I followed FM's instructions for my 93 rack to a T, and there were no discrepancies. I determined that rack had terminal corrosion and pitting inside from running with cracked boots, so I bought another rack from Ebay, from a 97 according to the seller. This rack is much different, and I cannot figure out how to remove the rack itself from the housing.

Here's FM's tutorial: Flyin' Miata : Tech: 1.8 conversion

And below are my pics of the differences.

Edit - There will be pics as soon as I can get some cooperation from my comp/photobucket/attachments.

 

I had the exact problems with the rack on my '97. I concluded that it was probably a replacement rack of some kind. I never did figure out how to disassemble it...

 

FWIW, when I was building my Locost, I depowered and shortened a rack by 5". The first one that I tried to disassemble into would NOT come apart like the FM instructions said it would. The center section wouldn't come out at all. I scrapped it and did again with another rack that I had. No problems with disassembly. One was from a 94, one a 96. Unfortunately, I don't remember which was which. I'm PRETTY sure that I did the 96 first. 94 came apart fine. Probably not what you want to hear, but it was my experience.

 

It appears the later design is the problematic one.

 

I have a P/S rack, it's a 97 so probably won't help much, but when I get back I can take pics and if it is the right one you can have it for the cost of shipping, your call.

 

But.. I already have a '97 rack, I don't need another. Thanks though.

 

You have a 97' rack "according to the seller", that also doesn't seem to be working out very well for you. Either way, I have nothing to gain. If you change your mind let me know I will take pictures to make sure it is the right one before hand.

 

no snap ring


no bottom nut


this is how the pinion shaft comes out


bit different than the earlier rack at the end too

 

That looks like the NB racks, except it has different mounts. Mine came apart the same way. There is no cylindrical collar like the earlier racks.

Also Be sure to drill out the dimple in the rack near the big aluminum end cap. if you dont, you risk stripping the thread of the end cap.

 

Yeah, Mazda changed the design at some point and I haven't had one apart to put in the instructions. From what I recall , you press it out. Check a factory manual though.