Mazda Trucks 1972-1986 Repair Guide

Manual Steering Gear

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ADJUSTMENTS



See Figures 1, 2, 3 and 4

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Fig. Fig. 1: Checking worm bearing preload on 1972-81 trucks



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Fig. Fig. 2: Checking worm bearing preload on 1982-86 trucks



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Fig. Fig. 3: Using a special tool to tighten the locknut on the adjuster



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Fig. Fig. 4: Checking and adjusting backlash

These adjustments are most accurately made with the steering gear out of the truck, mounted in a vise. Special tools are required.

Worm Bearing Preload

1972-81 VEHICLES
  1. Using an inch pound torque wrench, rotate the wormshaft. Note the torque required for shaft rotation. Torque should be:

    1979-81: 5.2-7.8 in. lbs.
     
    1978: 7.9-10.4 in. lbs.
     
    1976-77: 0.9-3.5 in. lbs.
     
    1972-75: 7.9-10.4 in. lbs.
     

  2.  
  3. If not, remove the end cover and correct it by adding or removing shims under the cover. Shims are available in sizes of 0.050mm, 0.060mm, 0.070mm, 0.075mm, 0.080mm, 0.100mm and 0.200mm.
  4.  

1982-86 VEHICLES
  1. Install a spring scale and adapter 49 0180 510B to the wormshaft. Rotating torque should be 1 / 2 -1 lb.
  2.  
  3. If not, loosen the wormshaft locknut and, using spanner 49 UB39 585, turn the adjuster until preload is within specifications.
  4.  
  5. Using wrench 49 1391 580, or equivalent, tighten the locknut to 140 ft. lbs.
  6.  

Sector Shaft Clearance

1982-86 VEHICLES
  1. Set the adjusting screw and shim in the T-groove on the top of the sector shaft, and measure the axial clearance. Proper clearance should be 0-0.1mm (0-0.0039 in.).
  2.  
  3. If the clearance is excessive, adjust it with different shims. Shims are available in 0.05mm increments from 1.95-2.10mm for 1982-86 trucks.
  4.  

Backlash

  1. Mount a dial indicator next to the vise, with the pointer on the end of the Pitman arm. With the gear in what would be the straight ahead position, backlash should be 0.
  2.  
  3. If not, adjust it using the adjusting screw on top of the gear. Hold the screw with a screwdriver and loosen the locknut. Turn the screw until backlash is correct. Make sure that the Pitman arm is in the position it would be with the wheels straight ahead.
  4.  
  5. When backlash is correct, hold the screw and tighten the locknut.
  6.  

REMOVAL & INSTALLATION1972-75 B1600



  1. Remove the steering wheel as outlined above.
  2.  
  3. Remove the light switch knob.
  4.  
  5. Remove the steering column covers.
  6.  
  7. Remove the stop ring, cancelling cam and spring from the end of the column.
  8.  
  9. Disconnect the combination switch wiring.
  10.  
  11. Remove the combination switch from the column.
  12.  
  13. Remove the steering column support bracket.
  14.  
  15. Loosen the nut securing the bottom of the steering column jacket and pull the jacket off of the shaft.
  16.  
  17. Remove the dust cover from the firewall at the bottom of the shaft.
  18.  
  19. Raise and support the front end on jackstands.
  20.  
  21. Remove the left front wheel.
  22.  
  23. Using a floor jack, raise the lower control arm until the upper control arm is off the bumper stop.
  24.  
  25. Place a chain through the coil spring as a safety measure, or install a spring compressor.
  26.  
  27. Remove the cotter pin and nut retaining the upper ball joint.
  28.  
  29. Using a ball joint separator, disconnect the ball joint from the spindle.
  30.  
  31. Working under the hood, remove the two upper arm retaining bolts and lift the arm from the truck. Note the number and position of any shims.
  32.  
  33. Disconnect the center link from the Pitman arm.
  34.  
  35. Unbolt the steering gear from the frame. Lift the gear off of the frame, noting the position of the shim for installation.
  36.  
  37. Installation is the reverse of removal. Mount the steering gear, placing the shim in its original position. Place the upper control arm shaft shims in their original locations. Observe the following torques:

    Steering gear-to-frame: 40 ft. lbs.
     
    Upper control arm shaft bolts: 65-75 ft. lbs.
     
    Ball joint-to-knuckle: 40-55 ft. lbs.
     
    Center link-to-Pitman arm: 30 ft. lbs.
     
