mazda miata front wheel bearing repair

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Kurt Batdorf Bellevue College, Winter 2016 | Technical Writing Certificate Program MAZDA MIATA FRONT WHEEL BEARING REPAIR Model Years 1990-1997 and 1999-2005

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Page 1: Mazda Miata Front Wheel Bearing Repair

Kurt Batdorf

Bellevue College, Winter 2016 | Technical Writing Certificate Program

MAZDA MIATA FRONT WHEEL BEARING REPAIR Model Years 1990-1997 and 1999-2005

Page 2: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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This document was completed as the final requirement for Technical Writing Certificate Program – Inclusive at Bellevue College, Winter 2016.

The author assumes no liability for injuries or damage that may result from following these instructions.

All photos by the author, unless otherwise credited.

Contents copyrighted and may not be used without permission.

Page 3: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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Table of contents

Statement of purpose ....................................................................................................... 4

Target audience ................................................................................................................ 4

Introduction ....................................................................................................................... 4 A. Verify the need for replacement ......................................................................................................................... 4 B. Who can do this procedure? ............................................................................................................................... 5 C. Safety considerations .............................................................................................................................................. 5 D. What parts will you need? .................................................................................................................................... 5 E. Required tools ......................................................................................................................................................... 6

Removal ............................................................................................................................. 7 A. Wheel ........................................................................................................................................................................ 7 B. Hub dust cap ............................................................................................................................................................ 7 C. Brakes: Caliper, pads, bracket and rotor .......................................................................................................... 8 D. Hub and retaining nut ............................................................................................................................................ 9 E. Reassembly ............................................................................................................................................................... 9

References ........................................................................................................................ 10

Style Sheet ....................................................................................................................... 11

Page 4: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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Statement of purpose This document will show how to remove and replace the front wheel bearings on 1990-1997 and 1999-2005 Mazda Miatas.

Target audience The target audience is enthusiast owners who are willing and able to perform basic mechanical repairs on their cars.

Introduction

A.   Verify the need for replacement Miata wheel bearings wear out with time, mileage and contaminated lubrication. They aren’t adjustable.

Listen for a bad wheel bearing in a turn. A right-front wheel bearing will tend to make noise in left-hand turns. A left-front wheel bearing will tend to make noise on right-hand turns.

Check the wheel bearing for looseness. Jack up your Miata. Grasp the tire or wheel with your hands at 6 and 12 o’clock and shake it. If you see movement or hear a “clunk,” replace that bearing immediately.

Check the other wheel bearing if one side shows signs of failure.

The author has replaced the front wheel bearings twice on his 1994 Mazda Miata (left) after driving 285,000 miles. The procedure also applies to second-generation 1999-2005 Miatas (right, 2003 model shown).

The signs of a bad wheel bearing: Ø Rumble Ø Metallic grinding Ø Speed-dependent,

rotational “thunk” Ø Vertical free play or

movement of the wheel Ø Wheel bearings

eventually fail, but the mileage range can vary widely depending on how the car is driven and the quality of the replacement parts.

Page 5: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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B.   Who can do this procedure? This procedure applies to all Mazda Miatas from model years 1990-1997 and 1999-2005. You will remove and replace four lug nuts, two bolts on the brake caliper, two bolts on the brake caliper bracket, and the hub nut.

You need some basic mechanical skills, access to tools and the willingness to perform this procedure. You will need a breaker bar and possibly a “cheater pipe” for leverage to loosen the hub nut.

C.   Safety considerations WARNING: Working on a vehicle is inherently dangerous. Exercise adequate precautions to prevent serious injury.

1.   Perform this procedure only on a solid, level surface where you can safely jack up the car.

2.   Set the handbrake and block the rear wheels to prevent vehicle movement.

3.   Use sturdy jack stands to hold the car safely. Place the jack stands under the reinforced section of the side rail, between two notches. Look for the notches at the rear edge of the fender beneath the front edge of the door.

D.  What parts will you need? Buy a new front hub assembly from a Mazda dealer or aftermarket supplier. Prices vary from about $20 for an aftermarket piece to more than $300 at the dealer.

All 1990-2005 Miatas without antilock brakes (ABS) use the same hub. If your Miata has ABS, there’s a hub for cars built before Aug. 1, 2004, and one for those built after. Factory stickers in the door jambs will state if your Miata has ABS and when it was built. If your Miata has (ABS), make sure the new hub has the ABS timing ring to retain ABS function.

