1987 MAZDA 626 height

CLUTCH
OUTLINE 6— 2
STRUCTURAL VIEW 6— 2
SPECIFICATIONS 6— 3
TROUBLESHOOTING GUIDE 6— 3
ON-VEHICLE MAINTENANCE 6— 4
FLUID LEVEL 6— 4
PEDAL HEIGHT 6— 4
PEDAL FREEPLAY 6— 4
CLUTCH PEDAL 6— 5
REMOVAL 6— 5
INSPECTION 6— 6
INSTALLATION 6— 6
ADJUSTMENT 6— 6
CLUTCH MASTER CYLINDER 6— 7
REMOVAL 6— 7
DISASSEMBLY 6—8
INSPECTION 6— 9
ASSEMBLY 6— 9
INSTALLATION 6—11
CLUTCH RELEASE CYLINDER 6—11
REMOVAL 6—12
DISASSEMBLY 6-12
INSPECTION 6—13
ASSEMBLY 6—13
INSTALLATION 6—14
AIR BLEEDING 6—14
CLUTCH AND FLYWHEEL 6—15
REMOVAL 6—15
INSPECTION 6—16
INSTALLATION 6—19
76G06X-001

TROUBLESHOOTING GUIDE 6
SPECIFICATIONS
Item Engine model F6 F8 FE FE DOHC RF-N RF-CX
Clutch control type Hydraulic
Clutch cover type Diaphragm spring
General 3,434
(350,770) 3,846
(392,862) 4,316 (440,968) 3,846
(392,862) —
Set load
N (kg, lb) ECE (Except UK) — 4,022
(410,902) 4,611 (470, 1,034) 4,022 (410, 902)
UK — 3,846
(392,862)
4,611 (470,1,034) 4,316
(440,968)
3,846 (392,862) 4,022 (410,902)
Clutch disc Outer diameter mm (in) 200 (7.874) 215 (8.465) 225 (8.858)
Inner diameter mm (in) 130 (5.118) 150 (5.906)
Pressure plate side
General 4.1 (0.16) —
Thickness Pressure plate side
ECE
(Except UK) — 3.8 (0.15)
mm(in)
Pressure plate side UK 4.1 (0.16)13.8 (0.15) 4.1 (0.16) 3.8 (0.15)
Flywheel side 3.5 (0.14)
Type Suspended
Pedal ratio LHD 6.00
Clutch pedal Pedal ratio RHD 5.96
Full stroke mm (in) 135 (5.31)
Height mm (in) 216.5-221.5 (8.524-8.720)
Master cylinder inner diameter mm (in) 15.87 (0.625)
Release cylinder inner diameter mm (in) 19.05 (0.750)
Clutch fluid type DOT-3 or DOT-4, FMVSS 116, or SAE J1703
76G06X-002
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Slipping Clutch disc facing worn excessively Replace 6—17 Clutch disc facing surface hardened or oil on Repair or replace 6-17
surface Pressure plate deformed Repair or replace 6-16 Diaphragm spring damaged or weakened Replace 6-16 Insufficient clutch pedal play Adjust 6—4 Clutch pedal does not function smoothly Repair or replace 6—4, 5 Flywheel deformed Repair or replace 6-18
Faulty Excessive runout or deformity of clutch disc Replace 6-17 disengagement Clutch disc splines rusted or worn Remove rust or 6—17 replace Oil on clutch cover facing surface Repair or replace 6-16 Diaphragm spring weakened Replace 6-16
Excessive clutch pedal play Adjust 6—4, 5
Insufficient clutch fluid Add fluid 6-4
Leakage of clutch fluid Reoair or reDlace —
Clutch vibrates Oil on clutch disc facing surface Repair or replace 6-17 when starting Torsion spring weakened Replace 6-17 Clutch disc facing surface hardened or deformed Repair or replace 6-17
Clutch disc facing rivets loose Replace 6-17 Pressure plate deformed Replace 6-16
Flywheel surface hardened or deformed Repair or replace 6-18
Loose or worn engine mount Tighten or replace —
Clutch pedal Pedal shaft not properly lubricated lubricate or replace 6-5 does not func-tion smoothlv
Abnormal noise Clutch release bearing damaged Replace 6—17 Poor lubrication of clutch release bearing sleeve Lubricate or replace 6-17
Torsion spring weakened Replace 6-17
Excessive crankshaft end play Repair Refer to Section 1 Pilot bearing worn or damaged by heat Replace 6-16
Worn pivot points of release fork • Reoair or replace 6-18
76G06X-003
6-3

6 ON-VEHICLE MAINTENANCE
6-4
ON-VEHICLE MAINTENANCE
FLUID LEVEL
1. Clean the area around the reservoir and the reser-
voir cap.
2. Check the fluid level. If the level is near or below
the "MIN" mark, add clutch fluid to the "MAX"
mark.
Fluid specification:
DOT-3 or DOT-4
(FMVSS 116, or SAE J1703)
PEDAL HEIGHT
Inspection
Measure the distance from the upper center of the
pedal pad to the firewall and ensure that the distance
is within specification.
Pedal height A:
216.5—221.5 mm (8.524—8.720 in)
Adjustment
To adjust the pedal height, loosen locknut and turn
stopper bolt or clutch switch.
PEDAL FREEPLAY
Inspection
Depress the pedal lightly by hand and measure the
freeplay to ensure that it is within specification.
Pedal freeplay: 5—13 mm (0.20—0.51 in)
Adjustment
1. Adjust the free play by loosening locknut C and
turning push rod D.
2. Check that the distance from the floor to the cen-
ter of the upper surface of the pedal pad is as
specified or more when the clutch is fully dis-
engaged.
Disengagement height B:
LHD 68 mm (2.7 in)
RHD 85 mm (3.3 in)
3. Tighten locknut C after adjustment.

