1997 MAZDA MX-5 wheel bolts

4. Disconnect SAS unit connector. Check wiring between terminal K of SAS unit connector and terminal C
of passenger-side air bag module connector for short to ground, short to power or open circuit. If wiring
is OK, replace SAS unit. See SAS UNIT
under REMOVAL & INSTALLATION. If wiring is not OK,
replace wiring harness between passenger-side air bag module and SAS unit. Perform SYSTEM
OPERATION CHECK .
WIRE REPAIR
DO NOT repair air bag system wiring. If a problem is found with air bag system wiring, replace faulty wiring.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAM
ApplicationFt. Lbs. (N.m)
Passenger-Side Air Bag Module Retaining Bolts13-20 (18-27)
Steering Wheel Nut29-36 (39-49)
INCH Lbs. (N.m)
Driver-Side Air Bag Module Retaining Nuts35-52 (4.0-5.8)
SAS Unit Retaining Nuts61-86 (6.7-9.8)

1997 Mazda MX-5 Miata
AIR BAG RESTRAINT SYSTEM 1997 ACCESSORIES/SAFETY EQUIPMENT Mazda - Air Bag Restraint System
Microsoft
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2. Disconnect ABS control module electrical connector. Remove ABS control module mounting bolts/nuts.
Remove ABS control module. To install, reverse removal procedure. Tighten ABS control module
mounting bolts/nuts to 61-87 INCH lbs. (6.9-9.8 N.m).
HYDRAULIC UNIT
Removal & Installation
1. Disconnect negative battery cable. Disconnect hydraulic unit electrical connector. Using Flare Nut
Wrench (49-0259-770B), disconnect brakelines from hydraulic unit. Note location of brakelines for
installation reference. Disconnect electrical connectors. Remove hydraulic unit mounting bolts and nuts.
2. Remove hydraulic unit. To install, reverse removal procedure. Tighten mounting bolts and nuts to
specification. See TORQUE SPECIFICATIONS
. Add fluid and bleed air from system. See
BLEEDING BRAKE SYSTEM
.
FRONT WHEEL SPEED SENSOR ROTOR
Removal
Raise and support vehicle. Remove front wheel assemblies. Remove brake caliper and wire aside. Remove
rotor. Remove grease cap and wheel bearing lock nut. Remove wheel hub. Using Puller (49-0839-425C) and
Attachment (49-F027-007), remove wheel speed sensor rotor from hub.
Installation
To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS .
REAR WHEEL SPEED SENSOR ROTOR
Removal
Raise and support vehicle. Remove rear wheel assemblies. Remove brake caliper and wire aside. Remove wheel
bearing lock nut. Remove lower control arm-to-rear steering knuckle bolt and nut. Remove drive axle. DO NOT
disassemble drive axle assembly to remove sensor rotor. Replace drive axle assembly.
Installation
To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS .
WHEEL SPEED SENSOR
Removal & Installation
Raise and support vehicle. Remove wheel assemblies. Disconnect wheel speed sensor electrical connector.
Remove wheel speed sensor mounting bolt. Remove wheel speed sensor from vehicle. To install, reverse

1997 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock
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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
table. 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
PARKING/EMERGENCY BRAKE
1. Depress brake pedal several times. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-9
notches, parking brake is properly adjusted. If stroke is not 7-9 notches, raise and support rear of vehicle.
Release parking brake lever.
2. Rotate cable adjusting nut at lever end of cable, located under console cover, until stroke is within
specification. Ensure rear brakes do not drag. Ensure parking brake warning light illuminates when brake
lever is pulled one notch.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
ApplicationIn. (mm)
Miata.16-.28 (4-7)
ApplicationFt. Lbs. (N.m)
Brake Caliper Mounting Bolts37-50 (50-68)
Brakeline Nuts10-16 (14-22)
Hydraulic Unit Brakeline Union Bolts18-26 (24-35)
Hydraulic Unit Mounting Bolts/Nuts14-18 (19-24)
I-Arm-To-Rear Steering Knuckle Bolt (RX7)44-54 (59-73)
Lower Control Arm-To-Rear Steering Knuckle Nut47-54 (64-73)
Push Rod Lock Nut18-25 (24-34)
Stoplight Switch Lock Nut10-13 (14-18)
Wheel Bearing Lock Nut
Front123-159 (167-216)
Rear159-217 (216-294)
Wheel Lug Nuts66-86 (89-117)
Wheel Speed Sensor Mounting Bolt12-16 (16-22)
INCH Lbs. (N.m)
ABS Control Unit Mounting Bolts/Nuts61-87 (6.9-9.8)

