Mazda RX7 Steering Column: adjustments, removal, installation and more
Mazda RX7 1993-1995 FD3SDESCRIPTION AND OPERATION
Mazda steering columns are designed to be collapsible upon impact. The steering column consists of solid steering shaft with a lower joint assembly. RX7 models are equipped with tilt steering. Turn signal, headlight, ignition and windshield washer/wiper switches are mounted on column. Switches can be serviced by removing steering wheel and column covers. All models are equipped with air bag restraint system consisting of an driver air bag module, passenger air bag module and clockspring connector assembly located in the steering column.
SYSTEM OPERATION CHECK
1. Turn ignition switch to ON or START position. AIR BAG warning light in instrument cluster should illuminate for about 4-8 seconds, and then turn off. This indicates air bag system is functioning properly.
2. If any of the following conditions exists, air bag system is malfunctioning and requires servicing.
- AIR BAG warning light does not illuminate as specified.
- AIR BAG warning light remains illuminated for more than 8 seconds.
- AIR BAG warning light illuminates while driving.
SERVICE PRECAUTIONS
Observe the following precautions when servicing air bag system on your Mazda RX7.
- Disable air bag system before servicing any air bag system or steering column component.
- After disabling air bag system, wait at least one minute before servicing. Air bag system voltage is maintained for approximately one minute after system is disabled. Failure to wait one minute before servicing system may cause accidental air bag deployment and possible personal injury.
- Obtain radio code number from customer and deactivate radio anti-theft function (if equipped) before disconnecting battery.
- Because of the critical operation requirements of system, DO NOT service any air bag system component. Repairs are made by replacement only.
- DO NOT use an ohmmeter to check resistance of air bag module, as it may cause air bag deployment.
- When carrying a live (undeployed) air bag module, ensure trim cover is pointed away from your body. This minimizes chance of injury in the event of accidental air bag deployment.
- When placing a live air bag module on any surface, always face trim cover upward to reduce motion of module if it is accidentally deployed.
- If an open circuit is present, replace entire wiring harness. DO NOT attempt to repair wire(s).
- Air bag system clockspring MUST be aligned in neutral position, since its rotation ability is limited. DO NOT turn steering wheel or column after removal of steering gear.
- A double-lock mechanism is used on clockspring connectors. DO NOT use excessive force when disconnecting connectors, as damage to connector may occur.
AIR BAG DISABLING AND ACTIVATING
WARNING: Wait about one minute after disabling air bag system before servicing. Air bag system voltage is maintained for about one minute after system is disabled. Failure to wait one minute before servicing system may cause accidental air bag deployment and possible personal injury.
CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.
DISABLING SYSTEM
1. Obtain radio code and deactivate audio anti-theft function. Turn ignition off. Disconnect and shield negative battery cable. Wait at least one minute for back-up power supply to be depleted.2. Disconnect diagnostic module connectors located at base of steering column and connect Short Circuit Connectors (49-H066-004 ) to diagnostic module harness connectors.
ACTIVATING SYSTEM
1. Ensure negative battery cable is still disconnected. Remove short circuit connectors from diagnostic module harness connectors. See Fig. 3 . Reconnect diagnostic module harness connectors to diagnostic module.2. Reconnect negative battery cable. Turn ignition on. Check AIR BAG warning light to ensure air bag system is operating properly. Activate audio anti-theft function (if equipped).
Fig. 1: Disconnecting Clockspring Connectors (Typical)
Fig. 2: Disconnecting Passenger Air Bag Module Connectors (Typical)
Fig. 3: Connecting Short Circuit Connectors (Typical)
ADJUSTMENTS
CLOCKSPRING CENTERING
Set front wheels in straight-ahead position. Rotate clockspring clockwise until it stops (DO NOT force). Rotate clockspring 2 3/4 turns counterclockwise. Rotate clockspring further, if necessary, to align arrows on clockspring and outer housing. See Fig. 4 .Fig. 4: Centering Clockspring
REMOVAL AND INSTALLATION
DRIVER AIR BAG MODULE
Removal
Before proceeding, follow air bag service precautions. Disable air bag system.Remove air bag module bolts or nuts from back of steering wheel. Disconnect driver air bag module harness connector(s) and support rope. Remove driver air bag module.
