2010 Mazda RX-8 R3

2010 TRANSMISSION Clutch - RX-8

GENERAL PROCEDURES (CLUTCH)

CAUTION: l Fluid will damage painted surfaces. Be careful not to spill any on
painted surfaces. If fluid does get on painted surfaces, wipe it off
immediately.

NOTE: l If any hydraulic related parts of the clutch system are removed during the
procedure, add brake fluid, bleed the system and inspect for leakage after
the procedure has been completed.

CLUTCH FLUID INSPECTION

1. Inspect whether the fluid level in the reserve tank is between MIN and MAX.

Fig. 2: Inspecting Fluid Level In Reserve Tank

Courtesy of MAZDA MOTORS CORP.

CLUTCH PEDAL INSPECTION/ADJUSTMENT

CLUTCH PEDAL STROKE INSPECTION/ADJUSTMENT

1. Measure the clutch pedal stroke.

l If there is any malfunction, loosen locknut A and adjust the pedal stroke with adjusting bolt B. Tighten
locknut A after adjustment.

Standard pedal stroke

130 mm {5.12 in}

miércoles, 2 de junio de 2021 15:11:11

15:11:05 Page 1 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Fig. 4: Measuring Clutch Pedal Stroke With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CLUTCH PEDAL PLAY INSPECTION/ADJUSTMENT

1. Lightly depress the clutch pedal by hand until clutch resistance is felt and then measure the pedal play.

Clutch pedal play

5-15 mm {0.20-0.59 in}

Clutch pedal push rod play

At push rod setting line : 0.1-0.5 mm {0.004-0.020 in} (Reference value)

At pedal pad : 0.5-2.9 mm {0.020-0.110 in}

2. If it is not within the specification, loosen locknut C and turn push rod D to adjust the pedal play.
3. Remeasure the pedal play and, if it is within the specification, tighten locknut C.

miércoles, 2 de junio de 2021 15:11:05 Page 2 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Fig. 5: Adjusting Pedal Play, With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

CLUTCH DISENGAGEMENT POINT INSPECTION

1. Start the engine.

2. With the clutch pedal depressed, move the shift lever to the position just before engaging the reverse gear.
(Do not shift completely to reverse position)
3. Gradually release the clutch pedal and then hold it at the point where the sound of gear-grinding begins
(clutch disengagement point.)
4. Measure distance A from the clutch disengagement point to the position where the pedal has returned
completely (not depressed), and verify that the measurement is within the specification.
l If the measurement is not within the specification, inspect the clutch fluid level and the fluid lines
for air infiltration.

Distance A (From clutch disengagement point to fully-returned pedal position)

111.8 mm {4.402 in}

miércoles, 2 de junio de 2021 15:11:05 Page 3 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Fig. 6: Measuring Distance A From Clutch Disengagement Point

Courtesy of MAZDA MOTORS CORP.

CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION

CAUTION: l Fluid will damage painted surfaces. Be careful not to spill any on
painted surfaces. If it is spilled, wipe it off immediately.

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.
3. Bleed the air from the system. (See CLUTCH FLUID REPLACEMENT.)
4. Inspect and adjust the clutch pedal. (See CLUTCH PEDAL INSPECTION/ADJUSTMENT.)

miércoles, 2 de junio de 2021 15:11:05 Page 4 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Fig. 11: Identifying Clutch Master Cylinder Components With Torque Specification
Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER, CLUTCH DISC REMOVAL NOTE

1. Install the SSTs .

2. In criss-cross pattern, loosen the bolts one rotation at a time until there is no remaining spring pressure.
3. Remove the clutch cover and the clutch disc.

Fig. 17: Installing SST

Courtesy of MAZDA MOTORS CORP.

miércoles, 2 de junio de 2021 15:11:05 Page 5 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

OIL SEAL, PILOT BEARING REMOVAL NOTE

NOTE: l Remove the pilot bearing only if there is a malfunction.

1. Remove the pilot bearing and the oil seal together using the SST .

Fig. 18: Removing Pilot Bearing

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL REMOVAL NOTE

1. Install the SST to the flywheel.

2. Remove the locknut using the SST .

NOTE: l Inspect the eccentric shaft for oil leakage after removing the flywheel.
If necessary, replace the oil seal. (See REAR OIL SEAL
REPLACEMENT [13B-MSP] .)

Fig. 19: Removing Locknut

Courtesy of MAZDA MOTORS CORP.

miércoles, 2 de junio de 2021 15:11:05 Page 6 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

3. Remove the flywheel using the SST .

4. Remove the key from the eccentric shaft.

Fig. 20: Removing Key From Eccentric Shaft

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL INSTALLATION NOTE

1. Install the key to the eccentric shaft.

2. Align the flywheel key groove with the eccentric shaft key and install.
3. Install the SST to the flywheel.

Fig. 21: Aligning Flywheel Key Groove With Eccentric Shaft Key
Courtesy of MAZDA MOTORS CORP.

4. Tighten the locknut using the SST .

Tightening torque

392-490 N.m {40.0-49.9 kgf.m, 289-361 ft.lbf}

miércoles, 2 de junio de 2021 15:11:05 Page 7 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

CAUTION: l Remove the seal protruding from the threads without it

becoming caught in the pilot bearing.

Fig. 22: Tightening Locknut

Courtesy of MAZDA MOTORS CORP.