Check the Sponsors link at www.miata.net for Mazda dealers and Miata specialists. Some sell blueprinted hubs that better withstand the stresses of racing.

Obtain a new hub bearing nut. If you don’t think you can remove the hub dust cap without damage (see Step B.2., page 7), buy a new cap, too.

C.3.: Support the car on jack stands behind the front wheel, between the notches in the seam.

D.: This is a blueprinted hub with an integrated wheel bearing. This project explains how to replace the entire hub assembly, which surrounds the wheel bearing. When the bearing fails, you replace the hub as a unit.

D.: The new hub and wheel bearing assembly sits on the steering knuckle’s stub shaft.

Page 6: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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With the wheel off, inspect the brakes for any defective or missing springs or clips. Replace brake pads if they are near or below the wear limit. Replace brake calipers that are leaking fluid or seized. Replace brake rotors with cracks or deep gouges. Refer to References for resources.

Mazda used three sizes of brakes on Miatas:

Ø   1990-1993 (1.6) Ø   1994-2002 (1.8) Ø   2001-2002 (Sport) on all LS models and Hard-S

Bilstein suspension option Ø   2003-2005 (Sport) on all models

Note: Mazda fitted Sport brakes and 1.8 brakes in 2001 and 2002. If your 2001 or 2002 Miata came factory equipped with 15-inch wheels, it has 1.8 brakes. If it came with 16-inch wheels, it has Sport brakes.

Pads, rotors, calipers, brackets and hardware do not interchange among the types.

E.   Required tools Ø   Low-profile floor jack Ø   Jack stands Ø   ½-inch ratchet wrench and breaker bar Ø   “Cheater” steel or iron pipe, 2-3 feet long; to fit

over breaker bar handle for additional leverage Ø   14 mm, 17 mm, 21 mm, 29 mm sockets Ø   17 mm open-end wrench (Sport brakes only) Ø   Small steel chisel Ø   Steel center punch Ø   Soft-faced hammer (plastic, rubber or bronze) or

small block of wood Ø   Ball peen hammer Ø   Large, flat-bladed screwdriver Ø   ½-inch, 150 ft.-lb. torque wrench Ø   Large C-clamp to retract brake caliper piston Ø   Metal coat hanger or 12-inch piece of heavy-gauge

wire to hang brake caliper Ø   Spray brake cleaner Ø   Shop towels or rags Ø   Wheel bearing grease Ø   High-temperature brake caliper grease Ø   Wooden blocks for tires Ø   2x8 scrap lumber, about 2 feet long (if necessary

for jack clearance)

Buy new wheel hub nuts from a Mazda dealer or Miata specialist. This nut holds the wheel onto the car.

Use a torque wrench to tighten the lug nuts, brake caliper bolts and hub nut. This wrench “clicks” when it reaches a preset torque of 25 to 150 foot-pounds. Other wrenches utilize a beam with a pointer to measure torque.

Page 7: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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Removal

A.  Wheel 1.   If necessary, remove any cap over the lug nuts. 2.   Check if your floor jack will fit under the front

subframe. If not, place a piece of lumber in front of each tire, parallel to the car, and drive onto it.

3.   Set the handbrake and block the rear tires to prevent vehicle movement.

4.   Loosen the lug nuts about one-half turn in an “X” pattern.

5.   Jack up the car using the steel subframe, not the aluminum oil pan.

6.   Place the jack stands under the reinforced seam at the front of the side sills. Lower the jack until the car sits on the jack stands.

7.   Remove the lug nuts and wheel.

B.   Hub dust cap 1.   If you’re replacing the cap, use the steel chisel and

hammer to remove the old cap. 2.   If the cap can be reused, use light hammer blows

and carefully tap the chisel into the gap around the hub’s perimeter without distorting the cap. Allow several rotations of the hub before the cap and hub begin to separate.

3.   As the gap opens, place the flat screwdriver’s tip between the hub and cap. Tap the screwdriver carefully with the hammer around the perimeter. When the screwdriver tip hits the inner lip of the cap, carefully twist the screwdriver, working around the hub to pry off the cap.

A.4.: Loosen the lug nuts in a crosswise “X” pattern about one-half turn as shown.

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3 4

2

A.6.: Place the jack stand between these notches.

A.3.: Block the rear tires.

