Mazda Car 2002-04

Driven Disc & Pressure Plate

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    negative battery cable
     
    Clutch release cylinder
     
    Transaxle
     
    Rubber boot
     
    Clutch release collar
     
    Clutch release fork
     
    Pressure plate loosening the bolts one turn each in a criss-cross pattern
     
    Clutch disc
     

  4.  
  5. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  6.  
  7. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  8.  
  9. Install Holder tool 49 E011 1A0 to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
  10.  
  11. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  12.  
  13. Inspect the release fork for wear or damage and replace as necessary.
  14.  

To install:

  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2.  
  3. Install or connect the following:

    clutch release bearing on the release fork
     
    New pilot bearing in the flywheel, if removed, using an installation tool
     

  4.  
  5. Be 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.

    flywheel
     
    sealant to the flywheel bolt threads and install them hand tight
     
    Flywheel holding tool. Tighten the bolts, in a crisscross pattern as follows:
     
    Except Mazda 3, 6 and 2.5L (KL) engines to 71-75 ft. lbs. (97-102 Nm).
     
    On the 2.5L (KL) engines, tighten to 45-49 ft. lbs. (61-66 Nm).
     
    Mazda 3 models, tighten to 79-85 ft. lbs. (108-116 Nm).
     
    Mazda 6 models equipped with the G35M-R transaxle, tighten to 79-84 ft. lbs. (108-115 Nm).
     
    Mazda 6 models equipped with the A65M-R transaxle, tighten to 54-64 ft. lbs. (73-87 Nm).
     

  6.  
  7. Install or connect the following:
    1. Small amount of molybdenum grease to the clutch disc splines
    2.  
    3. Clutch disc on the flywheel with the spring side toward the transaxle
    4.  
    5. An alignment tool in the pilot bearing to position the clutch disc
    6.  
    7. clutch pressure plate by aligning the dowel holes with the flywheel dowels
    8.  
    9. Pressure plate. Gradually, torque the bolts, in a crisscross pattern, to 19 ft. lbs. (26 Nm).
    10.  

  8.  
  9. Remove the alignment tool.

    Clutch release fork
     
    Clutch release collar
     
    Rubber boot
     
    Transaxle
     
    Clutch release cylinder
     
    negative battery cable
     

  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle

    Click image to see an enlarged view

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

     

  4.  
  5. Gradually loosen the clutch pressure plate bolts, in a crisscross pattern. Support the pressure plate and remove the bolts.
  6.  
  7. Remove the pressure plate and clutch disc.
  8.  
  9. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  10.  
  11. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  12.  
  13. Install Holder tool 49 E011 1A0 to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
  14.  
  15. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  16.  
  17. Inspect the release fork for wear or damage and replace as necessary.
  18.  

To install:

  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2.  
  3. Install or connect the following:

    Clutch release bearing on the release fork
     
    New pilot bearing in the flywheel, if removed, using a installation tool
     

  4.  
  5. Be 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.
  6.  
  7. Install the flywheel.
  8.  
  9. Apply sealant to the flywheel bolt threads and install them hand tight. Install the flywheel holding tool. Tighten the bolts, in a crisscross pattern, to specification.
  10.  
  11. Apply a small amount of molybdenum grease to the clutch disc splines.
  12.  
  13. Install or connect the following:

    Clutch disc on the flywheel with the spring side toward the transaxle
     
    An alignment tool in the pilot bearing to position the clutch disc
     
    Clutch pressure plate by aligning the dowel holes with the flywheel dowels
     
    Pressure plate. Gradually, torque the bolts, in a crisscross pattern, to 20 ft. lbs. (26 Nm)
     

  14.  
  15. Remove the alignment tool.
  16.  
  17. Install the transaxle.
  18.  
  19. Connect the negative battery cable.
  20.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Clutch release cylinder
     
    Transaxle
     
    Rubber boot
     
    Clutch release collar
     
    Clutch release fork
     
    Pressure plate loosening the bolts one turn each in a criss-cross pattern
     
    Clutch disc
     

  4.  
  5. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  6.  
  7. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  8.  
  9. Install Holder tool 49 E011 1A0 to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
  10.  
  11. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  12.  
  13. Inspect the release fork for wear or damage and replace as necessary.
  14.  

