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

Mazda RX7 1993-1995 FD3S


Rear suspension consists of MacPherson type struts, double wishbone design upper control arm, I-arm, trailing link and toe-control link. A stabilizer bar with stabilizer link mounts to frame and upper control arms. A rear strut bar is mounted between tops of each strut assembly. Upper control arm and I-arm mount to crossmember and knuckle/hub assembly. Trailing link mounts to I-arm and crossmember. Toe-control link mounts to crossmember and knuckle/hub assembly. Rear wheel camber alignment is adjusted using bolt and cam plate on upper control arm. Toe-in is adjusted using toe-control link. See Fig. 1 .

Fig. 1: Identifying Rear Suspension Components

WHEEL BEARING ADJUSTMENT

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

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REMOVAL AND INSTALLATION

WHEEL BEARING

Removal
1. Raise and support vehicle. Remove wheel assembly. Remove drive axle lock nut. Remove brake caliper, and wire aside. Remove brake rotor. Disconnect ABS speed sensor. Remove I-arm-to-knuckle/hub bolt. Remove toe-control link-to-knuckle/hub bolt. Remove upper control arm-to-knuckle/hub bolt. Remove knuckle/hub assembly from vehicle.
2. Using Handle (49-G033-102), Attachment (49-G033-105) and Puller (49-F026-103), remove hub from knuckle. Remove snap ring from knuckle. If bearing race remains on hub, grind race until
approximately .02" (.50 mm) thick and remove using chisel. Using Attachment (49-F027-005) and Support Block (49-H034-201), remove wheel bearing from hub.

Inspection
Check wheel hub and knuckle for cracks and damage. Check backing plate for deformation. Check bearing for excessive wear and seizure.

Installation
Press NEW wheel bearing into knuckle using Attachment (49-F027-004) and Support Block (49-H034-201). Press hub into knuckle using Adapter (49-F027-005). To install, reverse removal procedure. Perform final tightening of trailing link with vehicle resting on ground and suspension unloaded. Tighten drive axle lock nut to specification. Stake drive axle lock nut.

STRUT ASSEMBLY

Removal and Disassembly
1. Raise and support vehicle. Remove wheel assembly. Remove stabilizer link-to-upper control arm nut. Remove stabilizer link from upper control arm. Separate lower strut from upper control arm. Remove suspension tower cover from top of rear strut bar located in rear hatch compartment. Remove rear strut bar from top of strut assembly.
2. Remove upper strut assembly-to-body nut and rubber stopper. Remove strut assembly and gasket. Clamp strut securely in soft-jawed vise. Loosen upper strut shaft nut several turns, but DO NOT remove nut. Compress coil spring, then remove nut. Remove remaining components, noting order for reassembly reference.

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 and Installation
To reassemble, reverse disassembly procedure. Ensure coil spring is seated in lower seat. To install, reverse removal procedure. Ensure paint mark on lower strut mount faces rearward. Tighten nuts to specification. Check rear wheel alignment.

UPPER CONTROL ARM

Removal
Raise and support vehicle. Remove wheel assembly. Remove stabilizer link-to-upper control arm nut. Remove stabilizer link from upper control arm. See Fig. 2 . Separate lower strut from upper control arm. Remove upper control arm-to-crossmember nuts and bolts. Remove upper control arm-to-knuckle/hub assembly nut and bolt. Remove upper control arm.

Inspection
Inspect upper control arm for cracks and deformation. Check bushings for damage and excessive wear. Check pillow ball for excessive play. Replace components as necessary.

Bushing Replacement
Mount upper control arm in a soft-jawed vise. Remove old bushings using components from Bushing Replacer Set (49-F034-2A0). To install, apply soapy water to NEW bushings. Using components from Bushing Replacer Set (49-F034-2A0), install NEW bushings into upper control arm.

Pillow Ball Replacement
1. Mount upper control arm in a soft-jawed vise. Using screwdriver, remove rubber seals. Remove snap ring. Remove pillow ball using components from Bushing Replacer Set (49-F034-2A0). To install, coat diameter of NEW pillow ball with multipurpose grease.
2. Using components from Bushing Replacer Set (49-F034-2A0), install NEW pillow ball into upper control arm. Ensure step side of pillow ball is facing into upper control arm. Install snap ring. Fill space between pillow ball and rubber seals with grease. Install rubber seals into upper control arm.



Installation
To install, reverse removal procedure. Tighten nuts and bolts to specification. Check rear wheel alignment.

Fig. 2: Removing Upper Control Arm

TRAILING LINK AND I-ARM

Removal
Raise and support vehicle. Remove wheel assembly. Remove trailing link-to-I-arm bolt. See Fig. 1 . Remove trailing link-to-crossmember bolt and nut. Remove trailing link. Mark cam plate-to-crossmember position for installation reference. Remove I-arm-to-crossmember cam bolt, cam plate and nut. Remove I-arm-toknuckle/hub assembly bolt and nut. Remove I-arm.

Inspection
Inspect trailing link and I-arm for cracks and deformation. Check bushings for damage and excessive wear. Check pillow balls for excessive play. Replace components as necessary.

