Front Suspension: Removal & Installation Mazda MX-5 NC

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION

Scheme 2

1. Remove the front suspension tower bar. (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-244475-S20579544822006092400000) .)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Inspect the front wheel alignment, and adjust it if necessary. (See «FRONT WHEEL ALIGNMENT»(ref-244483-S41437420692006092400000) .)

Piston Rod Nut Removal Note

Scheme 3

1. Protect the coil spring from scratches using a piece of cloth and install the SSTs .
2. Compress the coil spring using the SSTs and remove the piston rod nut.

Scheme 4

1. Protect the coil spring from scratches using a piece of cloth and install the SSTs .
2. Compress the coil spring using the SSTs .
3. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.

Scheme 5

Scheme 6

1. Align the mark on the upper spring seat with the dust boot projection.
2. Install the upper spring seat so that the upper spring seat stud is at a 27°-33° angle to the shock absorber installation shaft (lower side).

FRONT UPPER ARM REMOVAL/INSTALLATION

Scheme 7

1. Remove in the order indicated in (Scheme 7).
2. Install in the reverse order of removal.
3. Inspect the front wheel alignment and adjust it if necessary. (See «FRONT WHEEL ALIGNMENT»(ref-244483-S41437420692006092400000).)

Scheme 8

1. Remove the front upper arm ball joint from the steering knuckle using the SST .

Front Shock Absorber, Coil Spring And Front Upper Arm Removal Note

1. Loosen the shock absorber upper nuts.
2. Remove the front shock absorber lower bolt and nut.

Front Upper Arm Removal Note

1. Remove the front upper arm bolts.
2. Push down the front lower arm, and then remove the front upper arm from the gap between the shock absorber lower end and the front lower arm.

Scheme 9

1. Remove the front upper arm from the vehicle. (See «FRONT UPPER ARM REMOVAL/INSTALLATION»(ref-244475-S04999526802006092400000) .)
2. Inspect the front upper arm for bending or damage. If there is any malfunction, replace it.
3. Inspect the ball joint for excessive play, and if there is any malfunction, replace the front upper arm.
4. Rotate the ball joint 5 times .
5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench. Front upper arm ball joint rotational torque 0.3-2.2 N.m {4-22 kgf.cm, 3-19 in.lbf} If not within the specification, replace the front upper arm. (See «FRONT UPPER ARM REMOVAL/INSTALLATION»(ref-244475-S04999526802006092400000) .)

FRONT LOWER ARM REMOVAL/INSTALLATION

1. Remove in the order indicated in (Scheme 10).
2. Install in the reverse order of removal.

Scheme 10

Caliper and Mounting Support Removal Note

1. Remove the caliper and mounting support from the steering knuckle and suspend it with a cable in a location out of the way.

Scheme 11

1. Disconnect the front lower arm ball joint from the steering knuckle using the SST . NOTE: When removing the front lower arm ball joint, the steering knuckle bushing may also come off. If it comes off, replace the steering knuckle.

Scheme 12

1. Loosen the bolts on the vehicle side.
2. Disconnect the upper arm ball joint using the SST .

Bushing (Rear Side) Removal Note

Scheme 13

Scheme 14

1. Mark the front upper arm (Scheme 13)
2. Remove the bushing using the SSTs.

Bushing (Front Side) Removal Note

Scheme 15

Scheme 16

Scheme 17

1. Cut off the stopper plate rubber using a razor.
2. Cut off 5-6 mm {0.20-0.23 in} from each side of the knob end of the bushing using a hacksaw.
3. Remove the bushing using the SSTs .

Bushing (Shock Absorber Lower Side Connecting Part) Removal Note

Scheme 18

1. Remove the bushing using the SSTs .

Scheme 19

1. Compress the bushing using the SSTs .

Scheme 20

Scheme 21

1. Press the bushing in using the SSTs .
2. Insert the stopper plate rubber into the inner pipe of the bushing (front side).

