to
specification is sequence. See Fig. 3
. See TORQUE SPECIFICATIONS .
4. On all models, to complete installation, reverse removal procedure. Bleed hydraulic clutch system. See
HYDRAULIC SYSTEM BLEEDING
under ADJUSTMENTS.
Fig. 3: Tightening Transfer Case Bolts (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.
Removal (Miata)
1. Disconnect negative battery cable. Remove gearshift knob, console, and shift lever. See Fig. 4. Raise and
support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark drive shaft
flanges for installation reference. Remove drive shaft.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
Microsoft
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Fig. 11: Exploded View Of Clutch Release Cylinder (Miata)
Courtesy of MAZDA MOTORS CORP.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE: Use exploded view of clutch release cylinder for overhaul procedure. See Fig.
11 .
ApplicationFt. Lbs. (N.m)
B2300, B2500, B3000 & B4000
Clutch Cover Bolts (1) 17-24 (23-32)
Crossmember Nuts39-53 (53-72)
Drive Shaft Bolts65-87 (88-119)
Flywheel-To-Crankshaft Nuts54-67 (73-91)
Gearshift Lever Bolt20-30 (27-40)
Starter Mounting Bolts17-20 (23-27)
Transfer Case Bolts (4WD) (2) 35-46 (47-62)
Transmission-To-Engine Block Bolts37-50 (50-68)
Miata
Clutch Cover Bolts (1) 13-19 (18-26)
Drive Shaft Nuts37-43 (50-58)
Flywheel-To-Crankshaft Bolts71-76 (96-103)
PPF-To-Differential Mounting Spacer Bolt (Short)27-38 (37-51)
PPF-To-Differential Side Mounting Bolts (Long)77-91 (104-123)
PPF-To-PPF Bracket Bolt27-40 (37-54)

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
Microsoft
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1997-98 DRIVE AXLES
Differentials & Drive Axles - MPV & MX-5 Miata
AXLE RATIO & IDENTIFICATION
See AXLE RATIO SPECIFICATIONS table. To determine axle ratio, divide number of ring gear teeth by
number of pinion teeth.
AXLE RATIO SPECIFICATIONS
DESCRIPTION
A Limited Slip Differential (LSD) is optional on Miata. On MPV, rear axle bearings are held in place by a
pressed-on collar. Front axle on MPV 4WD and rear axle on Miata use CV joints to connect differential to axle
hubs.
LUBRICATION
CAPACITY
DIFFERENTIAL CAPACITY SPECIFICATIONS
FLUID TYPE
Application
Number Of Teeth Pinion/Ring
Gear
Ratio
Miata
A/TN/A4.10:1
M/TN/A4.30:1
MPV
2WD11/433.91:1
4WD (Front & Rear)10/414.10:1
NOTE: For models with independent suspension, see AXLE SHAFTS - REAR or AXLE
SHAFTS - FRONT article for axle shaft overhaul.
Application(1) Qts. (L)
Miata1.06 (1.00)
MPV 2WD1.60 (1.50)
MPV 4WD
Front1.80 (1.70)
Rear1.60 (1.50)
(1)Fill to lower edge of filler plug hole.

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

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 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, July 05, 2009 1:52:46 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
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Fig. 6: Removing & Installing Front Differential (MPV 4WD)
Courtesy of MAZDA MOTORS CORP.
Removal (Rear MPV)
1. Raise and support vehicle. Remove wheel and tire assembly. Drain rear differential fluid. Remove axles.

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