To install:

  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2.  
  3. Install or connect the following:

    Clutch release bearing on the release fork
     
    New pilot bearing in the flywheel, if removed, using an installation tool
     

  4.  
  5. Be 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.

    Flywheel
     
    Sealant to the flywheel bolt threads and install them hand tight
     
    Flywheel holding tool. Tighten the bolts, in a crisscross pattern as follows:
     

    1. Mazda3 models, tighten to 79-85 ft. lbs. (108-116 Nm).
    2.  
    3. Mazda6 models equipped with the G35M-R transaxle, tighten to 79-84 ft. lbs. (108-115 Nm).
    4.  
    5. Mazda6 models equipped with the A65M-R transaxle, tighten to 54-64 ft. lbs. (73-87 Nm).
    6.  
    7. Mazdaspeed6 models equipped with the A26MX-R transaxle, tighten to 111-118ft. lbs. (151-161 Nm).
    8.  

  6.  
  7. Install or connect the following:

    Small amount of molybdenum grease to the clutch disc splines
     
    Clutch disc on the flywheel with the spring side toward the transaxle
     
    An alignment tool in the pilot bearing to position the clutch disc
     
    Clutch pressure plate by aligning the dowel holes with the flywheel dowels
     
    Pressure plate. Gradually, torque the bolts, in a crisscross pattern, to 19 ft. lbs. (26 Nm).
     

  8.  
  9. Remove the alignment tool.

    Clutch release fork
     
    Clutch release collar
     
    Rubber boot
     
    Transaxle
     
    Clutch release cylinder
     
    Negative battery cable
     

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Clutch release cylinder
     
    Transaxle
     
    Rubber boot
     
    Clutch release collar
     
    Clutch release fork
     
    Pressure plate loosening the bolts one turn each in a criss-cross pattern
     
    Clutch disc
     

  4.  
  5. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  6.  
  7. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  8.  
  9. Install Holder tool 49 E011 1A0 to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
  10.  
  11. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  12.  
  13. Inspect the release fork for wear or damage and replace as necessary.
  14.  

To install:

  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2.  
  3. Install or connect the following:

    Clutch release bearing on the release fork
     
    New pilot bearing in the flywheel, if removed, using an installation tool
     

  4.  
  5. Be 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.

    Flywheel
     
    Sealant to the flywheel bolt threads and install them hand tight
     
    Flywheel holding tool. Tighten the bolts, in a crisscross pattern as follows:
     

    1. Except Mazda 3, 6 and 2.5L (KL) engines to 71-75 ft. lbs. (97-102 Nm).
    2.  
    3. On the 2.5L (KL) engines, tighten to 45-49 ft. lbs. (61-66 Nm).
    4.  
    5. Mazda 3 models, tighten to 79-85 ft. lbs. (108-116 Nm).
    6.  
    7. Mazda 6 models equipped with the G35M-R transaxle, tighten to 79-84 ft. lbs. (108-115 Nm).
    8.  
    9. Mazda 6 models equipped with the A65M-R transaxle, tighten to 54-64 ft. lbs. (73-87 Nm).
    10.  

  6.  
  7. Install or connect the following:

    Small amount of molybdenum grease to the clutch disc splines
     
    Clutch disc on the flywheel with the spring side toward the transaxle
     
    An alignment tool in the pilot bearing to position the clutch disc
     
    Clutch pressure plate by aligning the dowel holes with the flywheel dowels
     
    Pressure plate. Gradually, torque the bolts, in a crisscross pattern, to 19 ft. lbs. (26 Nm).
     

  8.  
  9. Remove the alignment tool.

    Clutch release fork
     
    Clutch release collar
     
    Rubber boot
     
    Transaxle
     
    Clutch release cylinder
     
    Negative battery cable
     

  10.  

 
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