    Pitman arm-to-sector shaft: 130 ft. lbs.
     
    Steering wheel nut: 22-29 ft. lbs.
     

  38.  

1976-77 B1600

  1. Raise and support the front end on jackstands. Remove the left front wheel.
  2.  
  3. Loosen the bolt securing the wormshaft to the steering shaft joint.
  4.  
  5. Remove the cotter pin and nut securing the Pitman arm to the center link and separate the Pitman arm from the link with a ball joint tool.
  6.  
  7. Remove the speedometer cable from the clips securing it to the steering gear housing and power brake booster.
  8.  
  9. Unbolt the steering gear from the frame.
  10.  
  11. If the Pitman arm is to be removed from the sector shaft, first matchmark their positions, relative to each other.
  12.  
  13. Installation is the reverse of removal. Observe the following torques:

    Steering gear-to-frame: 40 ft. lbs.
     
    Wormshaft-to-steering shaft yoke: 28 ft. lbs.
     
    Pitman arm-to-sector shaft: 139 ft. lbs.
     
    Pitman arm-to-center link: 30 ft. lbs.
     

  14.  

Rotary Pick-Up

  1. Raise and support the front end on jackstands. Remove the left front wheel.
  2.  
  3. Loosen the bolt securing the wormshaft to the steering shaft joint.
  4.  
  5. Remove the cotter pin and nut securing the Pitman arm to the center link and separate the Pitman arm from the link with a ball joint tool.
  6.  
  7. Unbolt and remove the insulator from the Pitman arm.
  8.  
  9. Unbolt the steering gear from the frame.
  10.  
  11. If the Pitman arm is to be removed from the sector shaft, first matchmark their positions, relative to each other.
  12.  
  13. Installation is the reverse of removal. Observe the following torques:

    Steering gear-to-frame: 40 ft. lbs.
     
    Wormshaft-to-steering shaft yoke: 28 ft. lbs.
     
    Pitman arm-to-sector shaft: 139 ft. lbs.
     
    Pitman arm-to-center link: 30 ft. lbs.
     

  14.  

B1800 and 1979-81 B2000

  1. Remove the steering wheel as outlined above.
  2.  
  3. Remove the light switch knob.
  4.  
  5. Remove the steering column covers.
  6.  
  7. Remove the stop ring, cancelling cam and spring from the end of the column.
  8.  
  9. Disconnect the combination switch wiring.
  10.  
  11. Remove the combination switch from the column.
  12.  
  13. Remove the steering column support bracket.
  14.  
  15. Loosen the nut securing the bottom of the steering column jacket and pull the jacket off of the shaft.
  16.  
  17. Remove the dust cover from the firewall at the bottom of the shaft.
  18.  
  19. Raise and support the front end on jackstands.
  20.  
  21. Remove the left front wheel. Remove the air cleaner.
  22.  
  23. Disconnect the fluid pipe at the clutch master cylinder, and cap the openings.
  24.  
  25. Disconnect the fluid pipes at the brake master cylinder, and cap the openings.
  26.  
  27. Remove the brake master cylinder.
  28.  
  29. Disconnect the pushrod at the pedal.
  30.  
  31. Unbolt and remove the power booster from the firewall.
  32.  
  33. Drain the cooling system.
  34.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethelyne glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the EGR pipe.
  2.  
  3. Remove the accelerator linkage.
  4.  
  5. Disconnect the choke cable and fuel line. Plug the fuel line.
  6.  
  7. Disconnect the PCV valve hose.
  8.  
  9. Disconnect the heater return hose and by-pass hose.
  10.  
  11. Remove the intake manifold-to-cylinder head attaching nuts.
  12.  
  13. Remove the manifold and carburetor as an assembly.
  14.  
  15. Clean the gasket mating surfaces.
  16.  
  17. Using a floor jack, raise the lower control arm until the upper control arm is off the bumper stop.
  18.  
  19. Place a chain through the coil spring as a safety measure, or install a spring compressor.
  20.  
  21. Remove the cotter pin and nut retaining the upper ball joint.
  22.  
  23. Using a ball joint separator, disconnect the ball joint from the spindle.
  24.  
  25. Working under the hood, remove the two upper arm retaining bolts and lift the arm from the truck. Note the number and position of any shims.
  26.  
  27. Disconnect the center link from the Pitman arm.
  28.  
  29. Unbolt the steering gear from the frame. Lift the gear off of the frame, noting the position of the shim for installation.
  30.  
  31. Installation of the steering gear and control arm is the reverse of removal. Mount the steering gear, placing the shim in its original position. Place the upper control arm shaft shims in their original locations. When installing the brake booster, check the clearance between the master cylinder piston and the power booster pushrod. Clearance should be 0.10-0.50mm (0.0039-0.0197 in.). If not, adjust it at the pushrod. Observe the following torques:

    Steering gear-to-frame: 40 ft. lbs.
     
