clutch MAZDA MX-5 1994 Owner's Guide

OUTLINE, TROUBLESHOOTING GUIDE H OUTLINE SPECIFICATIONS I Clutch control L' Clutch cover Clutch disc Clutch pedal - Enginerrransmission BP DOHC item - M15M-D 1 Master cvlinder inne I Hydraulic Inner diameter mm {in) I 150 (5.91) I Pressure plate side I n n rn cr Tvpe . . Set load N {kgf, Ibf) Outer diameter mm {in) Pedal ratio 6.13 Full stroke mm {in) I 120 (4.72) Diaphraam spring .-.- 4,310 (440,968) 21 5 18.46) . - Height mm {in) * diameter mm {in) TROUBLESHOOTING GUIDE . - I 75--185 i6.89--7.283 15.87 (0.625) . - Release cylinder inner diameter mm {in) Clutch fluid I Problem I Possible Cause 19.05 i0.750) FMVSS116 DOT-3 Clutch disc facing surface hardened or oil on surface Pressure plate damaged u Diaphragm spring damaged or weak lnsufficient clutch pedal play I Slipping I Clutch disc facing worn excessively I Flywheel damaged Faulty disengagement I Clutch disc damaged or excessive runout Clutch disc spines rusted or worn Oil on clutch disc facing Diaphragm spring weak Excessive clutch pedal play Insufficient clutch fluid Leakage of clutch fluid I 1 Clutch disc facing hardened or damaged Clutch vibrates when accelerating I I Clutch disc facing rivets loose Oil on clutch disc facing Torsion dampers weak Clutch pedal stlcks Abnormal noise Pressure plate damaged or excessive runout Flywheel surface hardened or damaged Loose or worn engine mount Pedal shaft not pro~erlv lubricated Clutch release collar damaged Poor lubrication of release collar sleeve Torsion dampers weak Excessive crankshaft end play I I Pilot bearing worn or damaged I I Worn ~ivot points of release fork Action Replace Repair or replace Repair or replace Replace Adjust ~ebair or replace Replace Remove rust or replace Repair or replace Replace Adjust Add fluid Locate and repair or replace Repair or replace Replace Repair or replace Replace Replace Repair or replace Tighten or replace Lubricate or replace Replace Lubricate or replace Replace Repair Replace Repair or replace Page H-14 H-14 H-14 H-14 H-14 H-14 section B H- 6 H-14 H-14 H-14 section B H-14 H-14 45UOHX-OC Gartner Banana

H CLUTCH FLUID CLUTCH FLUID PREPARATION 49 0259 7708 For air bleeding Whench, flare nut REPLACEMENT Caution Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe it off immediately. 1. Drain the fluid from the reservoir by using a suction pump. (Refer to section P.) 2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder screw. 3. Insert the other end of the vinyl hose into a clear contain- er. 4. Loosen the bleeder screw by using the SST. 5. With another person slowly pumping the clutch pedal, drain the fluid from the clutch system. 6. Repeat step 5 until all the fluid is drained. 7. Modify the bleeder screw tightening torque to allow for ,-, a torque wrench-SST combination (Refer to section GI "Torque Formulas".) 8. Tighten the bleeder screw by using the SST. Tightening torque: 5.9--8.8 N.m (60-90 kgf.cm, 53-78 in4bf) 9. Fill the reservoir to MAX with new fluid of the specified type. 10. Bleed the air from the clutch. (Refer to page H-9.) 11. Check for correct clutch operation. 12. Verifv that there is no fluid leakaae. Gartner Banana

CLUTCHPEDAL H Minimum disengagement height: 68mm (2.68 in) (With carpet) CLUTCHPEDAL ADJUSTMENT Height lnspection 1. Measure the distance from the upper surface of the ped- al pad to the carpet. Pedal height: 175--185mm (6.89-7.28 in) (With carpet) 2. If necessary, adjust the height. Adjustment 1. Disconnect the clutch switch connector. 2. Loosen locknut @ and turn clutch switch @I until the height is correct. I 3. Tighten locknut @. Tightening torque: l3.Cl7.6 N-m (1 4Gl8O kgf-cm, 122-1 56 in-IM) 4. After adjustment, inspect the free play. Free Play lnspection 1. Depress the clutch pedal by hand until clutch resistance is felt. Free play: 0.6-3.lmm (0.02-0.12 in) Total free play: S13mm (0.20-0.51 in) 2. If necessary, adjust the free play. Adjustment 1. Loosen locknut 0 and turn push rod 03 until free play is correct. 2. Verify that the disengagement height as measured from the upper surface of the pedal pad to the carpet is correct when the pedal is fully depressed. 3. Tighten locknut 0. Tightening torque: 11 .&l6.6 N.m (120-1 70 kgtcm, 105--147 in.lbf} 4. After adjustment, inspect the height. Gartner Banana

H CLUTCH PEDAL REMOVAL I INSPECTION I INSTALLATION 1. Remove in the order shown in the figure, referring to Removal Note. 2. lnspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to lnstallation Note. 45UOHX-00 1. Spring 7. Push rod Removal Note .............. page H-7 Inspect for damage and bending Installation Note ............ page H-7 8. Nut 2. Nut and lock washer 9. Clip 3. Bolt 1 0. Wave washer 4. Spacer 11. Pin 5. Clutch pedal 12. Spacer 6. Bushing 13. Stop 14. Pedal pad Gartner Banana

CLUTCH PEDAL, CLUTCH MASTER CYLINDER H CLUTCH MASTER CYLINDER PREPARATION SST b 49 0259 7708 For disconnecting Wrench, flare and connecting nut clutch pipe Removal Note Spring 1. Place the clutch pedal assembly in the vise. 2. Pry the spring off the clutch pedal as shown in the figure. Installation Note Spring 1. Place the clutch pedal assembly in the vise. 2. Install the spring onto the clutch pedal as shown in the ~ - figure. 3. Adjust the clutch pedal height and free play after installa- tion. (Refer to page H-5.) Gartner Banana

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 MASTER CYLINDER H After-installation Procedure 1. Bleed the clutch system. (Below) I 2. Add fluid to the reservoir MAX mark. ' 3. Inspect and adjust the clutch pedal height and free play. (Refer to page H-5.) AIR BLEEDING The clutch hydraulic system must be bled to remove air introduced whenever a hydraulic line is disconnected. Caution Clutch fluid will damage painted surfaces. If clutch fluid does get on a painted surface, wipe it off immediately. 1. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug. 2. Insert the other end of the vinyl hose into a fluid-filled clear container. 3. Working with another person, have the person depress the clutch pedal several times, then hold it down. 4. With the clutch pedal depressed, loosen the bleeder screw by using the SST to let fluid and air escape. Close the bleeder screw. 5. Repeat steps 3 and 4 until no air bubbles are seen in the fluid. Make sure the reservoir is always 314 full or more during this procedure. 6. Modify the bleeder screw tightening torque to allow for use of a torque wrench-SST combination. (Refer to sec- tion GI "Torque Formulas".) 7. Tighten the bleeder screw by using the SST. Tightening torque: 5.9-8.8 N.m (60-90 kgf.cm, 53-78 in4bf) 8. Fill the reservoir to MAX with new fluid of the specified type. 9. Check for correct clutch operation. 10. Verify that there is no fluid leakage. Gartner Banana

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