Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Clutch Master Cylinder

Print

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. On 1988-89 626 and MX-6 equipped with ABS, remove the ABS relay box located forward of the brake power booster on the driver's side. Unfasten the hydraulic line from the master cylinder outlet. On 1988-89 turbocharged 626/MX-6s and on all 929s, disconnect the line from the banjo fitting, leave the union fitting connected to the master cylinder.
  2.  
  3. Remove the nuts which secure the master cylinder assembly to the firewall. On some vehicles one or both of these nuts are accessible from the inside of the cabin.
  4.  
  5. Withdraw the master cylinder and gasket straight out; away from the firewall. Inspect the gasket. If it is still in good condition use it again, otherwise a new gasket must be used during installation.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Clutch master cylinder-1988-89 626 and MX-6



Click image to see an enlarged view

Fig. Fig. 2: Clutch master cylinder-929



Click image to see an enlarged view

Fig. Fig. 3: Clutch master cylinder-RX-7

To install:
  1. Place the gasket and the master cylinder onto the firewall and attach with the nuts. Connect the line to the outlet connection. On 1988-89 626/MX-6s with ABS, install the ABS relay box.
  2.  
  3. Bleed the hydraulic system as detailed below.
  4.  

OVERHAUL



See Figure 4

  1. Thoroughly clean the outside of the master cylinder.
  2.  
  3. Drain the hydraulic fluid from the cylinder. Unbolt the reservoir from the cylinder body. If equipped with banjo fittings, loosen the union bolt, then remove the fitting and gaskets from the body of the master cylinder. Discard the old gaskets.
  4.  
  5. Remove the boot from the cylinder.
  6.  
  7. Release the wire piston stop with a screwdriver and withdraw the stop washer.
  8.  
  9. Withdraw the piston, piston cups, and return spring from the cylinder bore.
  10.  
  11. Wash all the parts in clean hydraulic (brake) fluid.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of a common clutch master cylinder

  1. Examine the piston cups. If they are damaged, softened, or swollen, replace them with new ones.
  2.  
  3. Check the piston and bore for scoring or roughness.
  4.  
  5. Use a wire gauge to check the clearance between the piston and its bore. Replace either the piston or the cylinder if the clearance is greater than 0.006 in. (0.15mm).
  6.  
  7. Be sure that the compensating port in the cylinder is not clogged.
  8.  

To assemble:
  1. Dip the piston and cups in clean hydraulic (brake) fluid.
  2.  
  3. Bolt the reservoir up to the cylinder body.
  4.  
  5. Fit the return spring into the cylinder.
  6.  
  7. Insert the primary cup into the bore so that its flat side is facing the piston.
  8.  
  9. Place the secondary cup on the piston and insert them in the cylinder bore.
  10.  
  11. Install the stop washer and the wire piston stop.
  12.  
  13. Fill the reservoir half-full of hydraulic fluid. Operate the piston with a screwdriver until fluid spurts out of the cylinder outlet. Install the banjo fittings with new gaskets. Leave the union bolt snug until such time as the master cylinder is in place on the firewall this way you can move the fitting up and down to align fluid line.
  14.  
  15. Fit the boot on the cylinder.
  16.  

 
label.common.footer.alt.autozoneLogo