Installation
To install, reverse removal procedure. Tighten driver air bag module bolts or nuts to specification. Activate air bag system. Check AIR BAG warning light to ensure system is functioning properly.
STEERING WHEEL
Removal
Set front wheels in straight-ahead position. Disconnect negative battery cable. Disable air bag system. Remove driver air bag module. Mark steering wheel and shaft for reassembly reference. Remove steering wheel nut. Using appropriate puller, remove steering wheel.
Installation
Ensure front wheels are in straight-ahead position. Install steering wheel, ensuring reference marks are aligned. Tighten steering wheel nut to specification. To install remaining components, reverse removal procedure.
COMBINATION SWITCH
Removal
1. Before proceeding, follow air bag service precautions. Disable air bag system.
2. Remove driver air bag module. Remove steering wheel. Remove upper and lower steering column covers. Disconnect combination switch electrical connectors. Remove combination switch screws.
3. Remove clockspring and combination switch as an assembly. Separate clockspring from combination switch.
Installation
1. To install, reverse removal procedure. Ensure front wheels are in straight-ahead position. Before installing steering wheel, center clockspring. See CLOCKSPRING CENTERING under
ADJUSTMENTS. Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS table.
2. After installation, activate air bag system. See AIR BAG DISABLING & ACTIVATING . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .
IGNITION SWITCH/STEERING LOCK ASSEMBLY REMOVAL AND INSTALLATION
1. Remove driver air bag module, steering wheel and combination switch. Disconnect ignition switch connectors. Remove key interlock cable from ignition switch/steering lockassembly (if equipped).
2. Using a hammer and chisel, make a groove in ignition switch/steering lock assembly shear screws. Remove 2 shear screws with screwdriver. Remove ignition switch/steering lock assembly. To install, reverse removal procedure. Tighten NEW shear screws until heads break off.
STEERING COLUMN REMOVAL AND INSTALLATION
CAUTION: Excessive pressure or impact to steering shaft assembly during service may cause column to collapse.
1. Remove driver air bag module, steering wheel and combination switch. See Fig. 5 . Remove ignition switch/steering lock assembly.
2. Remove lower panel. Remove air duct (if equipped). Remove "U" joint dust cover (if equipped). Remove steering shaft assembly-to-intermediate shaft "U" joint bolt. Mark steering shaft assembly-to-intermediate shaft for installation reference.
3. Remove steering column lower mounting bolts. Separate steering shaft from intermediate shaft. Remove steering column upper bracket bolts. Remove steering column.
4. To install, reverse removal procedure. Tighten bolts and nuts to specification.
Fig. 5: Exploded View Of Steering Column
OVERHAUL
STEERING COLUMN
Disassembly
1. Remove driver air bag module, steering wheel and combination switch. See Fig. 5 .
2. Remove ignition switch/steering lock assembly. Remove steering column. Turn steering shaft to remove.
Inspection
Inspect all components for damage and wear. Check steering shaft for bends, damage or sheared plastic pins. Check bearings for excessive play. Replace components as necessary. Measure length of steering shaft. See Fig. 6 .
Reassembly
To reassemble, reverse disassembly procedure. Grease steering shaft, bushings and bearings. Use NEW shear screws.
STEERING SHAFT DIMENSIONS
- Mazda RX7 1993-1995 30.69-30.76 (779.5-781.5) In. (mm)
Fig. 6: Measuring Steering Shaft Dimensions
TORQUE SPECIFICATIONS
- Steering Column Upper Mounting Bolts: 12-16 (16-22) Ft. Lbs. (N.m)
- Steering Column Lower Mounting Bolts: 13-19 (18-26) Ft. Lbs. (N.m)
- Steering Shaft "U" Joint Bolts: 13-19 (18-26) Ft. Lbs. (N.m)
- Steering Wheel Lock Nut: 29-36 (39-49) Ft. Lbs. (N.m)
- Key Interlock Cable Bolt: 35-53 (4-6) INCH Lbs. (N.m)
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Mazda RX-7 1993-1995 FD3S
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