Mazda RX7. Manual - part 59

CLUTCH

Article Text (p. 5)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

clearance exceeds .006" (.15 mm), replace defective part. Coat all
components with clean brake fluid before assembly.

Fig. 3: Exploded View of Clutch Master Cylinder
B2000 & B2200 master cylinder external appearance is slightly
different.

Reassembly
1) Install primary cup with flat side against piston. Ensure
compensating port is open. To complete assembly, reverse disassembly
procedure. After assembly, fill reservoir with clean brake fluid.
2) Bench bleed master cylinder by holding finger over outlet
port and operating piston with screwdriver. Pump piston until air is
ejected at outlet port and fluid pressure is felt. Install master
cylinder and bleed hydraulic system.

CLUTCH SLAVE CYLINDER

Disassembly (Except GLC Wagon)
With slave cylinder removed, detach dust boot and release
rod. Remove piston and cup assembly from cylinder, using compressed
air if required. Remove spring, bleeder screw and valve. See Fig. 4.

CLUTCH

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1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

Fig. 4: Exploded View of Clutch Slave Cylinder
Inspect clutch hydraulic components for leakage and repair or replace
as necessary.

Reassembly
1) Wash parts in clean brake fluid or denatured alcohol. Blow
dry with compressed air. Check all parts for wear or damage. Standard
piston-to-slave cylinder bore is .0016-.0049" (.040-.125 mm). If
cylinder bore-to-piston clearance exceeds .006" (.15 mm), replace
piston and/or cylinder.
2) Before assembly, coat pistons and cups with clean
hydraulic fluid. To complete reassembly, reverse disassembly
procedure.

ADJUSTMENTS

CLUTCH PEDAL HEIGHT

1) On RX7 and Pickup, measure distance from center of upper
surface of pedal pad-to-dash insulator. To adjust height, loosen lock
nut. Turn stopper bolt. Tighten lock nut after adjustment is made. See
Fig. 5.
2) On GLC Wagon, loosen clutch switch lock nut. Rotate switch
until correct height is obtained. Tighten lock nut. Standard pedal
height is 7.48-7.68" (190-195 mm).

CLUTCH PEDAL FREE PLAY

1) On RX7 and Pickups, adjust clutch pedal free play,
measured at pedal pad, to .02-.12" (0.6-3.0 mm). Loosen lock nut and
turn pedal stopper bolt to specification. Tighten lock nut. See
Fig. 5.

CLUTCH

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1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:33PM

Fig. 5: Clutch Adjustment Locations (Except GLC Wagon)
Check clutch pedal for proper height and free play.

2) On GLC Wagon, clutch pedal free play is .39-.59" (10-15
mm). Adjust by setting release cable clearance at engine side of
firewall. Loosen lock nut, pull outer cable and turn adjusting nut
until clearance is .06-.09" (1.5-2.3 mm). Tighten lock nut. Check
pedal free play. See Fig. 2.

CLUTCH PEDAL HEIGHT SPECIFICATIONS

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Application In. (mm)

GLC Wagon ....................... 7.48-7.68 (190-195)
RX7 ............................... 7.5-7.7 (190-195)
B2000 ............................. 8.1-8.3 (205-210)
B2200 ............................. 8.5-8.7 (215-220)

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TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

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Application Ft. Lbs. (N.m)

Flywheel-to-Crankshaft
B2000 ........................... 112-118 (155-163)
B2200 ............................ 95-137 (131-190)
GLC Wagon ........................... 60-65 (83-90)
Flywheel-to-Eccentric Shaft
RX7 Rotary Engine ............... 289-362 (393-492)
Pressure Plate-to-Flywheel ............ 13-20 (18-27)

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END OF ARTICLE

DRIVE AXLE

Article Text

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 06:34PM

ARTICLE BEGINNING

1983 Drive Axles
MAZDA

GLC Wagon, RX7,
B2000 Pickup, B2200 Diesel Pickup

DESCRIPTION

Axle housing is banjo type with removable differential
carrier and semi-floating drive axles. Ring and pinion are hypoid
type, in which centerline of pinion is set below centerline of ring
gear.
Differential case may be either 2 pinion or 4 pinion design.
The drive axles are retained in housing by ball bearings and bearing
retainers at axle housing outer ends. A clutch pack limited slip unit
is available on RX7 models.

AXLE RATIO & IDENTIFICATION

All Mazda models use one basic type of rear axle assembly.
Any differences in Removal & Installation or Overhaul procedures will
be noted where they occur.
Axle ratio on GLC Wagon (automatic), B2200 Pickup and RX7 is
3.909:1. B2000 Pickup is 3.307:1 and GLC Wagon (manual) is 3.727:1.
To determine axle ratio, divide number of ring gear teeth by number
of pinion teeth.

Fig. 1: Exploded View of Mazda Rear Axle Assembly

REMOVAL & INSTALLATION

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