Mazda RX-7 Front Suspension: strut assembly, toe control link and more

Mazda RX7 1993-1995 FD3S



An independent front suspension with MacPherson-type struts is used on all models. RX7 uses double wishbone design upper and lower control arms with struts mounted between lower control arm and upper fender panel. See Fig. 1 . Strut assembly mounts between steering knuckle and upper fender panel. Lower control arm pivots at crossmember and is connected by ball joint to steering knuckle. All models are equipped with a stabilizer bar which attaches to each lower control arm and frame. See Fig. 1 .

Fig. 1: Identifying Front Suspension Components

ADJUSTMENTS AND INSPECTION

WHEEL BEARING ADJUSTMENT

Raise and support vehicle. Remove wheel assembly. Remove brake caliper and wire aside. Attach dial indicator to rotor and axle hub assembly. Measure bearing play. Check bearing axial play by rocking hub assembly by hand. Maximum axial play should be .002" (.05 mm). If play exceeds specification, check and adjust lock nut torque or replace hub and bearing assembly.

BALL JOINT CHECKING

Lower and Upper Ball Joint
Remove lower control arm. Rotate ball joint stud 4-5 times. Install Preload Attachment (49-0180-510B) to ball joint stud. Measure ball joint preload using spring scale. If preload is not as specified, replace ball joint or lower control arm.

LOWER BALL JOINT PRELOAD SPECIFICATIONS

• Mazda RX7 1993-1995: 1.1-3.3 (0.5-1.5) Lbs. (kg)

UPPER BALL JOINT PRELOAD SPECIFICATIONS

• Mazda RX7 1993-1995: 0.9-2.6 (0.4-1.2) Lbs. (kg)

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REMOVAL AND INSTALLATION

WHEEL BEARING

Wheel bearing is not serviceable. If bearing is defective, replace hub and bearing assembly as a unit.

Removal
Raise and support vehicle. Remove wheel assembly. Remove brake caliper and wire aside. Remove grease cap and axle lock nut. Remove brake rotor. Remove hub and bearing assembly. Remove wheel speed sensor rotor from hub.

Inspection
Wash all disassembled components before inspection. Check for damage, excessive wear and signs of bearing seizure. Inspect steering knuckle and hub for cracks, scoring and rust. Check for damaged dust cover and poor fit with steering knuckle. Replace components as necessary.

Installation
To install, reverse removal procedure. Adjust wheel bearing preload.

LOWER CONTROL ARM AND BALL JOINT

Removal
1. Raise and support vehicle. Remove wheel assembly. Remove engine splash shield (if equipped). Remove brake caliper and wire aside (as necessary). Remove compression rod or tension rod (if equipped). Separate tie rod end from steering knuckle (as necessary). Remove stabilizer bar from lower control arm.
2. Remove strut lower mounting bolt and separate lower strut from lower control arm or steering knuckle. Remove lower control arm ball joint cotter pin and nut. Separate lower control arm ball joint stud from knuckle. Remove lower control arm pivot bolts and remove lower control arm.

Inspection
Check lower control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check ball joint for excessive wear. Examine dust boot for damage. Replace components as necessary.

Bushing Replacement
Cut away front bushing inner collar. Using a vise and Remover/Installer (49-F034-2A0), push out front bushing. Press out rear bushing using Remover/Installer (49-F034-2A0). To install front bushing, apply soapy water to bushing and use remover/installer to press in. Always install bushing from outer side of arm. Press in bushing until collar contacts arm. To install rear bushing, align arrows on bushing with marks on lower arm and use remover/installer to press in.

Installation
To install, reverse removal procedure. Tighten lower control arm-to-frame bolts to specification with vehicle resting on ground and suspension unloaded.

UPPER CONTROL ARM AND BALL JOINT

Removal
Raise and support vehicle. Remove wheel assembly. Disconnect brake line from strut assembly. Remove wheel speed sensor harness band. Remove strut lower mounting bolt and separate lower strut from lower control arm. Remove upper control arm ball joint bolt. Separate upper control arm ball joint stud from knuckle. Remove upper control arm pivot bolts and remove upper control arm.

Inspection
Check upper control arm for damage or cracks. Check bushings for deterioration and excessive wear. Check ball joint for excessive wear. Examine dust boot for damage. Replace components as necessary.

Bushing Replacement
Cut away front and rear bushing inner collars. Using a vise and Remover/Installer (49-F034-2A0), push out front and rear bushings. To install front and rear bushings, apply soapy water to bushings and use remover/installer to press in. Always install bushings from outer side of arm. Press in bushings until collar contacts arm.