B.1., B.2.: You can reuse the metal dust cap if you carefully use a small steel chisel and screwdriver to separate the cap from the hub.

Page 8: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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C.   Brakes: Caliper, pads, bracket and rotor Note: Inspect all brake parts for wear and defects during disassembly and obtain necessary replacements. See References, Page 10.

Note: DO NOT press on the brake pedal after you remove the brake caliper. That will force the piston out of the caliper and spill brake fluid. Brake fluid damages painted surfaces. Promptly wipe up any spills.

1.   1.6 and 1.8: Two caliper bolts (slider pins) face the inside of the wheel well. Loosen the 17 mm pin and remove the 14 mm pin.

a.   On 1.6 brakes, the 17 mm pin is on top and the 14 mm pin is on the bottom; 1.8 brakes are pictured.

b.   Rotate the caliper away from the rotor to expose the pads. When the caliper can clear the rotor, slide it out of the bracket.

2.   Sport: Working one at a time, hold each slider pin with a 17 mm open-end wrench to remove each 14 mm bolt that holds the caliper to the bracket. Lift off caliper. Remove slider pins (note pin location).

3.   Thread wire through a caliper bolt hole to hang it on the spring or control arm. Don’t stress the brake hose.

4.   Remove the brake pads: a.   1.6 and 1.8: Remove the “\_/” springs. b.   All: Remove the pads by tilting the upper

edge away from the rotor until the tabs clear the bracket. Note backing plate fitment.

5.   Note fitment of the four brake pad clips in the bracket. Some will fall off.

6.   Remove the two 14 mm bolts that secure the caliper bracket to the steering knuckle.

7.   Remove the rotor. Note: If the rotor is stuck, thread a 6 mm bolt into the hole on the rotor and tighten until it pops free. Remove the bolt.

8.   Obtain replacement brake parts.

C.4.b.: Remove the brake pads.

C.2., Sport brakes: To remove the 14 mm bolt (left) that secures the caliper to the bracket, hold the 17 mm bolt head (right) with a slim wrench. It can be a very tight fit.

14 mm

17 mm

C.1.a.: Loosen the 17mm bolt. Remove the 14 mm bolt.

C.1.b.: Rotate the caliper away from the rotor to slide it off.

Photo courtesy Rob Huntley

Page 9: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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D.  Hub and retaining nut 1.   Use a hammer and chisel to create adequate

clearance in the threads where the nut was staked to the shaft.

2.   Attach the 29 mm socket to the breaker bar. Place the breaker bar with the handle facing left, just above horizontal. Gradually use your body weight to press down on the breaker bar to release the nut counterclockwise.

a.   WARNING: Sudden pressure can cause the breaker bar to snap and cause injury.

b.   If the nut won’t release, slide the cheater pipe over the breaker bar handle for additional leverage to release the nut. Use caution.

3.   Remove the nut and hub.

E.   Reassembly 1.   Spray brake cleaner onto the hub shaft and backing

plate. Wipe off grease and grime. 2.   Spread a thin layer of wheel bearing grease on the

hub shaft. 3.   Fit the new hub on the shaft, studs facing outward. 4.   Install the new hub nut finger tight.

a.   Before torqueing the hub nut, make sure the hub spins freely and has no free play.

b.   With a torque wrench, tighten the nut to 123-159 ft.-lbs. by pressing down. Verify that the new hub spins and has no free play.

c.   With the nut properly torqued, use the steel punch and hammer to stake the nut into the slot.

d.   Replace the hub dust cap. Use a soft-faced hammer to tap the cap into the hub, or put a small block of wood over the dust cap to absorb the hammer’s impact.

5.   Slide the brake rotor over the wheel studs. 6.   Install the caliper bracket on the steering knuckle.

Tighten the bolts to 60 ft.-lbs. 7.   Verify that the four pad clips are properly attached

to the bracket, then install the brake pads.

D.1.: Before removing the hub nut, use a chisel or drift to make clearance where the nut was staked to the slot in the shaft.

E.1.: Clean the hub shaft and backing plate before installing the new hub.

E.4.c.: Tighten the hub nut to 123-159 ft. lbs., then stake the nut into the slot.

E.4.d.: Replace the dust cap.

Page 10: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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8.   If you installed new brake pads, use the C-clamp to retract the caliper piston. Place the top of the clamp against the outside of the caliper. Run the threaded shaft against the piston between the two caliper “fingers.” Slowly tighten the clamp. Watch for fluid leaks from the seal. Note: Retracting the piston pushes brake fluid into the master cylinder in the engine compartment. Remove excess fluid from the reservoir first.

