2002 MAZDA 6 clutch

H–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E490216003201•The construction and operation of the clutch is essentially carried over from that of the current MPV (LW)
models, except for the following features. (See Mazda MPV Training Manual 3340-1*-99F.)
End Of Sie
FEATURESA6E490216003202Adoption of the A65M-R manual transaxle models
•The specifications for the A65M-R manual transaxle models have been added.
Increased torque transmission capacity
•Increased clutch cover set load.
Reduced noise
•The flywheel with a damper has been adopted for the A65M-R manual transaxle model.
End Of Sie
SPECIFICATIONSA6E490216003203
Bold frames:New specifications
End Of Sie
SUPPLEMENTAL SERVICE INFORMATIONA6E490216003204•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
CLUTCH RELEASE CYLINDER
•Removal/installation procedure has been modified.
•Disassembly/assembly procedure has been modified.
CLUTCH UNIT
•Removal/installation procedure has been modified.
•Clutch cover inspection procedure has been modified.
FLYWHEEL
•Flywheel inspection procedure has been modified.
End Of Sie
OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
EngineMZR-CD (RF Turbo)
Manual transaxle type A65M-R
Clutch control Hydraulic
Clutch coverSpring type Diaphragm
Set load (N {kgf, lbf}) 6,550 {668, 1,472}
Clutch discOuter diameter (mm {in}) 239 {9.41}
Inner diameter (mm {in}) 160 {6.30}
Clutch pedalType Suspended
Pedal ratio 5.9 6.41
Full stroke (mm {in}) 140 {5.51} 148 {5.83}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.625}
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.750}
Clutch fluid type SAE J1703, FMVSS116 DOT-3 or DOT-4
OUTLINE

CLUTCH RELEASE CYLINDER
H–3
H
CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS)A6E4918419202011. Remove the under cover.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
.
End Of Sie
CLUTCH RELEASE CYLINDER
12.7—21.6 N·m
{130—220 kgf·cm,
113—190 in·lbf}
18.6—25.5 {1.90—2.60,13.8—18.8}
N.
m {kgf.
m,ft.
lbf}
3
GREASE
2
1
SST*
*
49 0259 770B
(MOLYBDENUM SULFIDE)
A6E4918W010
1 Clutch pipe
2Bolt3 Clutch release cylinder

H–4
CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY (A65M-R MANUAL TRANSAXLE MODELS)A6E4918419202021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
End Of Sie
56
7
5.9—8.8 N.
m
{60—90 kgf.
cm,53—78 in.
lbf}
4
BRAKEFLUID
BRAKEFLUID3
1
2
A6E4918W011
1 Boot
2 Push rod
3 Piston and cap
4 Return spring5 Bleeder cap
6 Bleeder screw
7 Release cylinder body

CLUTCH UNIT
H–5
H
CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS)A6E4920160002011. Remove in the order indicated in the table.
2. Install in the reverse order oremoval.
.
CLUTCH UNIT
SST
SST
SSTSEALANT
25—33
{2.6—3.3, 19—24}
151.3—161.1
{15.43—16.42, 111.6—118.8} 18.6—25.5
{1.90—2.60, 13.8—18.8}
1
GREASE
GREASE
GREASE
GREASE
GREASE
5
6
7
8
4
3
2
(MOLYBDENUM SULFIDE) TRANSAXLE SIDE ENGINE SIDE
N·m {kgf·m, ft·lbf}
A6E4920W010
1 Clutch release cylinder
2 Manual transaxle
(See J2–7 MANUAL TRANSAXLE REMOVAL/
INSTALLATION)
3Boot
4 Clutch release collar
5 Clutch release fork6 Clutch cover
(See H–6 Clutch Cover and Disc Removal Note)
(See H–7 Clutch Cover Installation Note)
7Clutch disc
(See H–6 Clutch Cover and Disc Removal Note)
(See H–7 Clutch Disc Installation Note)
8 Flywheel
(See H–6 Flywheel Removal Note)
(See H–6 Flywheel Installation Note)

