Mazda RX-8 2004-06

Master Cylinder

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Overhaul



  1. Remove the master cylinder, as outlined in this section.
  2.  
  3. Disassemble the master cylinder by removing the following components (the numbers correspond with the illustration):
    NOTE
    While pressing the piston in with a cloth-wrapped pin punch to protect the push rod contacting surface, remove/install the snapring.



    1. Hose clip
     
    2. Reserve tank hose
     
    3. Joint
     
    4. Bushing
     
    5. Bolt
     
    6. Packing
     
    7. Connector
     
    8. Packing
     



    9. Snapring

    Click image to see an enlarged view

    Fig. While pressing the piston in with a cloth-wrapped pin punch to protect the push rod contacting surface, remove/install the snapring.

     
    10. Piston, secondary cup component
     
    11. Spacer
     
    12. Primary cup
     
    13. Return spring
     
    14. Clutch master cylinder body

    Click image to see an enlarged view

    Fig. Exploded view of the clutch master cylinder overhaul

     

  4.  

To assemble:

  1. Assembly is the reverse of the disassembly procedure.
  2.  
  3. Install the master cylinder.
  4.  
  5. Bleed the air from the system, as outlined later in this section.
  6.  
  7. Inspect and adjust the clutch pedal, as outlined under Clutch.
  8.  

Removal & Installation




WARNING
Brake fluid will damage painted surfaces. Do NOT spill any on painted surfaces. If any is spilled, wipe it off immediately.

  1. Remove the components as outlined in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Remove the hose clip (1), clutch pipe (2), nut (3), cluster master cylinder (4) and packing (5)

  2.  

To install:

  1. Installation is the reverse order of removal.
  2.  
  3. Bleed the air from the system, as outlined later in this section.
  4.  
  5. Inspect and adjust the clutch pedal, as outlined under Clutch.
  6.  

 
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