1994 MAZDA MX-5 SECTION T

H CLUTCH MASTER CYLINDER REMOVAL I INSTALLATION Caution Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe -. - - - it off immediately. 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to Installation Note. 3. Refer to After-installation Procedure on page H-9. 1. Clutch pipe 3. Clutch master cylinder Removal Note .................. below Check for fluid leakaae from cvlinder bore 2. Nut " Installation Note ................ below Overhaul .................. page H-10 Air bleeding ............... page H- 9 4. Gasket Removal Note Clutch pipe Disconnect the clutch pipe by using the SST. Installation Note Clutch pipe 1. Modify the clutch pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI "Torque Formulas".) 2. Tighten the clutch pipe by using the SST. Tightening torque: -1 12.8-21.5 N.m (1 30-220 kgf.cm, 11 %-I90 in.lbf) Gartner Banana

CLUTCH RELEASE CYLINDER H Installation Note Clutch pipe 1. Modify the clutch pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI "Torque Formulas".) 2. Tighten the clutch pipe by using the SST. Tightening torque: 12.8-21.5 N-m (1 30-220 kgfam, 11%-190 in-lbf) Air Bleeding After installation, bleed the clutch system. (Refer to page H-9.) OVERHAUL 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. lnspect all parts and repair or replace as necessary. Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. 3. Wipe all parts, and clean all ports, passages, and inner parts with compressed air. 4. Assemble in the reverse order of disassembly. 1. Boot 5. Bleeder cap 2. Push rod 6. Bleeder screw 3. Piston and cup assembly 7. Steel ball Disassembly Note . . . . . . . . . . . . . . . below 8. Release cylinder body Inspect for wear, scoring, and cracks Inspect cylinder bore for scoring and corro- 4. Spring sion Disassembly Note Piston and cup assembly Warning Applying compressed air to the cylinder assem- bly can make the contents suddenly pop out, possibly causing injury. Hold a rag over the cylin- der opening when using compressed air. Remove the piston-and-cup assembly by applying com- pressed air through the clutch pipe installation hole. Gartner Banana

CLUTCH UNIT H 97-1 02 {O&-10.5,71-75.9) 18--26 {I .6-2.7,14-19) (MORI WHITE TA No.2 OR EQUIVALENT ORGANIC MOLYBDENUM GREASE) 1. Clutch release cylinder 2. Transmission Service ..................... section J 3. Boot 4. Clutch release collar Inspection ................. page H-17 5. Clutch release fork 6. Clutch cover Removal Note ............. page H-16 Inspection ................. page H-17 Installation Note ........... page H-17 7. Clutch disc Removal Note ............. page H-16 Inspection ................. page H-17 Installation Note ........... page H-17 8. Pilot bearing Inspection ................. page H-18 Removal Note ............. page H-16 Installation Note ........... page H-16 9. Flywheel Removal Note ............. page H-16 Inspection ................. page H-18 Installation Note ........... page H-16 Gartner Banana

H CLUTCH UNIT Removal Note Clutch cover and disc 1 . Install the SST. 2. Hold the flywheel by using the SST or equivalent. e 3. Loosen each bolt one turn at a time in a crisscross pat- tern until spring tension is released. Then remove the clutch cover and disc. Flywheel 1. Hold the flywheel by using the SST or equivalent. 2. Remove the flywheel. 3. Inspect for oil leakage from the crankshaft rear oil seal. If there is any such leakage or if the oil seal is damaged, refer to section B and replace the crankshaft oil seal. Pilot bearing Note The pilot bearing does not need to be removed unless you are replacing it. Remove the pilot bearing by using the SST. L' Installation Note Flywheel 1. Wipe the bolts clean, and apply sealant to the bolt threads. 2. Install the flywheel, and secure it by using the SST or equivalent. 3. Tighten the bolts in the pattern shown. Tightening torque: 97-1 02 N.m (9.8-1 0.5 kgf.m, 71-75.9 ft-lbf) Pilot bearing Install a new pilot bearing flush with the flywheel by using a suitable pipe. Gartner Banana

Before beginning any service procedure. refer to section T of this manual for air bag system service warnings and audio antitheft system alarm conditions . MANUAL TRANSMISSION INDEX ....................................... J- 2 ..................................... OUTLINE J- 3 SPECIFICATIONS ........................... J- 3 ........................ STRUCTURAL VIEW J- 4 ............................. COMPONENTS J- 5 ............................. POWER FLOW J- 6 TROUBLESHOOTING GUIDE .................. J- 7 .......................... TRANSMISSION OIL J- 8 ............................... INSPECTION J- 8 ............................ REPLACEMENT J- 8 TRANSMISSION .............................. J- 9 ............................. PREPARATION J- 9 REMOVAL .................................. J-10 DISASSEMBLY ............................. J-13 ............................... INSPECTION 5-23 ASSEMBLY ................................. J-26 INSTALLATION ............................. J-45 25UOJX-011 Gartner Banana

TROUBLESHOOTING GUIDE J TROUBLESHOOTING GUIDE Problem ~bnormal noise lumps out of gear libration Possible Cause nsufficient oil leterioration of oil quality Norn bearing Norn contact surface of countershaft gear Norn contact surface of gears Excessive gear backlash larnaged gear teeth nsufficient oil leterioration of oil quality Worn synchronizer ring Worn synchronizer cone of gear Poor contact of synchronizer ring and gear cone Excessive longitudinal play of gears Worn bearing Improper disengagement of clutch Weak detent ball spring Worn shift fork Worn clutch hub Worn clutch hub sleeve Worn gears Excessive gear backlash Worn bearing Incorrect installation or looseness of power plant frame Action 4dd oil 3eplace with specified )il qeplace 4dd oil 3eplace with specified ~il Replace Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Replace Correct or tighten Page 5-8 J-8 J-9 J-16 5-1 6,19,20 J-16,19,20 J-16,19,20 J-8 J-8 J-16,19 J-16,19 J-16, 19 J-l6,19,20 J-9 section H J-15 J-15 J-16,19 J-16,19 J-16, 19,20 J-l6,19,20 J-9 J-45 35UOJX-O( Gartner Banana

J TRANSMISSION REMOVAL 1. Obtain the code number and deactivate the audio antitheft system before disconnecting the battery. (Refer to section T.) 2. is connect the negative battery cable. 3. On level grand, jack up the vehicle and support it evenly on safety stands. 4. Drain the transmission oil into a suitable container. 5. Remove in the order shown in the figure, referring to Removal Note. I. Shift lever knob ?. Rear console 9. Clutch release cylinder 10. Starter I 1 3. Shift lever 11. speedometer cable 4. Undercover 12. Power plant frame (PPF) 5. Performance rod Removal Note ............... page J-1 1 6. Differential mounting pipe 13. Transmission 7. Exhaust pipe J Removal Note ............... page J-12 8. Propeller shaft Service ...................... section L Gartner Banana

J TRANSMISSION Disassembly note Extension housing Turn the extension housing to remove it. Transmission case Remove the transmission case from the intermediate housing and gear assembly by using the SST. On-vehicle replacement Oil seal (rear) 1. Raise the vehicle and support it with safety stands. 2. Remove the propeller shaft. (Refer to section L.) 3. Remove the oil seal from the extension housing. 4. Apply the specified oil to a new oil seal. 5. Install the new oil seal by using the SST. 6. Install the propeller shaft. (Refer to section L.) 7. Inspect the oil level. (Refer to page J-8.) Gartner Banana