H–6
CLUTCH UNIT
Clutch Cover and Disc Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
Flywheel Removal Note
1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in a crisscross pattern.
3. Remove the flywheel.
Flywheel Installation Note
1. Install the flywheel to the crankshaft.
2. When reusing the bolts, clean threads and hole, then apply locking compound to the threads.
Note
•No locking compound is needed when using new bolts.
3. Hand-tighten the flywheel lock bolts.
4. Install the SST to the flywheel.
5. Gradually tighten the flywheel lock bolts in a
crisscross pattern.
Tightning torque
151.3—161.1 N·m
{15.43—16.42 kgf·m, 111.6—118.8 ft·lbf}
49 SE01 310A
49 E011 1A0
A6E4920W011
49 E011 1A0
5
4
3
61
2
8
7
A6E4920W012
49 E011 1A0
5
4
3
61
2
8
7
A6E4920W013

CLUTCH UNIT
H–7
H
Clutch Disc Installation Note
1. Hold the clutch disc position using the SST.
Clutch Cover Installation Note
1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a
crisscross pattern.
Tightening torque
25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf}
End Of SieCLUTCH COVER INSPECTION (A65M-R MANUAL TRANSAXLE MODELS)A6E4920164102011. Measure the wear of the diaphragm spring
fingers.
•If not as specified, replace the clutch cover.
Depth
0.6 mm {0.024 in} max.
2. Measure the flatness of the pressure plate with a
straight edge and a feeler gauge.
•If not as specified, replace the clutch cover.
Maximum clearance
0.3 mm {0.012 in}
3. When checking the diaphragm spring fingers,
mount a dial indicator on the cylinder block.
49 SE01 310A
A6E4920W014
5
4
3
49 SE01 310A
49 E011 1A06
1
2
A6E4920W015
XME4920W010
XME4920W011

H–8
CLUTCH UNIT, FLYWHEEL
4. Rotate the flywheel and check for misaligned
diaphragm spring fingers.
•If not as specified, replace the clutch cover.
Misalignment
0.6 mm {0.024 in} max.
End Of Sie
FLYWHEEL INSPECTION (A65M-R MANUAL TRANSAXLE MODELS)A6E4922115002011. Install a dial gauge on the cylinder block.
2. Measure the flywheel runout using a dial
indicator.
•If the runout is excessive, replace the
flywheel.
Runout
0.3 mm {0.012 in} max.
End Of Sie
A6E4920W016
FLYWHEEL
A6E4922W001

J2–8
MANUAL TRANSAXLE
.
2
6
3
5
8
1
7
16
13
10
11
21
20
4
9
18
19
17
15
22
22
1423
12
R
R
R
R
85.3—116.6
{8.70—11.88, 62.91—85.98}
58.8—80.4
{6.00—8.19, 43.4—59.2}
58.8—80.4
{6.00—8.19, 43.4—59.2}
93.1—131.3
{9.50—13.38, 68.67—96.84} 119.6—154.8
{12.20—15.78,
88.22—114.1} 43—61 {4.6—6.3, 32—45}
18.6—25.5
{1.90—2.60, 13.8—18.8}
89.3—116
{9.1—11.8, 65.9—85.5}
89.3—116 {9.1—11.8, 65.9—85.5}
37.3—51.9 {3.81—5.29, 27.5—38.2}166.6—200.0
{16.99—20.39,
122.9—147.5} 43.1—60.8
{4.40—6.19, 31.8—44.8} 33.0—44.1
{3.21—4.49, 23.2—32.5}
38—51
{3.9—5.2,
28—37}
27.4—40.2
{2.80—4.09,
20.2—29.6}
93.1—116.6
{9.50—11.88,
68.66—85.98}93.1—126.4
{9.50—12.88,
68.67—93.22}
66.6—93.1
{6.80—9.49, 49.2—68.6}
A
B
B
A
D
D
N·m {kgf·m, ft·lbf}
A6E5212W018
1 Shift cable
2 Select cable
3 Reverse switch connector
4 Neutral switch connector
5 Clutch release cylinder6Starter
(See G–9 STARTER REMOVAL/INSTALLATION)
7 GND harness, harness bracket
8 Transaxle mounting bolt (upper side)