MAZDA MX-5 1997 Factory Repair Manual

Installation (B2300, B2500, B3000 & B4000)
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide
grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS
.
2. Raise transmission into position. Install and tighten transmission-to-engine block bolts. See TORQUE
SPECIFICATIONS . Install crossmember.
3. On 4WD models, install NEW transfer case gasket. Install transfer case. Tighten transfer case bolts to
specification is sequence. See Fig. 3
. See TORQUE SPECIFICATIONS .
4. On all models, to complete installation, reverse removal procedure. Bleed hydraulic clutch system. See
HYDRAULIC SYSTEM BLEEDING
under ADJUSTMENTS.
Fig. 3: Tightening Transfer Case Bolts (B2300, B2500, B3000 & B4000)

Courtesy of MAZDA MOTORS CORP.
Removal (Miata)
1. Disconnect negative battery cable. Remove gearshift knob, console, and shift lever. See Fig. 4. Raise and
support vehicle. Remove engine undercover. Disconnect exhaust pipe from manifold. Mark drive shaft
flanges for installation reference. Remove drive shaft.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 4: Exploded View Of Drive Line (Miata)
Courtesy of MAZDA MOTORS CORP.
2. Remove clutch release cylinder. Remove starter. Disconnect speedometer cable from transmission. Note
locations, and disconnect wiring harness from Power Plant Frame (PPF).
3. Remove PPF bracket from rear transmission extension housing. Remove PPF-to-differential side bolts.
Pry out spacer. Remove PPF/differential mounting spacer. See Fig. 5
.
4. Thread M14 X 1.5 bolt into sleeve. See Fig. 6
. Twist bolt side to side while pulling it downward. Thread
M6 X 1 bolt into hole in housing block to hold sleeve. Remove long bolt. Remove short bolt.
5. Remove PPF side bolts. Remove PPF. Remove transmission-to-engine block bolts. Remove transmission.
Remove clutch cover bolts evenl
y in crisscross pattern. Remove clutch cover and disc. See Fig. 7.
NOTE: Do not remove spacers attached to top of Power Plant Frame (PPF). If they
are removed, replace PPF.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 5: Installing & Removing Power Plant Frame (Miata)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 6: Removing Reamer Bolt Sleeve (Miata)
Courtesy of MAZDA MOTORS CORP.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 7: Exploded View Of Clutch Assembly (Typical)
Courtesy of MAZDA MOTORS CORP.
Inspection (Miata)
1. Inspect disc for loose rivets, worn springs, excessive wear, or oil contamination. Inspect flywheel and
clutch cover for burns, scoring, or grooves.
2. Measure flywheel and clutch cover runout. Resurface or replace flywheel and clutch cover if beyond
specification. See CLUTCH RUNOUT (MAXIMUM)
table. If flywheel ring gear is replaced, ensure
chamfer on flywheel teeth faces engine.
3. Measure clutch disc runout. Replace disc if it is not to specification. See CLUTCH RUNOUT
(MAXIMUM) table. Inspect disc hub and input shaft splines for excessive wear. Hub must slide
smoothly on input shaft splines.
4. Inspect pilot bearing for wear. Apply inward pressure while rotating pilot bearing. If bearing sticks or has
excessive resistance, replace bearing. Check for tight fit in crankshaft. Replace as necessary. Inspect
release bearing for smooth operation, wear, damage, or looseness. Replace bearing as necessary.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Installation (Miata)
1. Lightly coat input shaft splines, release bearing, and fork contact areas with molybdenum disulfide
grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover bolts evenly in a
crisscross pattern to specification. See TORQUE SPECIFICATIONS
.
2. Place a wooden block on jack, and position jack under front of oil pan. Raise front of engine to ease
transmission installation. Install transmission. Tighten transmission-to-engine block bolts to specification.
See TORQUE SPECIFICATIONS
. Place jack (from front of engine) under transmission.
3. Raise transmission until level with engine. Position Power Plant Frame (PPF) in place. Install
PPF/differential mounting spacer, and tighten bolts to 27-38 ft. lbs. (37-51 N.m). Install and tighten PPF
side mounting bolts.
4. Install sleeve into PPF housing block. Install spacer and bolts. Install reamer bolt into front hole, and
tighten bolt. See Fig. 5
.
5. Install transmission-to-PPF bracket. Install remaining PPF bolts, and tighten to specification. See
TORQUE SPECIFICATIONS
. To complete installation, reverse removal procedure.
RELEASE BEARING & FORK
Removal (B2300, B2500, B3000 & B4000)
With transmission removed, twist release bearing and carrier assembly until preload spring pushes bearing
assembly from slave cylinder. See Fig. 8
.
Installation
Lubricate bearing bore and bearing carrier with NIGI No. 2 (lithium base) grease. Push release bearing
assembl
y onto clutch slave cylinder. NOTE: Front PPF-to-differential side mounting bolt is the reamer bolt, used to
align frame.
NOTE: Use only lithium base grease on release bearing. DO NOT use petroleum base
lubricants.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 8: Servicing Clutch Release Bearing (B2300, B2500, B3000 & B4000)
Courtesy of FORD MOTOR CO.
Removal & Installation (Miata)
1. Remove transmission. See CLUTCH ASSEMBLY . Remove release bearing and fork. Turn release
bearing in both directions. Replace bearing if rough or noisy.
2. Inspect release fork for wear and damage. Replace if necessary. Apply molybdenum disulfide grease to
release bearin
g contact and sliding surfaces. To complete installation, reverse removal procedure.