9.   Lubricate caliper slider pins with high-temperature brake caliper grease.

10.  Attach the caliper. a.   1.6, 1.8: Slide the caliper and 17 mm pin

into the bracket. b.   Install each “\_/” spring in the brake pads.

Hold the brake pads together and rotate the caliper over the pads. Install and tighten the 14 mm slider pin to 50 ft.-lbs. Tighten the 17 mm slider pin to 62 ft.-lbs.

c.   Sport: Fit slider pins into the bracket. Slide the caliper over the pads. Hold slider pins with 17 mm wrench and tighten 14 mm bolts to 50 ft.-lbs.

d.   Press the brake pedal a few times to reposition the brake caliper and pads. Check for leaks.

11.  Attach the wheel with the lug nuts finger tight, wheel flat against the hub.

12.  Lift the car to remove jack stands. 13.  Tighten lug nuts to 70-80 ft.-lbs. 14.  Test drive to check for abnormal noises,

performance and proper brake function.

References Ø   “Mazda Miata 1.8 Liter Enthusiast’s Shop Manual,” by

Rod Grainger and Pete Shoemark, 2003

Ø   “Mazda Miata MX-5 Performance Projects,” by Keith Tanner, 2003

Ø   Miata.net Sponsors

Ø   Miata.net Garage

E.10.b: With “\_/” springs on 1.6 and 1.8 brakes, hold the pads together as you rotate the caliper into position. Sport brakes do not use these springs.

E.10.a.: Slide the 17mm slider pin and caliper into the bracket (1.8 shown).

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3 4

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E.13.: With the car on the ground, tighten the lug nuts to 75 ft.-lbs. in the pattern shown.

Page 11: Mazda Miata Front Wheel Bearing Repair

MAZDA MIATA FRONT WHEEL BEARING REPAIR | Kurt Batdorf

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Style Sheet Style references: Purdue Online Writing Lab, “Associated Press Style Book 2012” (47th edition)

Dictionary: Webster’s New World College Dictionary (fourth edition), 2001

A

Abbreviations: Name institution, group, agency, etc., on first reference, then abbreviate on second reference. Follow AP guide for exceptions (AP).

B

C

Comma: No serial comma (A, B and C) unless last item in series contains “and” or “or” (AP).

Compound modifiers: Use a hyphen to join two or more words serving as a single adjective before a noun (OWL).

D

Dashes, hyphens: Do not use spaces with dashes or hyphens (AP).

Use dash with comparative measurements (123-159 ft.-lbs.)

E

Em-dash: Use single space on each side of em-dashes (AP).

F

Figures: For comparative measurements, separate with dash (123-159 ft.-lbs).

Foot-pounds: Use to measure torque, as with a torque wrench; abbreviate to ft.-lb. or ft.-lbs.

G

H

Headings, headlines: Capitalize first word and proper nouns only (AP).

I

Introductory phrases: Set off phrase with comma where speech would naturally pause (OWL).

J

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K

L

M

Miles: Use figures for any distances over 10. For any distances below 10, spell out the distance (AP).

Millimeter, millimeters: Abbreviate to “mm” on second reference.

N

Numbers: In sentences, spell out zero through nine (“Drive six blocks”). Use numerals for 10 or more (“She bought 13 apples”) (AP).

Numerals: When writing about height, weight or other dimensions, use figures and spell out feet, meters, etc. Use figures for ages (AP).

O

P

Prefixes: Generally not hyphenated. Hyphenate only when prefix creates double letters, as in “re-election.” (AP)

Punctuation: Always place punctuation within quotation marks (AP).

Q

Quotation marks: Use double marks (“) to open or close a quote. Use a single mark (‘) for quotes (see also “Titles”) within a quote (AP). Use smart quotation marks where formatting permits.

Quote attribution: Use “LASTNAME said” in most constructions (AP).

R

S

Spaces: Use single spaces between words, sentences and punctuation (AP).

Spelling: Follow American spelling conventions (OWL).

T

Titles: Use quotation marks around the titles of books, songs, television shows, computer games, poems, lectures, speeches and works of art; no quotation marks with magazines, newspapers, the Bible or reference materials. Do not underline or italicize any of these (AP).

U

V

W

X

Y

Z