Mazda Protege 5. Manual - part 243

CLUTCH 

05–10–11

05–10

CLUTCH UNIT REMOVAL/INSTALLATION

A3U051016000W01

1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.

.

Y3U510WA1

1

Clutch release cylinder

2

Transaxle
(See 05–15A–4 MANUAL TRANSAXLE (MTX) 
REMOVAL/INSTALLATION [F25M-R].)
(See 05–15B–4 MANUAL TRANSAXLE (MTX) 
REMOVAL/INSTALLATION [G15M-R].)

3

Boot

4

Clutch release collar

5

Clutch release fork

6

Clutch cover
(See 05–10–12 Clutch Cover Removal Note.)
(See 05–10–13 Clutch Cover Installation Note.)

7

Clutch disc
(See 05–10–13 Clutch Disc Installation Note.)

8

Pilot bearing
(See 05–10–12 Pilot Bearing Removal Note.)
(See 05–10–13 Pilot Bearing Installation Note.)

9

Flywheel
(See 05–10–12 Flywheel Removal Note.)
(See 05–10–12 Flywheel Installation Note.)

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CLUTCH 

05–10–12

Clutch Cover Removal Note

1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until the spring tension is released.
3. Remove the clutch cover and disc.

Pilot Bearing Removal Note

Note

•

The pilot bearing does not need to be removed unless you are replacing it.

1. Use the SSTs to remove the pilot bearing.

Flywheel Removal Note

1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in the 

pattern shown.

3. Remove the flywheel.
4. Inspect for oil leakage from the crankshaft rear oil 

seal.

•

If there is any such leakage or if the oil seal is 
damaged, replace the crankshaft rear oil seal.

Flywheel Installation Note

1. Install the flywheel to the crankshaft.
2. Hand-tighten the flywheel installation bolts.
3. Install the SST to the flywheel.
4. Tighten the flywheel installation bolts in the 

pattern shown.

Tightening torque

97—102 N·m {9.8—10.5 kgf·m, 70.9—75.9 

ft·lbf}

X3U510WA8

X3U510WA9

U3U51013

U3U51014

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CLUTCH 

05–10–13

05–10

Pilot Bearing Installation Note

1. Install a new pilot bearing using the SST.

Bearing installation depth

0—0.4 mm {0—0.01 in}

Clutch Disc Installation Note

1. Hold the clutch disc in position using the SSTs.

Clutch Cover Installation Note

1. Install the SSTs.
2. Tighten the bolts evenly and gradually in the 

pattern shown.

Tightening torque

18—26 N·m {1.8—2.7 kgf·m, 14—19 ft·lbf}

End Of Sie

CLUTCH COVER INSPECTION

A3U051016410W01

1. Measure the wear of the diaphragm spring 

fingers.

Depth

0.5 mm {0.020 in} max.

X3U510WB0

U3U51016

U3U51017

U3U51018

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CLUTCH 

05–10–14

2. Measure the flatness of the pressure plate 

surface using a straightedge and a feeler gauge 
as shown in the figure.

Maximum clearance

0.5 mm {0.020 in}

Note

•

When inspecting the diaphragm spring 
fingers, mount a dial indicator on the cylinder 
block.

3. Rotate the flywheel and inspect for misaligned 

diaphragm spring fingers.

•

If the misalignment exceeds the maximum, 
replace the clutch cover.

Misalignment

0.6 mm {0.024 in} max.

End Of Sie

CLUTCH DISC INSPECTION

A3U051016460W01

1. Inspect the contact surface of the clutch disc for 

scoring, cracks, burning, and oil contamination.

2. Remove minor scoring or burning using emery 

paper.

•

Repair if scoring or burning is major.

•

Replace if cracked or contaminated with oil.

3. Inspect for loose facing rivets and dampers.

•

If the clutch disc is loose, replace the clutch 
disc.

4. Using vernier calipers, measure the thickness of 

the lining at a rivet head on both sides.

•

If the thickness of the lining at any rivet head 
is less than the minimum, replace the clutch 
disc.

Thickness

0.3 mm {0.012 in} min.

U3U51019

U3U51020

U3U51021

W3U510WC1

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