Mazda RX-8 2004-06

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
     
    Transmission
     
    Rubber boot
     
    Clutch release collar
     
    Clutch release fork
     
    Clutch cover
     
    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 F011 101 to keep the flywheel from turning, remove the flywheel lock bolt and 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 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 lock bolt and threads.

    Flywheel
     
    Sealant to the flywheel lock bolt threads and install it tight
     
    Flywheel holding tool. Tighten the lock bolt to 289-361 ft. lbs. (392-490 Nm)..
     
    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 13-19 ft. lbs. (18-27 Nm).
     

  6.  
  7. Remove the alignment tool.

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

  8.  
  9. On models with dynamic suspension, perform the steering angle sensor initialization procedure.
  10.  

 
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