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

Clutch Release Cylinder (Slave Cylinder)

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REMOVAL & INSTALLATION



  1. Raise the vehicle and safely support with jackstands.
  2.  
  3. Unscrew the hydraulic line from the release cylinder.
  4.  
  5. Unhook the release fork return spring from the cylinder.
  6.  
  7. Unfasten the nuts which secure the release cylinder to the transmission/transaxle.
  8.  
  9. Installation is performed in the reverse order of removal. Bleed the hydraulic system as detailed below, and adjust the release fork free-play as previously described.
  10.  

OVERHAUL



See Figure 1

  1. Thoroughly clean the outside of the cylinder body.
  2.  
  3. Drain the hydraulic fluid from the cylinder.
  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. 1: Exploded view of a common clutch slave 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.  

To assemble:
  1. Dip the piston and cups in clean hydraulic (brake) fluid.
  2.  
  3. Fit the return spring into the cylinder.
  4.  
  5. Insert the primary cup into the bore so that its flat side is facing the piston.
  6.  
  7. Place the secondary cup on the piston and insert them in the cylinder bore.
  8.  
  9. Install the stop washer and the wire piston stop.
  10.  
  11. Fit the boot on the cylinder.
  12.  

HYDRAULIC SYSTEM BLEEDING



See Figure 2

  1. Remove the rubber cap from the bleeder screw on the release cylinder.
  2.  
  3. Place a bleeder tube over the end of the bleeder screw.
  4.  
  5. Submerge the other end of the tube in a jar half-filled with hydraulic (brake) fluid.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Bleeding the hydraulic clutch system

  1. Depress the clutch pedal fully and allow it to return slowly.
  2.  
  3. Keep repeating Step 4 while watching the hydraulic fluid in the jar. As soon as the air bubbles disappear, close the bleeder screw.
  4.  

During the bleeding procedure, the reservoir must be kept at least3/4full.

  1. Remove the tube and refit the rubber cap. Fill the reservoir with hydraulic fluid.
  2.  

 
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