Mazda 323/MX-3/626/MX-6/Millenia/Protégé 1990-1998 and Ford Probe 1993-1997

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 11

  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Remove the transaxle.
  4.  



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Fig. Fig. 1: Exploded view of a typical clutch disc and pressure plate assembly with related components

  1. Gradually loosen the clutch pressure plate bolts, in a criss-cross pattern. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc.
  2.  
  3. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  4.  



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Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 3: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 4: Check across the flywheel surface, it should be flat



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Fig. Fig. 5: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 6: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 7: Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts



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Fig. Fig. 8: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 9: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 10: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 11: Be sure to use a torque wrench to tighten all bolts

  1. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  2.  
  3. Install holder tool 49 E011 1A0 or equivalent, to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a criss-cross pattern. Remove the flywheel.
  4.  
  5. Install holder tool 49 F011 101 or equivalent, to keep the flywheel from turning. Remove the locknut. Remove the flywheel, using a suitable puller and remove the key from the eccentric shaft.
  6.  
  7. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  8.  
  9. Inspect the release fork for wear or damage and replace as necessary.
  10.  

To install:
  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2.  
  3. Install the clutch release bearing on the release fork.
  4.  
  5. If removed, install a new pilot bearing in the flywheel, using a suitable installation tool.
  6.  
  7. Make sure the flywheel mounting surface and the crankshaft or eccentric shaft mounting surfaces are clean. Remove any old sealant from the flywheel bolt hole threads and the flywheel bolts.
  8.  
  9. Install the flywheel.
  10.  
  11. Apply sealant to the flywheel bolt threads and install them hand tight. Install the flywheel holding tool. Tighten the bolts, in a criss-cross pattern, to specification.
  12.  
  13. Apply a small amount of molybdenum grease to the clutch disc splines and install the clutch disc on the flywheel, spring side toward the transaxle. Install a suitable alignment tool in the pilot bearing to position the clutch disc.
  14.  
  15. Install the clutch pressure plate, aligning the dowel holes with the flywheel dowels. Install the pressure plate bolts and gradually tighten, in a criss-cross pattern to 20 ft. lbs. (26 Nm). Remove the alignment tool.
  16.  
  17. Install the transaxle and lower the vehicle.
  18.  

ADJUSTMENTS



See Figure 12



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Fig. Fig. 12: Clutch pedal measurement and adjustment points. (A) and (B) are for adjusting the pedal height, while (C) and (D) are for the free-play adjustment

Pedal Height
  1. Measure the distance from the upper surface of the pedal pad to the carpet.
  2.  
  3. The distance should be as follows:

    MX-3 and 1990-94 23/Protege: 7.72-8.03 in. (196-204mm)
     
    1995-98 Protege: 8.5-8.45 in. (212-217 mm)
     
    1990-92 MX-6/626: 6.73-7.13 in. (171-181mm)
     
    1993-98 626/MX-6/Probe: 7.2-8.31 in. (186-211mm)
     

  4.  
  5. If the distance is not as specified, loosen the locknut on the stopper bolt or switch.
  6.  
  7. Turn the switch or bolt until the distance is correct, then tighten the locknut.
  8.  

Free-Play
  1. Depress the clutch pedal by hand until resistance is felt. The free-play should be 0.03-0.13 in. (0.7-3.4mm).
  2.  
  3. If the free-play is not correct, loosen the clutch master cylinder pushrod locknut and turn the pushrod to adjust.
  4.  

 
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