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Manual Rack and Pinion

REMOVAL AND INSTALLATION

1993-94 323, MX3 and Protege
Without 4WD
  1. Disconnect the negative battery cable. Raise and safely support the vehicle and remove the wheel and tire assemblies.
  2. Remove the engine undercover.
  3. Remove the cotter pins and nuts and disconnect the tie rod ends.
  4. Remove the steering column universal joint bolt. Matchmark the joint to the pinion shaft.
  5. If equipped with power steering, disconnect the hydraulic lines and drain the fluid into a container.
  6. If equipped with manual transaxle, disconnect the extension bar and shift control rod from the transaxle.
  7. Remove the bracket nuts or bolts and remove the steering rack from the vehicle.

    To install:

  8. When fitting the rack into place, make sure the pinion shaft and universal joint matchmarks are correctly aligned. Fit the shaft into the joint and start the steering rack bracket nuts or bolts.
  9. Tighten the bracket nuts or bolts to 38 ft. lbs. (52 Nm). Install the universal joint bolt and torque it to 20 ft. lbs. (26 Nm).
  10. Connect the tie rod ends and torque the nuts to 42 ft. lbs. (57 Nm), then tighten as required to install a new cotter pin.
  11. If equipped, connect the power steering hydraulic lines and install the undercover.
  12. Install the wheel and tire assemblies and lower the vehicle. If equipped with power steering, fill the system with the proper fluid and bleed the air from the system.
With 4WD
  1. Remove the battery and battery tray. Raise and safely support the vehicle and remove the front wheels and front crossmember.
  2. Disconnect the tie rod ends and remove the bolt from the steering column universal joint. Matchmark the universal joint to the pinion shaft.
  3. Disconnect the hydraulic lines and drain the fluid into a container.
  4. To remove the steering rack, the front-to-rear engine mount member must be removed:
    1. Use the proper lifting equipment and support the engine from above.
    2. Disconnect the front and rear engine mounts from the mount member and remove the mount member.
    3. Remove the rear mount from the engine.
  5. Remove the exhaust pipe and catalytic converter.
  6. Matchmark the flanges and remove the driveshaft.
  7. Lower the engine gradually until the lower left rack mounting bolt can be reached. Do not lower too far or the halfshaft joints will be damaged.
  8. Remove the mount bolts and move the rack to the left to remove the steering rack.

    To install:

  9. When fitting the rack into place, make sure the pinion shaft and universal joint matchmarks are correctly aligned. Fit the shaft into the joint and start the steering rack bracket bolts. Torque the nuts and bolts to 38 ft. lbs. (52 Nm).
  10. Use new gaskets and install the exhaust pipe. Torque the flange nuts to 34 ft. lbs. (46 Nm).
  11. Install the driveshaft and torque the flange nuts to 22 ft. lbs. (30 Nm).
  12. Install the engine mount and mount member. Torque the mount member nuts to 66 ft. lbs. (89 Nm), the mount-to-engine nuts to 38 ft. lbs. (52 Nm).
  13. Connect the fluid lines. Install the universal joint bolt and torque it to 20 ft. lbs. (27 Nm).
  14. Connect the tie rod ends and torque the nuts to 42 ft. lbs. (57 Nm) and tighten as required to install a new cotter pin.
  15. Install the front crossmember and torque the bolts to 86 ft. lbs. (117 Nm).
  16. Fill the pump with fluid and bleed the air from the system.
1993-97 Miata
  1. Disconnect the negative battery cable. Raise and safely support the vehicle and remove the wheel and tire assemblies.
  2. Remove the engine undercover.
  3. Remove the cotter pins and nuts, and disconnect the tie rod ends.
  4. Remove the steering column universal joint bolt. Matchmark the joint to the pinion shaft.
  5. Remove the bracket bolts, and remove the steering rack from the vehicle.

    To install:

  6. When fitting the rack into place, make sure the pinion shaft and universal joint matchmarks are correctly aligned. Fit the shaft into the joint and start the steering rack bracket nuts or bolts.
  7. Tighten the bracket bolts to 34-43 ft. lbs. (47-58 Nm) on 1995-97 models and 38 ft. lbs. (52 Nm) on 1993-94 models. Install the universal joint bolt, and torque it to 14-19 ft. lbs. (18-26 Nm) on 1995-97 models and 20 ft. lbs. (26 Nm) on 1993-94 models.
  8. Connect the tie rod ends, and torque the nuts to 22-32 ft. lbs. (30-44 Nm) on 1995-97 models and 42 ft. lbs. (57 Nm) on 1993-94 models. Install a new cotter pin.
  9. Install the undercover.
  10. Install the wheel and tire assemblies and lower the vehicle.
  11. Adjust the front alignment.
 
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