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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CLUTCH MASTER CYLINDER
Removal (B2300, B2500, B3000 & B4000)
1. Disengage master cylinder push rod from clutch pedal. Disconnect clutch/starter interlock switch
connector. See Fig. 9
.
2. Using Clutch Disconnect Tool (T88T-70522-A), disconnect hydraulic line. See Fig. 2
. Pull hydraulic
line to disconnect line from clutch slave cylinder. Remove master cylinder, reservoir, and hydraulic line.
Plug lines.
Fig. 9: Removing Clutch/Starter Interlock Switch (B2300, B2500, B3000 & B4000)

Courtesy of FORD MOTOR CO.
CAUTION: Disconnect master cylinder push rod if slave cylinder is to be
disconnected from release lever or bearing. Permanent damage to master
cylinder will occur if master cylinder is activated with slave cylinder

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CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Installation
Insert master cylinder push rod through opening in bulkhead. Install master cylinder. Connect hydraulic lines.
Install fluid reservoir. Install push rod on clutch pedal. Bleed hydraulic system. See HYDRAULIC SYSTEM
BLEEDING .
Removal & Installation (Miata)
Disconnect hydraulic line and master cylinder mounting nuts. Disengage push rod from clutch pedal. Remove
master cylinder. To install, reverse removal procedure and bleed hydraulic system. See HYDRAULIC
SYSTEM BLEEDING .
CLUTCH RELEASE CYLINDER
Removal & Installation (B2300, B2500, B3000 & B4000)
Release cylinder is removed with clutch. See CLUTCH ASSEMBLY.
Removal & Installation (Miata)
Raise and support vehicle. Disconnect and plug hydraulic line. Remove clutch release cylinder. To install,
reverse removal procedure. Bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING
.
OVERHAUL
CLUTCH MASTER CYLINDER disconnected.
NOTE: Overhaul procedures for B2300, B2500, B3000 and B4000 are not available.
NOTE: Use exploded view of clutch master cylinder for overhaul procedure. See Fig.
10 .

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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Fig. 10: Exploded View Of Clutch Master Cylinder (Miata)
Courtesy of MAZDA MOTORS CORP.
CLUTCH RELEASE CYLINDER

1997 Mazda MX-5 Miata
CLUTCH 1997-98 CLUTCHES Mazda - RWD
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