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Pinion Gap Inspection

WARNING: This page is about a different car, the 2004 Mazda 3. However, it is still accessible from the selected car via links, so may be relevant.
  1. Pull out the drive pinion with battery positive voltage connected to terminal (S) and the starter body grounded. See Figure.
  2. Measure the pinion while the drive pinion is pulled. If not as specified, adjust with an adjustment washer, between the drive housing front cover and the magnetic switch. The correct measurement is 0.02-0.07" (0.5-2.0 mm). See Fig 1.
Fig 1: Measuring Pinion Gap
G00356715Courtesy of MAZDA MOTORS CORP.
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