Bushing Replacement (I-Arm)
Mount I-arm in a soft-jawed vise. Carefully cut away outer flange of bushing. Remove old bushing using components from Bushing Replacer Set (49-F034-2A0). To install, apply soapy water to NEW bushing. Using components from Bushing Replacer Set (49-F034-2A0), install NEW bushing into I-arm.

Bushing Replacement (Trailing Link)
Mount trailing link in a soft-jawed vise. Remove old bushing using components from Bushing Replacer Set (49-F034-2A0). To install, apply soapy water to NEW bushing. Using components from Bushing Replacer Set (49-F034-2A0), install NEW bushing into trailing link.

Pillow Ball Replacement
1. Mount I-arm in a soft-jawed vise. Using screwdriver, remove rubber seals. Remove snap rings. Remove pillow balls using components from Bushing Replacer Set (49-F034-2A0). To install, coat diameter of NEW pillow balls with multipurpose grease.
2. Using components from Bushing Replacer Set (49-F034-2A0), install NEW pillow balls into I-arm. Ensure step side of pillow ball is facing into I-arm. Install snap rings. Fill space between pillow ball and rubber seals with grease. Install rubber seals into I-arm.

Installation
To install, reverse removal procedure. Perform final tightening of trailing link with vehicle resting on ground and suspension unloaded. Check rear wheel alignment.

TOE-CONTROL LINK

Removal
Raise and support vehicle. Remove wheel assembly. Remove ABS speed sensor harness bracket from toecontrol link. Remove toe-control link-to-crossmember bolt and nut. Remove toe-control link-to-knuckle/hub assembly bolt and nut. Remove toe-control link.

Inspection
Inspect toe-control link for cracks and deformation. Check bushings for damage and excessive wear. Replace components as necessary.

Installation
To install, reverse removal procedure. Ensure paint mark on toe-control link faces upward after installation. Check rear wheel alignment.

STABILIZER BAR AND LINK REMOVAL AND INSTALLATION

1. Raise and support vehicle. Remove wheel assembly. Remove stabilizer link-to-upper control arm nut. See Fig. 2 . Remove stabilizer bar-to-frame mounting bolts and brackets. Remove stabilizer bar from vehicle. Remove stabilizer bar-to-stabilizer link nut. Separate stabilizer link from stabilizer bar.
2. To install, reverse removal procedure. Ensure bushing is aligned with stopper or White paint mark on stabilizer bar. Check marks on stabilizer links and ensure stabilizer links are installed on correct side of stabilizer bar.

REAR STRUT BAR REMOVAL AND INSTALLATION

Remove suspension tower cover from top of rear strut bar located in rear hatch compartment. Remove nuts retaining strut plate to upper strut assembly. Remove rear strut bar assembly from vehicle. Remove strut plate from strut bar (if necessary). Inspect strut bar for bends or damage. To install, reverse removal procedure. Tighten nuts/bolts to specification.

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TORQUE SPECIFICATIONS

• ABS Speed Sensor Bolt: 14-18 (19-24) Ft. Lbs. (N.m)
• ABS Speed Sensor Bracket Bolt: 14-18 (19-24) Ft. Lbs. (N.m)
• Brake Caliper Bolts: 34-49 (46-66) Ft. Lbs. (N.m)
• Drive Axle Lock Nut: 174-231 (235-313) Ft. Lbs. (N.m)
• I-Arm-To-Crossmember Pivot Bolt/Nut: 69-86 (93-117) Ft. Lbs. (N.m)
• I-Arm-To-Knuckle/Hub Bolt/Nut: 44-54 (59-73) Ft. Lbs. (N.m)
• Rear Strut Bar-To-Strut Plate Bolt/Nut: 14-19 (19-26) Ft. Lbs. (N.m)
• Stabilizer Bar Bracket-To-Frame Bolts: 14-19 (19-26) Ft. Lbs. (N.m)
• Stabilizer Bar-To-Stabilizer Link Nut: 40-56 (54-76) Ft. Lbs. (N.m)
• Stabilizer Link-To-Upper Control Arm Nut: 69-81 (93-110) 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 (33-45) Ft. Lbs. (N.m)
• Strut Piston Rod Lock Nut: 12-17 (16-23) Ft. Lbs. (N.m)
• Toe-Control Link-To-Crossmember Bolt/Nut: 44-54 (59-73) Ft. Lbs. (N.m)
• Toe-Control Link-To-Knuckle/Hub Bolt/Nut: 48-57 (65-77) Ft. Lbs. (N.m)
• Trailing Link-To-Crossmember Bolt/Nut: 69-86 (93-117) Ft. Lbs. (N.m)
• Trailing Link-To-I-Arm Bolt: 44-54 (59-73) Ft. Lbs. (N.m)
• Upper Control Arm-To-Crossmember Pivot Bolt/Nut: 44-54 (59-73) Ft. Lbs. (N.m)
• Upper Control Arm-To-Knuckle/Hub Bolt/Nut: 44-54 (59-73) Ft. Lbs. (N.m)
• Wheel Lug Nuts: 65-87 (88-118) Ft. Lbs. (N.m)

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Mazda RX-7 1993-1995 FD3S

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