6 CLUTCH PEDAL
INSPECTION
Check the following, and repair or replace any faulty
parts.
1. Worn or damaged pedal bushing
2. Twisted or bent pedal
3. Worn or damaged pedal pad
76G06X-008
INSTALLATION
Install in the reverse order of removal referring to the
installation note.
Installation Note
Apply grease (lithium base, NLGI No.2) to the
bushings.
76G06X-009
ADJUSTMENT
1. Adjust the pedal height. (Refer to page 6—4.)
2. Check the pedal free play, and adjust if necessary.
(Refer to page 6—4.)
3. Adjust the installation length of the assist spring.
The installation length is adjusted by turning nut
A show in the figure and adjusting dimension B.
Standard dimension:
38.6—39.6 (1.520—1.559 in)
76G06X-010
6-6

ASSEMBLY 7B
(2) Install the clutch assembly by rotating it.
86U07B-414
Note
Measure the height difference between the re-
verse and forward drum and transaxle case.
Standard height: 0.8 mm (0.032 in)
76G07B-185
17. Install the snap ring into the bottom ring groove
of the turbine shaft.
86U07B-416
7B—207

BRAKE PEDAL 1 1
Pedal height
"tt^
Pedal-to-floor clearance
76G11X-008
BRAKE PEDAL
ON-VEHICLE INSPECTION
Pedal Height
Inspection
Check that the distance from the center of the upper
surface of the pedal pad to the firewall is as specified.
LHD and RHD
Pedal height: 222 mm (8.74 +0-200 in)
Adjustment
1. Disconnect the stop light switch connector.
2. Loosen locknut B and turn switch A until it does
not contact the pedal.
3. Loosen locknut D and turn rod C to adjust the
height.
4. Adjust the pedal free play and tighten locknut D.
5. Turn the stop light switch until it contacts the ped-
al; then turn an additional 1/2 turn. Tighten lock-
nut B.
Locknut B tightening torque:
14—18 N m (1.4—1.8 m-kg, 10—13 ft-lb)
Locknut D tightening torque:
24—34 Nm (2.4—3.5 m-kg, 17—25 ft-lb)
Pedal Play
Inspection
1. Depress the pedal a few times to eliminate the
vacuum in the system.
2. Gently depress the pedal again by hand, and
check the free play. (Until the valve plunger con-
tacts the stopper plate = until the power piston be-
gins to move.)
Pedal play: 4—7 mm (0.16—0.28 in)
76G11X-099
Adjustment
Loosen the locknut D of the operating rod C; then
turn the rod to adjust the free play.
Locknut D tightening torque:
24—34 Nm (2.4—3.5 m-kg, 17—25 ft-lb)
86U11X-018
11—11

BRAKE PEDAL 1 1
INSPECTION
Check the following and replace or repair any faulty
parts.
1. Pedal pad for wear or damage
2. Bushing for wear
3. Bolt for bending
4. Pedal for bending
5. Return spring for weakness or damage
86U11X-021
INSTALLATION
1. Install in the reverse order of removal.
2. Tighten all nuts and bolts, referring to torque specifications.
3. After installation:
Check and adjust the pedal height and play. (Refer to page 11—11.)
Torque specifications
76G11X-010
Installation Note
Application of grease
Apply grease to the following parts:
(1) Inner and outer surfaces of bushing
(2) Outer surface of guide pipe
(3) Contact surface of clevis pin and spring
86U11X-023
11—13

MASTER CYLINDER 1 1
Adjustment
Adjust the piston to push rod clearance in the follow-
ing order.
1. For (a) of judgement table
(1) Measure the height of (D) and record after
removing the SST from the master cylinder.
76G11X-028
Adjust nut
(2) Install the SST again to the master cylinder,
and turn the adjust nut so that clearance (C)
between the SST and the master cylinder is
0 mm (Oin).
(3) Measure the height of (E) when clearance (C)
is 0 mm (Oin).
(E) — (D) = Projecting amount of the power
brake unit push rod
76G11X-029
(4) Remove the push rod from the power brake
unit.
63G11X-349
(5) Make the piston to push rod clearance 0 mm
(Oin) by turning the push rod and shortening
the push rod length by the amount of (E) — (D).
Note
The threads of the push rod are specially
designed so that the push rod bolt becomes
harder to turn past a certain point to prevent
loosening of the bolt. Turn the push rod bolt
only within this range when adjusting.
76G11X030
11—25