Scheme 22

Scheme 23

1. Align the marks placed during removal and install the bushing.
2. Press the bushing in using the SSTs .

Scheme 24

1. Wipe the grease off the ball joint stud.
2. Fill the inside of the new dust boot with grease.
3. Install the dust boot to the ball joint.
4. Install the clip using the SST .
5. Verify that the clip is installed securely to the groove.
6. Wipe off any excess grease.

Front Lower Arm Installation Note

1. Install the front lower arm rear side bushing part horizontally.
2. Install the front lower arm front side bushing.

Scheme 25

1. Remove the front lower arm from the vehicle. (See «FRONT LOWER ARM REMOVAL/INSTALLATION»(ref-244475-S17548442662006092400000) .)
2. Inspect the front lower arm for bending or damage. If there is any malfunction, replace it.
3. Inspect the ball joint for excessive play. If there is any malfunction, replace the front lower arm.
4. Rotate the ball joint 5 times .
5. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench. Front lower arm ball joint rotational torque 0.4-2.9 N.m {5-29 kgf.cm, 4-25 in.lbf} If not within the specification, replace the front lower arm. (See «FRONT LOWER ARM REMOVAL/INSTALLATION»(ref-244475-S17548442662006092400000) .)

FRONT STABILIZER REMOVAL/INSTALLATION

Scheme 26

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

Scheme 27

1. Apply rubber grease to the inner side of the stabilizer bushing.
2. Align the outer side of the stabilizer slide stopper with the stabilizer bushing.
3. Install the stabilizer bracket.

Scheme 28

1. Remove the stabilizer control link from the vehicle. (See «FRONT STABILIZER REMOVAL/INSTALLATION»(ref-244475-S12649939922006092400000) .)
2. Inspect the stabilizer control link for bending or damage. If there is any malfunction, replace it.
3. Rotate the ball joint stud 10 times , and then rock it side to side 10 times .
4. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench. Stabilizer control link ball joint rotational torque 0.2-2.0 N.m {3-20 kgf.cm, 2-17 in.lbf} If not within the specification, replace the stabilizer control link. (See «FRONT STABILIZER REMOVAL/INSTALLATION»(ref-244475-S12649939922006092400000) .)

FRONT CROSSMEMBER REMOVAL/INSTALLATION

Scheme 29

1. Remove the front suspension tower bar. (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-244475-S20579544822006092400000).)
2. Remove the front stabilizer (See «FRONT STABILIZER REMOVAL/INSTALLATION»(ref-244475-S12649939922006092400000).)
3. Remove the transverse members (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-244475-S19815374922006092400000).)
4. Remove the steering gear and linkage, and suspend it using a cable.
5. Remove in the order indicated in (Scheme 29).
6. Install in the reverse order of removal.
7. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-244483-S41437420692006092400000).)

Axle and Hub Component Removal Note

1. Loosen the front upper arm inner bolts.
2. Remove the axle and hub component.

Scheme 30

Scheme 31

Scheme 32

1. Secure the chain to install the SST to the position (Scheme 30)using the bolts ( M10 x 1.5, length 30 mm {1.18 in} ).
2. Suspend the engine.
3. Support the front crossmember using a jack. WARNING: Verify that the crossmember component is securely supported by a jack. If the crossmember component falls, it could cause serious injury or death, or damage to the vehicle.
4. Lower the front crossmember component slightly.
5. Remove the engine mounting rubber, pipes and hoses installed to the front crossmember.
6. Remove the front crossmember component.

Scheme 33

1. Remove in the order indicated in (Scheme 33).
2. Install in the reverse order of removal.

Transverse Member Removal Note

1. Support the crossmember using a jack.
2. Remove the transverse member.

Scheme 34

Scheme 35

1. Align projection A with the transverse member opening to temporarily support the under cover.
2. Tighten the bolts in the order of A, B and C.

Scheme 36

1. Remove in the order indicated in (Scheme 36).
2. Install in the reverse order of removal.

Scheme 37

1. Install the plates with the identification marks facing upward.