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who, well, didn’t do much this time, since Paul Lee provided the thing already
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The original document is © 1979 Toyo Kogyo Co., Ltd., and remains so.
This version is provided as a service for owners of first generation Mazda RX-7s
who are having a devil of a time locating the factory service manual for a
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09/16/03
 CLUTCH
. . CLUTCH REMOVAL ........................
6A 6:1
6-B . CLUTCH INSPECTION....................... 6 2
6-B-1 . Checking Release Fork and Bearing . . . . . . . . 6 : 2
6B
.2. . Checking Pressure Plate and Cover
Assembly ........................... 6:2
6B.3. .Checking Clutch Disc . . . . . . . . . . . . . . . . . . 6 : 2
6-B-4 . Checking Flywheel ................... 6 : 2
6-B-5 . Replacing Ring Gear. . . . . . . . . . . . . . . . . . . 6 : 3
6-B-6 .Checking Eccentric Shaft Rear Oil Seal ..... 6 : 3
.
6-B-7 Checking Needle Bearing (Pilot bearing) ..... 6 : 3
6-C . CLUTCH INSTALLATION .................... 6 :4
6-D . CLUTCH PEDAL ADJUSTMENT ................ 6 : 4
6-E . CLUTCH MASTER CYLINDER. . . . . . . . . . . . . . . . . 6 : 5
6-E-1 . Removing Clutch Master Cylinder . . . . . . . . . 6 : 5
6-E-2 . Disassembling Clutch Master Cylinder ....... 6 : 5
.
6-E-3 Checking Clutch Master Cylinder .......... 6 : 5
.
6-E-4 Assembling Clutch Master Cylinder ........ 6 : 6
6-E-5 . Installing Clutch Master Cylinder . . . . . . . . . . 6 : 6
6-F . CLUTCH RELEASE CYLINDER ................ 6 : 6
6-F-1 . Removing Clutch Release Cylinder ......... 6 : 6
6-F-2 . Disassembling Clutch Release Cylinder ...... 6 : 6
.
6-F-3 Checking Clutch Release Cylinder ......... 6 : 6
6-F-4 .Assembling Clutch Release Cylinder . . . . . . . . 6 : 7
6-F-5 .Installing Clutch Release Cylinder ......... 6 : 7
6-G . AIR BLEEDING ........................... 6 :7
 6
6-A. CLUTCH REMOVAL
1. Remove the transmission as described in Par. 7-A.
2. Remove the release fork and release bearing.
-

Fig. 6-1

1 3. Lock the flywheel with the brake (49 1881 060).

4. Remove the clutch pressure plate and cover assembly,
and clutch disc.

Note :
Take care not to get oil or grease on the clutch disc
linings, and the pressure plate and flywheel surface
that contact on the clutch disc.

I I
Fig. 6-2

I 1 5. Loosen the lock nut by using the box wrench (49

0820 035).

I I
Fig. 6-3

I 1 6. Remove the flywheel with the puller (49 0823

300A), turning the puller handle and lightly hitting
the puller head.
Be careful not to drop the flywheel.

Note :
After removing the flywheel, inspect for oil leaking
through the eccentric shaft rear oil seal.

I I
Fig. 6-4

6 :1
 6
6-B. CLUTCH INSPECTION

6-B-1. Checking Release Fork and Bearing

Note :
The release bearing is pre-lubricated and must not be
washed with gasoline or any other solvent.

Check the release bearing by pressing and turning the

front race slowly by hand. Replace if the bearing feels
rough or seems noisy when turning.

Check the release fork for crack or bend.

If necessary, replace the release fork.
Fig. 6-5

6-8-2. Checking Pressure Plate and Cover

>-
- b 0 - Assembly
Check the contact surface of the pressure plate for wear,
damage or warp.
If the warp is slight, correct it by lapping with
compound or by turning a lathe. But if they are severe,
replace with a new one.
Check the diaphragm spring and cover and if any wear
or damage is found, replace the pressure plate and
cover assembly.

L
Fig. 6-6

6-8-3. Checking Clutch Disc

Inspect the clutch disc for worn or loose facing, dis-
tortion, loose rivets at the hub, and for broken springs.

Rivet head depth limit: 0.3mm (0.012 in)

Run-out limit: 1.0 mm (0.039 in)

If oil is evident on the facing, clean or replace the

clutch disc and eliminate the cause of oil leakage.
Make certain that the clutch disc slides easily on the
main drive shaft without any excessive play.

Fig. 6-7

6-B4. Checking Flywheel

Inspect the contact surface of the flywheel with the
clutch facing for burnt surface, scored surface or rivet
grooves.
If it is slight, it can be reconditioned by grinding or
by turning a lathe. If the damage is deep, the flywheel
should be replaced.
Check the ring gear teeth and replace if the ring gear
teeth are broken, cracked or seriously burred.

Fig. 6-8

6:2
6
6-B-5. Replacing Ring Gear
1. Heat the old ring gear and remove it from the i/

-
flywheel.
2. Heat a new ring gear evenly 250
57OOF).
- 3OOOC (480

3. Place the ring gear on the cold flywheel, making

sure that the chamfer on the teeth is faced to the
transmission.
4. Allow the ring gear to cool slowly to shrink it onto
the flywheel.

.rrrrr --
Fig. 6-9

6-B-6. Checking Eccentric shaft Rear Oil Seal

Check the oil seal for wear or damage. If traces of oil
leakage are found, replace the oil seal.

Fig. 6-10

6-8-7. Checking Needle Bearing (Pilot bearing)

Check the pilot bearing for roughness, loose and any
damage. If necessary, replace the pilot bearing.

