1994 MAZDA MX-5 Workshop Manual

H CLUTCH MASTER CYLINDER OVERHAUL 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Inspect all parts and repair or replace as necessary. Warning d 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, referring to Assembly Note. 'a REPLACE Gartner Banana

CLUTCH MASTER CYLINDER H 1. Snap ring 5. Return spring Disassembly Note ............... below 6. Cap Assembly Note ................. below 7. Packing 2. Piston and secondary cup assembly 8. Reservoir Disassembly Note ............... below 9. Bushing Inspect for wear, scoring, and cracks 10. Master cylinder body Assemblv Note ................. below Inspect cylinder bore for scoring and 3. Spacer 4. Primary cup lnspect for wear and cracks corrosion 35UOHX-018 Disassembly Note Snap ring While holding the piston down with a cloth-wrapped Phil- lips screwdriver, remove the snap ring. Piston and secondary 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-secondary-cup assembly, spacer, and primary cup by applying compressed air through the clutch pipe installation hole. Assembly Note Piston and secondary cup assembly Install the spring, primary cup, spacer, and piston and secondary cup assembly, noting the proper direction of the parts. (Refer to page H-1 0.) Snap ring While holding the piston down with a cloth-wrapped Phil- lips screwdriver, remove the snap ring. Gartner Banana

H CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER PREPARATION SST I I I 05UOHX-015 REMOVAL / INSTALLATION - 49 0259 7708 Wrench, flare nut Caution Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe For disconnecting and connecting clutch pipe -. - 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. 1. Clutch pipe 3. Clutch release cylinder Removal Note .................. below Remove boot and check for fluid leakage .................. Installation Note ........... page H-13 Overhaul page H-13 ............... 2. Bolt Air Bleeding page H-13 Removal Note Clutch pipe 1. Disconnect the clutch pipe from the clutch release cylin- der by using the SST. 2. Plug the clutch pipe after removing, to avoid fluid leak- age. 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

H CLUTCH UNIT CLUTCH UNlT PREPARATION SST 49 E011 1AO Brake set, ring gear 49 E011 104 Collar (Part of 49 EOll 1AO) 49 SEOl 310A 0 Clutch disc centering tool 49 1285 073 Chuck (Part of 49 1285 071) For holding ring gear For holding ring gear For removal and installation of clutch disc For removal of pilot bearing 49 EOll 103 Shaft (Part of 49 EOll 1AO) 49 E011 105 Stopper (Part of 49 E011 1 AO) 49 1 285 071 Puller, bearing For holding ring gear For holding ring gear For removal of pilot bearing REMOVAL / INSTALLATION Note The clutch release cylinder can be removed from the transaxle with the clutch pipe connected. 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. 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

CLUTCH UNIT, CLUTCH RELEASE COLLAR, CLUTCH COVER, CLUTCH DlSC H Clutch disc 1. Clean the clutch disc splines and main drive gear splines, and apply Mori White TA No.2 or equivalent or- ganic molybdenum grease. 2. Hold the clutch disc in position by using the SST. Clutch cover 1. Hold the flywheel by using the SST or equivalent. 2. Align the dowel holes with the flywheel dowels. 3. 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} CLUTCH RELEASE COLLAR INSPECTION Caution Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. Turn the collar while applying force in the axial direction. If the collar sticks or has excessive resistance, replace it. CLUTCH COVER INSPECTION 1. lnspect the contact surface for scoring, cracks, and burning. Repair or replace as necessary. 2. Remove minor scoring or burning with emery paper. Repair if scoring or burning is major. Replace if cracked. 3. lnspect the tips of the diaphragm spring for wear and cracks. 4. If there is wear or cracks, replace the clutch cover. I I 45UOHX-027 CLUTCH DlSC INSPECTION 1. lnspect the lining surface for burning and oil contamina- tion. Repair with sandpaper if the trouble is minor. Re- place the clutch disc if it is badly burned or oil soaked. 2. lnspect for loose facing rivets or torsion dampers. Replace the clutch disc if any are loose. Gartner Banana