    Wormshaft-to-steering shaft yoke: 20 ft. lbs.
     
    Upper control arm shaft bolts: 65-75 ft. lbs.
     
    Ball joint-to-knuckle: 40-55 ft. lbs.
     
    Center link-to-Pitman arm: 30 ft. lbs.
     
    Pitman arm-to-sector shaft: 130 ft. lbs.
     
    Steering wheel nut: 22-29 ft. lbs.
     
    Power brake booster-to-firewall: 17 ft. lbs.
     
    Master Cylinder-to-booster: 15 ft. lbs.
     

  32.  
  33. Install a new gasket and the manifold on the studs. Torque the attaching nuts to specification, working from the center outward.
  34.  
  35. Connect the PCV valve hose to the manifold.
  36.  
  37. Connect the by-pass and heater return hoses.
  38.  
  39. Install the accelerator linkage.
  40.  
  41. Connect the fuel line and choke cable.
  42.  
  43. Replace the air cleaner.
  44.  
  45. Fill the cooling system. Bleed the brakes and clutch. Run the engine and check for leaks.
  46.  

1982-84 B2000 and B2200

  1. Remove the steering wheel as outlined above.
  2.  
  3. Remove the steering column covers.
  4.  
  5. Remove the stop ring, cancelling cam and spring from the end of the column.
  6.  
  7. Disconnect the combination switch wiring.
  8.  
  9. Remove the combination switch from the column.
  10.  
  11. Remove the steering column support bracket.
  12.  
  13. Loosen the nut securing the bottom of the steering column jacket and pull the jacket off of the shaft.
  14.  
  15. Remove the dust cover from the firewall at the bottom of the shaft.
  16.  
  17. Remove the bolt securing the yoke joint to the wormshaft and remove the steering shaft.
  18.  
  19. Remove the air cleaner.
  20.  
  21. On trucks with column shift, unbolt the lower bracket from the gear select rod and the shift rod.
  22.  
  23. Remove the lower bracket from the steering gear.
  24.  
  25. Remove the brake lines from the master cylinder and cap the lines.
  26.  
  27. Unbolt and remove the master cylinder from the firewall or power booster. These trucks have a remotely mounted reservoir, so the lines will have to be unclipped and plugged.
  28.  
  29. Remove the cotter pin and nut and disconnect the center link from the Pitman arm using a ball joint tool.
  30.  
  31. Remove the cotter pin and nut, matchmark the Pitman arm and sector shaft and disconnect the Pitman arm from the sector shaft using a ball joint tool.
  32.  
  33. Unbolt the steering gear from the frame, noting the position of any shim that might be installed.
  34.  
  35. Installation is the reverse of removal. Mount the steering gear, placing the shim in its original position. Observe the following torques:

    Steering gear-to-frame: 40 ft. lbs.
     
    Center link-to-Pitman arm: 30 ft. lbs.
     
    Pitman arm-to-sector shaft: 130 ft. lbs.
     
    Steering wheel nut: 22-29 ft. lbs.
     
    Master Cylinder-to-booster: 15 ft. lbs.
     
    Wormshaft-to-steering shaft yoke: 20 ft. lbs.
     

  36.  

1986 B2000

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the pinch bolt securing the wormshaft to the steering shaft coupling.
  4.  
  5. Remove the cotter pin and nut securing the Pitman arm to the center link and separate the Pitman arm from the link with a ball joint tool.
  6.  
  7. Unbolt the steering gear from the frame.
  8.  
  9. If the Pitman arm is to be removed from the sector shaft, first matchmark their positions, relative to each other.
  10.  
  11. Installation is the reverse of removal. Observe the following torques:

    Steering gear-to-frame: 40 ft. lbs.
     
    Wormshaft-to-steering shaft yoke: 28 ft. lbs.
     
    Pitman arm-to-sector shaft: 139 ft. lbs.
     
    Pitman arm-to-center link: 30 ft. lbs.
     

  12.  

 
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