PILOT BEARING, OIL SEAL INSTALLATION NOTE

1. Install the pilot bearing using the SSTs.

NOTE: l Bearing outer diameter: 20 mm {0.787 in}

l Press-in depth: 11.5-12.25 mm {0.453-0.482 in}

2. Install a new oil seal using the SSTs .

Fig. 23: Installing Pilot Bearing

miércoles, 2 de junio de 2021 15:11:05 Page 8 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Courtesy of MAZDA MOTORS CORP.

CLUTCH DISC INSTALLATION NOTE

1. Clean the splines of the clutch disc and the main drive gear with a brush.
2. Spread a thin layer of clutch grease on the splines.
3. Secure the clutch disc to the flywheel using the SSTs .

Fig. 24: Aligning And Securing Clutch Disc To Flywheel

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER INSTALLATION NOTE

1. Align the clutch cover with the flywheel knock pin and install.
2. Tighten the bolts evenly and gradually in the order shown in the figure.

Tightening torque

22.1-33.1 N.m {2.26-3.37 kgf.m, 16.3-24.4 ft.lbf}

Fig. 25: Identifying Clutch Cover Bolt Tightening Sequence

miércoles, 2 de junio de 2021 15:11:05 Page 9 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Courtesy of MAZDA MOTORS CORP.

CLUTCH COVER INSPECTION

1. Remove the clutch cover.
2. Measure the wear of the diaphragm spring fingers using a vernier caliper.

Clutch cover diaphragm spring fingers maximum depth

0.6 mm {0.024 in}

l If it exceeds the maximum specification, replace the clutch cover.

Fig. 26: Measuring Wear Of Diaphragm Spring Fingers

Courtesy of MAZDA MOTORS CORP.

3. Measure the pressure plate flatness using a straight edge and a feeler gauge.

NOTE: l Measure the pressure plate flatness across the center.

Clutch cover maximum clearance

0.5 mm {0.020 in}

l If it exceeds the maximum specification, replace the clutch cover.

miércoles, 2 de junio de 2021 15:11:05 Page 10 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Fig. 27: Measuring Pressure Plate Flatness

Courtesy of MAZDA MOTORS CORP.

4. Attach a dial gauge to the rear housing, rotate the flywheel, then inspect for height difference between the
diaphragm spring fingers.

Clutch cover maximum height difference

1.0 mm {0.039 in}

l If it exceeds the maximum specification, replace the clutch cover.

Fig. 28: Inspecting Height Difference Between Diaphragm Spring Fingers

Courtesy of MAZDA MOTORS CORP.

CLUTCH DISC INSPECTION

1. Remove the clutch disc.
2. Inspect the lining surface for discoloration and grease adhesion.
3. Inspect the torsion spring for weakness and the rivet for looseness.
4. Using a vernier caliper, measure the depth between the lining surface and the rivet head.

miércoles, 2 de junio de 2021 15:11:05 Page 11 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Clutch disc minimum depth

0.3 mm {0.012 in}

l If it is less than the minimum specification, replace the clutch disc.

Fig. 29: Measuring Depth Between Lining Surface And Rivet Head
Courtesy of MAZDA MOTORS CORP.

5. Measure the clutch disc runout using a dial gauge.

Clutch disc maximum runout

0.7 mm {0.028 in}

l If it exceeds the maximum specification, replace the clutch disc.

6. Install the clutch disc.

Fig. 30: Measuring Clutch Disc Runout

Courtesy of MAZDA MOTORS CORP.

CLUTCH RELEASE COLLAR INSPECTION

CAUTION:

miércoles, 2 de junio de 2021 15:11:05 Page 12 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

l Do not clean the clutch release collar with cleaning fluids or a steam
cleaner because it is filled with grease.

1. Remove the clutch release collar.

2. Turn the collar while applying force in the axial direction, and inspect for sticking, excessive resistance,
and an abnormal noise.
l If there is any malfunction, replace the clutch release collar.

3. Install the clutch release collar.

Fig. 31: Inspecting Clutch Release Collar

Courtesy of MAZDA MOTORS CORP.

PILOT BEARING INSPECTION

NOTE: l Inspect the pilot bearing when it is installed to the eccentric shaft.

1. Remove the clutch unit so that the pilot bearing can be inspected.
2. Inspect the pilot bearing for damage, wear, and proper rotation.
l If there is any malfunction, replace the pilot bearing.

3. Install the clutch unit.

miércoles, 2 de junio de 2021 15:11:05 Page 13 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

Fig. 32: Inspecting Pilot Bearing

Courtesy of MAZDA MOTORS CORP.

FLYWHEEL INSPECTION
1. Remove the flywheel.

NOTE: l Correct slight scratches and discoloration using sandpaper.

l Inspect the runout of the surface that contacts the clutch disc with
the flywheel installed to the eccentric shaft.

2. Inspect the surface that contacts the clutch disc for scratches, nicks, and discoloration.
3. Inspect the ring gear teeth for damage and wear.
4. Install the flywheel.

Fig. 33: Correcting Slight Scratches

Courtesy of MAZDA MOTORS CORP.

5. Measure the runout of the surface that contacts the clutch disc using a dial gauge.

Flywheel maximum runout

miércoles, 2 de junio de 2021 15:11:05 Page 14 © 2011 Mitchell Repair Information Company, LLC.
 2010 Mazda RX-8 R3
2010 TRANSMISSION Clutch - RX-8

0.2 mm {0.008 in}

l If it exceeds the maximum specification, replace the flywheel.

Fig. 34: Measuring Flywheel Clutch Disc Surface Runout

Courtesy of MAZDA MOTORS CORP.

miércoles, 2 de junio de 2021 15:11:05 Page 15 © 2011 Mitchell Repair Information Company, LLC.