Mazda MX-5 Miata (1997+). Manual — part 49

1997 Mazda MX-5 Miata

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

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. Tighten side bearing adjusters equally until adjusters contact bearing races. Mark ring gear in 4 locations,

Application

Gauge Block No.

Front Differential

MPV
4WD

49-0305-555

Rear Differential

Miata

49-0305-555

MPV

49-0660-555

Application

INCH Lbs. (N.m)

Miata

7.8-12.1 (0.9-1.3)

MPV 2WD

11.3-15.6 (1.3-1.8)

MPV 4WD

Front

7.8-12.2 (0.9-1.4)

Rear

11.3-15.6 (1.3-1.8)

1997 Mazda MX-5 Miata

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

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)

Miata

7.300-7.303 (185.43-185.50)

MPV 2WD

8.022-8.050 (203.78-204.50)

MPV 4WD

Front

7.275-7.303 (184.78-185.50)

Rear

8.022-8.050 (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

Fig. 13: Measuring Carrier Case Spread
Courtesy of MAZDA MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (MIATA)

Application

Ft. Lbs. (N.m)

Differential Carrier Bearings Cap Bolts

28-38 (38-52)

Differential Carrier Bearings Lock Plate Bolt

13-18 (18-25)

Differential Carrier-To-Housing Bolts

17-19 (23-26)

Differential-To-Chassis Mount Nuts

Inner Nut

61-72 (83-98)

Outer Nuts (2)

13-20 (18-27)

Drive Axle Inner CV Joint Flange Nuts

40-47 (54-64)

Drive Pinion Lock Nut

94-209 (128-284)

Drive Shaft Companion Flange Nuts

20-22 (27-30)

Exhaust Pipe Mount Nuts

30-41 (40-55)

Filler Plug

29-40 (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