Mazda Car 2002-04

Master Cylinder

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Removal & Installation



  1. Remove the charcoal canister.
  2.  
  3. Remove the clip and the clutch pipe.
  4.  
  5. Remove the nut, master cylinder and gasket.
  6.  

To install:

  1. Installation is the reverse of removal. User a new gasket and tighten the nuts to 14-18 ft. lbs. (19-25 Nm).

    Click image to see an enlarged view

    Fig. Clutch master cylinder assembly-626

  2.  

  1. Disconnect the clutch pipe.
  2.  
  3. Remove the nut, master cylinder and packing.
  4.  

To install:

  1. Installation is the reverse of removal. Install the gasket as shown and tighten the nuts to 14-18 ft. lbs. (19-25 Nm).
  2.  
  3. Fill and bleed the clutch hydraulic system.

    Click image to see an enlarged view

    Fig. Install the clutch master cylinder gasket as shown -Miata



    Click image to see an enlarged view

    Fig. Clutch master cylinder assembly-Miata

  4.  

  1. Remove the clip and the clutch pipe.
  2.  
  3. Remove the nut, master cylinder and gasket.
  4.  

To install:

  1. Installation is the reverse of removal. User a new gasket and tighten the nuts to 14-18 ft. lbs. (19-25 Nm).

    Click image to see an enlarged view

    Fig. Clutch master cylinder assembly-Protégé

  2.  

  1. Remove the battery and battery tray.
  2.  
  3. Separate the steering shaft.
  4.  
  5. Remove the reserve hose from the master cylinder while pressing on the coupling.
  6.  
  7. Pull the clutch master cylinder clip down and pull out the clutch pipe connector straight to detach it
  8.  
  9. Plug the clutch pipe after removing it to avoid leakage.
  10.  
  11. Unplug the clutch pedal position switch connector and starter interlock switch connector.
  12.  
  13. Remove the starter interlock switch.
  14.  
  15. Remove the nuts and the clutch pedal assembly
  16.  
  17. Rotate the clutch master cylinder in the counterclockwise direction and remove.
  18.  
  19. Press on the tabs on the left and right sides of the push rod using a flathead screwdriver and remove the rod.
  20.  

To install:

  1. Push the push rod in until the tabs lock. On the master cylinder.
  2.  
  3. Rotate the clutch master cylinder in a clockwise direction until it stops.
  4.  
  5. Install the clutch pedal assembly and tighten the nuts to 13-18 ft. lbs. (18-25 Nm).
  6.  
  7. Install the starter interlock switch.
  8.  
  9. Connect the clutch pedal position switch connector and starter interlock switch connector.
  10.  
  11. Install the clutch pipe and engage the retaining clip.
    NOTE
    Verify that there is no chipping or damage to the seal ring of the clutch pipe connector.

  12.  
  13. Insert the clutch pipe connector straight.
  14.  
  15. Pull the clutch pipe to verify that it does not come off, and reinsert it completely.
  16.  
  17. Insert the reserve hose connector straight until a click is heard.
  18.  
  19. Pull the reserve hose to verify that it does not come off, and reinsert it completely.
  20.  
  21. Fill and bleed the clutch hydraulic system.
    WARNING
    When performing the following procedure, make sure that the area around the vehicle is free of people or objects as the vehicle might move suddenly.

  22.  
  23. Apply the parking brake and fix the front and rear of the wheels with the wheel chocks.
  24.  
  25. Start the engine at idle.
  26.  
  27. Without depressing the clutch pedal, move the shift lever slowly to the reverse position.
  28.  
  29. Hold the lever when the gear noise is heard.
  30.  
  31. Depress the clutch pedal slowly.
  32.  
  33. Hold the pedal when the gear noise stops (clutch pedal disengagement point).
  34.  
  35. Measure distance A, verify that they are within the following specifications. Refer to the illustration for further detail.
    1. The clutch pedal disengagement stroke should be 3.55-4.33 in. (90-110 mm)
    2.  
    3. The pedal stroke should be 5.31 in. (135 mm).

      Click image to see an enlarged view

      Fig. Clutch pedal measurement locations-Mazda 3

    4.  

  36.  

  1. Remove the battery and tray.
  2.  
  3. Disconnect the hose clip.
  4.  
  5. Disconnect the clutch pipe.
  6.  
  7. Remove the nut, master cylinder and packing.
  8.  

To install:

  1. Installation is the reverse of removal. Tighten the nuts to 13-18 ft. lbs. (18-25 Nm).
  2.  
  3. Fill and bleed the clutch hydraulic system.
  4.  

 
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