1997 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1997 BRAKES Mazda - Anti-Lock
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POWER BRAKE UNIT
1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake
pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal
does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is
operating. If length of strokes is equal, check valve and vacuum hose between vacuum source and power
brake unit. Repair as necessary, and go to next step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake unit is operating. If pedal height recedes, check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (B2300, B3000 & B4000)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder reservoir. Raise and support vehicle. Remove front wheel assemblies. Place a
large "C" clamp on caliper.
2. Tighten clamp to bottom piston in cylinder bore. Remove clamp. Remove 2 caliper pin bolts. Remove
caliper from rotor and wire aside. Slide brake pads off caliper anchor plate. Remove anchor plate (if
necessary). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING
SPECIFICATIONS (FRONT) .
3. To install, reverse removal procedure. Use "C" clamp and old pad to push caliper piston into piston bore
until piston bottoms out. Bleed air from brake system (if necessary).
Removal & Installation (Miata, Millenia, MPV, MX-6, 626 & 929)
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt.
See Fig. 4
, Fig. 5 or Fig. 6 . Pivot caliper upward and support using rope.
2. Remove pads, shims, guide plates or pad guides and "V" springs (if equipped). Replace pad if lining
thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT)
.
3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push
piston full
y inward to install disc pads.
(38-46)

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Removal & Installation (RX7)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Remove lower guide bolt from caliper.
Rotate caliper upward and support using wire. Remove "V" spring. Remove pads, shims and guide plates.
Replace pad if lining thickness is less than .04" (1.0 mm).
2. To install, reverse removal procedure. Use Disc Brake Piston Wrench (49-FA18-602) to rotate piston
clockwise to install disc pads. Ensure grooves in piston are aligned. See Fig. 14
.
Fig. 14: Aligning Brake Caliper Piston (RX7)

Courtesy of MAZDA MOTORS CORP.
REAR BRAKE CALIPER
Removal & Installation (Miata, MPV, MX-6, Protege, RX7, 626 & 929)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. On all models except MPV and 929,
release parking brake and disconnect parking brake cable from caliper. On all models, disconnect brake
hose from caliper.
2. On Miata, MX-6, Protege and 626, remove manual adjustment gear concealment plug from caliper. See
Fig. 11
. Insert an appropriate size Allen wrench through hole and turn manual adjustment gear
counterclockwise to retract caliper piston.
3. On all models, remove guide bolts from caliper. Remove brake caliper from caliper mount. To install,
reverse removal procedure. Bleed air from system.
Removal & Installation (Millenia)
1. Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from

1997 Mazda MX-5 Miata
BRAKE SYSTEM 1995-97 BRAKES Mazda - Disc & Drum
Microsoft
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Caliper Guide Bolts (Front)
Miata58-65 (78-88)
Millenia & 92946-62 (63-84)
MPV62-69 (84-93)
MX-6 & 62622-30 (30-40)
Caliper Guide Bolts (Rear)
Miata33-36 (45-49)
MPV28-36 (38-49)
Millenia & MX-312-18 (16-24)
MX-6 & 62626-29 (35-39)
Protege33-44 (45-60)
RX746-62 (63-84)
92928-36 (38-49)
Caliper Mount Bracket Bolts (Front)
Miata36-51 (49-69)
Millenia75-101 (102-137)
MPV66-79 (89-107)
MX-6 & 62658-74 (79-100)
92975-87 (102-118)
Caliper Mount Bracket Bolts (Rear)
Miata34-48 (46-66)
Millenia & MPV37-50 (50-68)
MX-3 & Protege33-44 (45-60)
MX-6 & 62634-48 (46-66)
RX734-49 (46-67)
92934-49 (46-67)
Front Caliper Mounting Bolt
B2300, B3000 & B400074-96 (100-130)
MX-3 & Protege30-36 (40-49)
RX758-72 (79-98)
Power Brake Unit Nuts
B2300, B3000 & B400016-21 (22-28)
Except B2300, B3000 & B400014-18 (19-25)
Rear Axle Lock Nut
Miata160-216 (216-294)
Millenia, MX-3, MX-6, Protege, RX7, 626 & 929131-173 (177-235)
Wheel Lug Nut
B2300, B3000 & B400085-115 (115-155)
All Other Models65-87 (88-118)
INCH Lbs. (N.m)
Wheel Cylinder Bleeder Screw (1) MX-3 & Protege52-78 (5.9-8.8)

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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