MAZDA MX-5 1994 Workshop Manual

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

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