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Mazda RX7. Manual - part 58

CLUTCH

Article Text

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

ARTICLE BEGINNING

1983 Clutch

Mazda - RWD GLC Wagon, RX-7, B2000 Pickup, B2200 Pickup

DESCRIPTION

The clutch assembly for all models is a single plate, dry
disc, diaphragm spring type. The clutch release system used on the RX7
and B2000 and B2200 Pickups is hydraulic, using a firewall-mounted
master cylinder and a slave cylinder attached to the clutch housing.
The GLC Wagon clutch assembly has a mechanical release system
consisting of clutch pedal, cable, release lever and release bearing.
On all models, release bearing is prelubricated and sealed.

REMOVAL & INSTALLATION

CLUTCH ASSEMBLY

Removal
1) Disconnect negative battery cable. Place shift lever in
Neutral. Remove shift knob. Remove console box (if equipped). Remove
shift lever dust boot, lever and related components. On RX7, remove
air cleaner. On GLC Wagon, remove 2 upper clutch housing mount bolts.
2) On all models, raise and support vehicle. Drain
transmission. Remove drive shaft. Remove under covers. Remove any
interfering exhaust components. On all except GLC Wagon, remove clutch
slave cylinder and set aside without removing fluid line.
3) On all models, remove starter, speedometer cable and
related electrical connections. Place jack under rear end of engine.
Protect oil pan with wood block. Position jack under transmission.
Remove transmission-to-engine mount bolts.
4) If equipped, remove transmission-to-crossmember bolts,
crossmember-to-frame bolts and crossmember. Slide transmission back
until input shaft is cleared and remove from vehicle.
5) Install flywheel holding tool (49 0118 271A for GLC Wagon
and B2000 Pickup, 49 E301 060 for B2200 Pickup and 49 1881 060 for
RX7). Index mark pressure plate-to-flywheel.
6) Install clutch assembly alignment tool (49 SE01 310 for
all models). Loosen pressure plate mounting bolts evenly, in a
diagonal pattern. Separate clutch disc and pressure plate. Remove
release bearing and fork. See Fig. 1.

CLUTCH

Article Text (p. 2)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

Fig. 1: Exploded View of RWD Clutch Assembly
Check clutch disc and flywheel for excessive wear, cracks or damage
and release bearing for noise or roughness.

Inspection
1) Check disc for loose rivets, worn springs or oil
contamination. Minimum lining height above rivet heads is .012"
(.30 mm). On RX7, minimum disc free thickness is .276" (7 mm).
2) Inspect flywheel and pressure plate friction surfaces for
burns, scoring or grooves. Friction surface warpage limit is
.002" (.05 mm). Resurface or replace flywheel and/or pressure plate as
necessary. If flywheel ring gear is replaced, ensure chamfer on teeth
faces engine.
3) On RX7, inspect pressure plate diaphragm spring fingers
for excessive wear or out of alignment. Maximum out of alignment limit
is .039" (1 mm). Finger groove wear limit is .039" (1 mm).
4) Mount clutch disc on input shaft. Check runout using dial
indicator. Maximum runout is .039" (1 mm). Check disc hub and input
shaft splines for excessive wear. Hub must slide smoothly on input
shaft splines.

Installation
1) Lightly coat input shaft splines and release bearing
contact areas with molybdenum grease. Use clutch alignment tool to
center clutch assembly. Clutch cover and flywheel "O" alignment marks
must be aligned at installation.
2) Tighten pressure plate bolts evenly, in diagonal pattern.
To complete installation, reverse removal procedure.

RELEASE BEARING & FORK

Removal & Installation
1) With clutch assembly removed, detach release bearing and
fork. On GLC Wagon, loosen and remove bolt attaching release shaft to
transmission. Slide bearing off bearing cover. Remove shaft from
clutch housing.
2) On all models, check release bearing by turning by hand

CLUTCH

Article Text (p. 3)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

in thrust direction. Replace if bearing feels rough or noisy. Inspect
release fork for cracks or bends. Replace if necessary.
3) Lightly apply molybdenum grease to clutch component
contact areas and sliding surfaces. To complete installation, reverse
removal procedures.

CLUTCH MASTER CYLINDER

Removal & Installation (Except GLC Wagon)
Disconnect hydraulic line and mount nuts from master
cylinder. Unhook clutch pedal from push rod. Remove cylinder. To
install, reverse removal procedure and bleed hydraulic system.

CLUTCH SLAVE CYLINDER

Removal & Installation (Except GLC Wagon)
Raise and support vehicle. Disconnect fluid hose and plug.
Remove slave cylinder-to-clutch housing mount nuts. Detach cylinder.
To install, reverse removal procedure and bleed hydraulic system.

CLUTCH CABLE

Removal & Installation (GLC Wagon)
1) Loosen clutch release cable lock nuts at stop ring on
engine side of firewall. Pull inner cable toward clutch pedal.
Disconnect inner cable from pedal assembly.
2) Pull and remove cable through stop ring from engine side
of firewall. Disconnect inner cable at release lever. Remove retaining
clip, pull outer cable and remove from clutch housing bracket. See
Fig. 2.

Fig. 2: GLC Wagon Clutch Cable Assembly
After installation, adjust the clutch cable to specification.

CLUTCH

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1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

3) Inspect for damage to stop ring, cable ends and inner and
outer cable. Check cable function. Before installing, apply molybdenum
grease to bushings, pedal hook and roller. To complete installation,
reverse removal procedure. Adjust cable for proper pedal free play.

PILOT BEARING

Removal & Installation (RX7)
With clutch components removed, check pilot bearing for
roughness, looseness and any damage. If necessary, remove bearing and
oil seal with puller tool (49 1285 071). To install new bearing, use
installer tool (49 0823 072A). Apply multipurpose grease to bearing
and install oil seal.

Removal & Installation (All Other Models)
Pilot bearing is pressed into flywheel. To replace, install
flywheel holding tool and remove flywheel. Using arbor press and
driver, press old bearing out. Press new bearing in until it is flush
with flywheel surface. Lubricate with multipurpose grease. Install
flywheel and holder. Tighten mount bolts evenly, in a diagonal
pattern.

FLYWHEEL

Removal & Installation (RX7)
1) With clutch assembly removed, lock flywheel in position
using holding tool. Loosen and remove lock nut with box wrench (49
0820 035). Remove flywheel using puller tool (49 0823 300A). Turn tool
handle and lightly tap puller head. Once lock nut is loose, do not
drop flywheel.
2) Inspect rear oil seal for leakage and replace as
necessary. Before installing flywheel, apply sealer to surface of lock
nut that contacts flywheel and install. Tighten lock nut to
specification. To complete install, reverse removal procedure.

OVERHAUL

CLUTCH MASTER CYLINDER

NOTE: Master cylinders used on B2000 & B2200 Pickup have a
different external appearance, but procedures are the same.

Disassembly (Except GLC Wagon)
1) Remove reservoir cap assembly. Drain brake fluid. On RX7,
remove reservoir connector bolt and reservoir. On B2000 & B2200
Pickups, remove hydraulic line adapter, washer, 1-way valve, spring
and pin.
2) Remove piston stop ring, washer and piston assembly.
Separate piston, cups and return spring. See Fig. 3. Clean parts in
denatured alcohol or brake fluid. Blow dry with compressed air.
3) Check all parts for wear, damage or deformation. Standard
piston-to-cylinder bore clearance is .001-.004" (.032-.102 mm). If

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