Installation
To install, reverse removal procedure. Tighten upper control arm pivot bolts to specification with vehicle resting on ground and suspension unloaded.

STRUT ASSEMBLY

Removal
Raise and support vehicle. Remove wheel assembly. Disconnect brake line from strut assembly. Remove wheel speed sensor harness band and sensor. Remove upper control arm pivot bolts. Remove cap, nut and rubber stopper from upper strut. Remove strut upper mount nuts and remove strut plate. Remove insulator from upper strut. Remove strut lower bolt. Move upper control arm just enough to remove strut assembly.

Disassembly
Clamp upper strut mount in vise. Loosen piston lock nut 2 turns only. Compress coil spring using coil spring compressor. Remove piston lock nut. Slowly release compressor tension. Remove components. Remove coil spring. Remove strut from vise.

Inspection
Check strut tube for damage, oil leakage and abnormal noise. Check rubber components for deterioration or damage. Inspect coil spring for signs of fatigue or damage. Replace components as necessary.

Reassembly
Clamp strut in vise. Install coil spring and components in reverse order of disassembly. Ensure coil spring is well seated in upper and lower spring seats.

Installation
To install, reverse removal procedure. Fully tighten all bolts with vehicle resting on ground and suspension unloaded.

STABILIZER BAR REMOVAL AND INSTALLATION

1. Raise and support vehicle. Remove engine splash shield (if equipped). Remove mounting hardware and stabilizer bar. Note position of frame bushing seam.
2. Remove steering gear mounting bracket nuts and remove steering gear. Support crossmember with jack and remove bolts and nuts. Slowly lower crossmember and remove stabilizer bar. On all models, inspect all components for wear, bends or damage. Replace components as necessary.
3. To install, reverse removal procedure. Ensure frame bushing is aligned with White line on stabilizer bar. Ensure seam faces front of vehicle. Fully tighten all bolts with vehicle resting on ground and suspension unloaded.

FRONT STRUT BAR REMOVAL AND INSTALLATION

1. Strut bar is located in engine compartment mounted on top of strut assembly.See Fig. 2 . Remove nut, washer and bolt retaining strut bar to strut plate. Remove strut bar from vehicle. Loosen lock nut and remove joint "A" and joint "B" from strut bar.
2. To install, reverse removal procedure. Rotate joint "B" counterclockwise to 3.5-5.2 INCH lbs. (.4-.6 N.m) to set tension. Tighten lock nut to 87-121 INCH lbs. (10-14 N.m). Tighten strut bar-to-strut plate nut.

Fig. 2: Removing Front Strut Bar

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TORQUE SPECIFICATIONS

• Brake Caliper Bracket Bolts: 58-72 (78-98) Ft. Lbs. (N.m)
• Drive Axle Lock Nut: 130-175 (177-235) Ft. Lbs. (N.m)
• Front Strut Bar-To-Strut Plate Nut: 24-33 (32-46) Ft. Lbs. (N.m)
• Lower Ball Joint-To-Knuckle Nut: 58-80 (78-108) Ft. Lbs. (N.m)
• Lower Control Arm-To-Frame Bolt/Nut: 69-86 (93-117) Ft. Lbs. (N.m)
• Stabilizer Bar Bracket-To-Frame Bolts: 13-19 (18-26) Ft. Lbs. (N.m)
• Stabilizer Bar-To-Stabilizer Link Nut: 27-40 (36-54) Ft. Lbs. (N.m)
• Stabilizer Link-To-Lower Control Arm Nut: 44-54 (59-73) Ft. Lbs. (N.m)
• Strut Assembly Lock Nut: 12-17 (16-23) Ft. Lbs. (N.m)
• Strut Assembly-To-Body Nuts (Strut Plate): 34-46 (46-63) Ft. Lbs. (N.m)
• Strut Assembly-To-Body Shaft Nut: 24-33 (32-46) Ft. Lbs. (N.m)
• Strut Assembly-To-Lower Control Arm Bolt: 69-86 (93-117) Ft. Lbs. (N.m)
• Tie Rod-To-Knuckle Nut: 22-32 (30-44) Ft. Lbs. (N.m)
• Upper Ball Joint-To-Knuckle Bolt: 27-39 (37-53) Ft. Lbs. (N.m)
• Upper Control Arm Pivot Bolt/Nut: 44-54 (59-73) Ft. Lbs. (N.m)
• Wheel Lug Nuts: 65-87 (88-118) Ft. Lbs. (N.m)
• Wheel Speed Sensor Bolt: 12-17 (16-23) Ft. Lbs. (N.m)

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Mazda RX-7 1993-1995 FD3S

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