Replace the pilot bearing, proceed as follows.

1. Remove the bearing and seal with the puller (49
1285 071).

Fig. 6-1 1

2. Install a new pilot bearing with the installer (49

0823 072A) and apply the multipurpose grease
on it.
3. Install the oil seal.

Fig. 6-12

6:3
 6
6-C. CLUTCH INSTALLATION
Install the clutch in the reverse order of removal, noting
the followings.

1. Apply the sealing agent to lock nut surface that

contact with flywheel and install the lock nut.

Fig. 6-13

2. Attach the brake (49 1881 060) and tighten the

lock nut to the specifications with the box wrench
(49 0820 035).

40 - 50 m-kg (289 -
Flywheel tightening torque:
362 ft-lb)

Fig. 6-14

3. Hold the clutch disc in its mounting position with

the centering tool (49 0813 310).
If the tool is not available, use a spare main drive
shaft.

4. Install the pressure plate and cover assembly, aligning

the "0" mark (small hole) of the clutch cover and
reamer bolt hole on the flywheel, and install the
4 standard and 2 reamer bolts finger tight. To avoid
pressure plate cover distortion, tighten the bolts
a few turns at a time until they are all tight.
Then torque the bolts to specifications.

Fig. 6-15
Tightening torque: 1.8 - 2.7 m-kg (13 - 20 ft-lb)

6-D. CLUTCH PEDAL ADJUSTMENT

1. Adjust the pedal height by loosening the lock nut
(1) and turning the stopper bolt (2).

Pedal height:

2. Adjust the free travel by loosening the lock nut

(3) and turning the push rod (4).

Free travel: 0.6 - 3.1 mm (0.02

a t pedal pad
- 0.12 in)

Fig. 6-16

6:4
6
6-E. CLUTCH MASTER CYLINDER
L
6-E-1. Removing Clutch Master Cylinder
Remove and disconnect the following parts in sequence.

1. Fluid pipe (Disconnect)

Use the spanner (49 0259 770A).
2. Attaching nuts (From inside of cabin)
3. Clutch master cylinder

Note :
Never allow the brake fluid to drop on painted surfaces.

Fig. 6-17

6-E-2. Disassembling Clutch Master Cylinder

After draining the brake fluid, disassemble the clutch
master cylinder in the numerical order.
1. Connector bolt and reservoir
2. Piston stop ring and washer
3. Piston and secondary cup assembly
4. Primary piston cup and spacer
5. Return spring

Fig. 6-18

6-E-3. Checking Clutch Master Cylinder

1. Wash the parts in clean alcohol or brake fluid.
Never use gasoline or kerosene. Blow the parts dry
with compressed air.
2. Check the piston cups and replace if they are
damaged, worn, softened, or swelled.
3. Examine the cylinder bore and the piston for wear,
roughness, or scoring.
4. Check the clearance between the cylinder bore and
piston. If it exceeds the limit, replace the cylinder
or piston.

7
Fig. 6-19
Clearance limit: 0.15 mm (0.006 in)

5. Ensure that the compensating port on the cylinder

is open.

Fig. 6-20

6:s
 6
6-E-4. Assembling Clutch Master Cylinder
Assemble the clutch master cylinder in the reverse
order of disassembly.

Note :
a) Before assembling, dip the piston and cups in clean
brake fluid.
b) After assembling, fill the cylinder with brake fluid
and operate the piston w i t h a screwdriver until the
fluid is ejected at the outlet.

Fig. 6-21

6-E-5. Installing Clutch Master Cylinder

To install the clutch master cylinder, carry out the
removal operations in the reverse order.
After installing, bleed the clutch hydraulic system,
as described

Fig. 6-22

m w 6-F. CLUTCH RELEASE CYLINDER

6-F-1. RIenloving Clutch Release Cylinder

Remove the following parts.
1
I.
P---..,.&.
Lullllcting - L-l*
UUIL
...-A Ci--.ZLl-
~ I I UIICAIUIC
L---
IIUSB
2. Attaching nuts
3. Release cylinder

Fig. 6-23

6-F-2. Disassembling Clutch Release Cylinder

Disassemble the clutch master cylinder in the numerical
order.

1. Dust boot and release rod

2. Piston and cup assembly
3. spring
4. Bleeder screw and valve (steel ball)

6-F-3. Checking Clutch Release Cylinder

Check the clutch release cylinder in the same manner
for the clutch master cylinder.

Fig.6-24

6:6
6
6-F-4. Assembling Clutch Release Cylinder
Assemble the clutch release cylinder in the reverse
order of disassembly.
-
Note :
Before assembling, dip the piston and cups in the clean
brake fluid. >

6-F-5. Installing Clutch Release Cylinder

Install the clutch release cylinder in the reverse order
of removing and bleed the hydraulic system as described
in Par.6-G.

6-G. A I R BLEEDING
1. Remove the rubber cap from the bleeder screw
and attach a vinyl tube to the bleeder screw.
2. Place the end of the tube in the glass jar and
submerge in brake fluid.
3. Loosen the bleeder screw. Depress the clutch pedal
and allow it to return slowly. Continue this pumping
action and watch the flow of fluid in the jar.
4. When air bubbles cease to appear, tighten3he bleeder
screw, remove the vinyl tube and fit the cap to the

1
d
bleeder screw.
5. Fill the fluid reservoir and fit the ffler cap.

Note :
L

a) During bleeding operation, the reservoir of the

master cylinder must be kept a t least 3/4 full of the
brake fluid.
b) Never re-use the brake fluid which has been drained
from the clutch hydraulic system.

Fig. 6-26

6:7