Mazda RX-7 Clutch: assembly, master cylinder, adjustments and etc.

Mazda RX7 1993-1995 FD3S

HYDRAULIC SYSTEM BLEEDING

1. Remove bleeder screw cap, located at clutch release cylinder. Install vinyl hose onto bleeder screw. Submerge other end of hose in container of brake fluid.
2. Fill reservoir with DOT 3 brake fluid. Have an assistant press and release clutch pedal several times, then hold pedal down. With pedal pressed, loosen bleeder screw to let air and fluid escape.
3. Repeat step 2) until no more air bubbles emerge from hose. Tighten bleeder screw. Fill reservoir. Operate clutch while inspecting for leaks. Check clutch and brake operation.

ADJUSTMENTS

CLUTCH PEDAL FREE PLAY

Mazda RX7 1993-1995: 0.2-0.5 (5-13) In. (mm)

Measure clutch pedal free play. See Fig. 1 . If free play is not within specification, inspect hydraulic and mechanical system components. If adjustment is required, loosen lock nut and rotate master cylinder push rod to obtain specified free play. Tighten lock nut.

CLUTCH PEDAL HEIGHT

Mazda RX7 1993-1995: 6.52-6.97 (166-177) In. (mm), Measure to carpet on bulkhead. See Fig. 1.

Measure clutch pedal height from bulkhead to front side of pedal pad. See Fig. 1 .

CLUTCH DISENGAGEMENT HEIGHT (MINIMUM):

Mazda RX7 1993-1995: 1.89 (48) In. (mm), Measure to carpet on bulkhead. See Fig. 1 .

Measure clutch disengagement height, where clutch disengages, from pedal pad to bulkhead. See Fig. 1 .

Fig. 1: Adjusting Clutch Pedal
Fig.1

REMOVAL AND INSTALLATION

CLUTCH ASSEMBLY

CLUTCH RUNOUT (MAXIMUM)

Disc: 0.024 (0.6) In. (mm)
Flywheel: 0.008 (0.20) In. (mm)

Fig. 2: Exploded View Of Clutch Assembly (Typical)
Fig.2

Removal
1. Disconnect negative battery cable. Remove console, gear shift knob, and insulator. Remove gear shift lever. Remove transmission cover.
2. Raise and support vehicle. Remove right and left under covers. Leave fluid pipe connected to clutch release cylinder. Remove clutch release cylinder from transmission housing and secure aside with wire. Remove starter and center tunnel reinforcement. Remove secondary air injection pipe and catalytic
converter. Remove front and rear tunnel reinforcement.
3. Mark drive shaft flange for reassembly reference. Remove drive shaft. Insert Main Shaft Holder (49-S120-440 ) into extension housing. Support engine and differential. Remove Power Plant Frame (PPF)from transmission and differential. Remove back up light switch from transmission.
4. Remove service access covers "A" and "B". See Fig. 3 . Through service hole "A", swing clutch fork forward and hold release collar against pressure plate. Insert a screwdriver through service hole "B" into space between release collar and wedge collar. Pry and separate release from pressure plate.

Fig. 3: Identifying Clutch Housing Service Access Holes
Fig.3

If release collar cannot be separated from clutch cover, remove cover-toflywheel bolts through service hole "B". Remove clutch cover and disc with transmission.

5. Secure transmission jack under transmission. Remove transmission-to-engine block bolts. Remove transmission. If clutch disc and clutch cover were removed with transmission, remove wire ring from release collar. Separate release collar from clutch cover. Remove clutch cover and disc.

Inspection
1. Inspect disc for loose rivets, worn or defective springs, excessive wear, or oil contamination. Inspect flywheel and clutch cover for burns, scoring, or grooves.
2. Inspect flywheel and clutch cover for excessive runout. Resurface or replace flywheel and clutch cover if necessary.
3. Inspect clutch disc for excessive runout. Replace disc if necessary. Inspect disc hub and input shaft splines for excessive wear. Hub must slide smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating bearing. If bearing sticks or has excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.

Installation
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide grease. Align clutch disc onto flywheel. Install NEW wedge collar and wire ring on clutch cover. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a crisscross pattern to specification.
2. Raise transmission into position. Install and tighten transmission-to-engine block bolts to specification. Install PPF and tighten bolts/nuts, in sequence, to specification. See Fig. 4 or Fig. 5 . To complete installation, reverse removal procedure.

Fig. 4: PPF Bolt/Nut Tightening Sequence Differential-Side
Fig.4

Fig. 5: PPF Bolt/Nut Tightening Sequence Transmission-Side
Fig.5

RELEASE BEARING AND FORK: REMOVAL AND INSTALLATION

1. Remove transmission. Remove release bearing and fork. Turn release bearing in both directions. Replace bearing if rough or noisy.
2. Inspect release fork for wear and damage. Replace if necessary. Apply molybdenum disulfide grease to release bearing contact and sliding surfaces. To complete installation, reverse removal procedure.

CLUTCH MASTER CYLINDER REMOVAL AND INSTALLATION

Disconnect hydraulic line and master cylinder mounting nuts. Disengage push rod from clutch pedal. Remove master cylinder. To install, reverse removal procedure and bleed hydraulic system.

CLUTCH RELEASE CYLINDER REMOVAL AND INSTALLATION

Raise and support vehicle. Disconnect and plug hydraulic line. Remove clutch release cylinder. To install, reverse removal procedure. Bleed hydraulic system.

OVERHAUL

CLUTCH MASTER CYLINDER

Fig. 6: Exploded View Of Clutch Master Cylinder
Fig.6

CLUTCH RELEASE CYLINDER

Use exploded view of clutch release cylinder for overhaul procedure. See Fig. 7.

Fig. 7: Exploded View Of Clutch Release Cylinder
Fig.7

TORQUE SPECIFICATIONS

Catalytic Converter Nuts: 48-65 (64-89)
Clutch Cover Bolts, Tighten in a crisscross pattern: 13-19 (18-26)
Drive Shaft Bolts 38-42 (51-58)
Flywheel-To-Crankshaft Nuts 290-361 (393-490)
Power Plant Frame (PPF) Mounting: Tighten in sequence. See Fig. 4 or Fig. 5.
- Bolt 55-68 (75-93)
- Nuts 109-130 (148-176)
Starter Mounting Bolts: 28-38 (38-51)
Transmission-To-Engine Block Bolts: 28-38 (38-51)
Tunnel Reinforcement: 13-19 (18-26)

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Mazda RX-7 1993-1995 FD3S

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