Mazda Tribute 2001-06

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
     
    Transmission and lock the flywheel to the engine with special tool 303-103
     
    Pressure plate bolts by loosening them evenly
     
    Clutch pressure plate and disc
     

  4.  
  5. Clean the pressure plate and inspect it for burn marks, scores, flatness or ridges, replace if damaged.
  6.  
  7. Inspect the pressure plate diaphragm finger for wear, replace if damaged.
  8.  
  9. Measure the depth of the rivet heads. Minimum depth is 0.012 inch (0.3mm).
  10.  
  11. Inspect the clutch disc for signs of wear and replace if needed.
  12.  
  13. Check the clutch disc runout. Replace the disc if not with specification: 0.027 inch (0.7mm).
  14.  


    Click image to see an enlarged view

    Fig. Clutch components


To install:



Click image to see an enlarged view

Fig. Torque the pressure plate bolts in the proper sequence

  1. Install or connect the following:

    Clutch disc to the flywheel
     
    Pressure plate to the flywheel. Torque the bolts in sequence to 21 ft. lbs. (29 Nm).
     
    Transmission
     
    Negative battery cable
     

  2.  
  3. Check the transmission fluid level and top off if necessary.
  4.  


WARNING
Clutches and brakes contain asbestos fibers. Avoid breathing dust. Breathing asbestos dust may cause asbestosis and cancer. Failure to follow these instructions may result in personal injury.


WARNING
Breathing asbestos dust is hazardous to your health. Failure to follow these instructions may result in personal injury.


WARNING
Dust and dirt present on wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing. Failure to follow these instructions may result in personal injury.


WARNING
Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum 164-R3600. Dust and dirt from vacuum should be disposed of in a manner that prevents dust exposure such as sealed bags. The bag must be labeled as per OSHA instructions and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury.


WARNING
If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury.


WARNING
Grinding or sanding on brake linings, pads, rotors, drums or clutch facings should be done only while using correctly exhaust-ventilated equipment. Failure to follow these instructions may result in personal injury.


WARNING
OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with carrying out brake or clutch service should be present in the area. Failure to follow these instructions may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the transaxle.

    Click image to see an enlarged view

    Fig. Using special tool, 303-637 to lock flywheel

  6.  
  7. Using special tool 303-637, lock the flywheel to the engine.
    WARNING
    The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.


    CAUTION
    Loosen bolts evenly to prevent pressure plate damage.

  8.  
  9. Remove the bolts, clutch pressure plate and clutch disc.
    CAUTION
    Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Using a suitable commercial alcohol base solvent, clean the clutch pressure plate.

  10.  
  11. Inspect the clutch pressure plate surface for burn marks, scores, flatness or ridges.
  12.  
  13. Inspect the clutch pressure plate diaphragm fingers for wear. Install a new clutch pressure plate as necessary.

    Click image to see an enlarged view

    Fig. Measuring rivet heads

  14.  
  15. Measure the depth to the rivet heads. Install a new clutch disc if any rivet head measurement is not within specifications.
    CAUTION
    If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation.


    NOTE
    Use an emery cloth to remove minor imperfections in the clutch disc lining surface.


    NOTE
    Install a new clutch disc if any of the following conditions are present.

  16.  
  17. Inspect the clutch disc for the following:

    Oil or grease saturation
     
    Worn or loose facings
     
    Warpage or loose rivets at the hub
     
    Loose or broken torsion dampening springs
     
    Wear or rust on splines

    Click image to see an enlarged view

    Fig. Checking clutch disc runout

     

  18.  
  19. Using the special tool 100-D002, check clutch disc runout. Install a new clutch disc if not within specifications.
    NOTE
    Install a new clutch release fork if any of the following conditions are present.

  20.  
  21. Inspect the clutch release fork for the following:

    Cracks
     
    Distortion
     
    Excessive wear on the release bearing contact surface
     

  22.  

To install:

Click image to see an enlarged view

Fig. Positioning the clutch disc on the flywheel



Click image to see an enlarged view

Fig. Pressure plate bolt tightening sequence

  1. Using the special tool 308-020, position the clutch disc on the flywheel.
  2.  
  3. Position the clutch pressure plate on the flywheel. Install the pressure plate bolts and tighten them in sequence to:

    2001-2004 vehicle years: 18 ft. lbs. (24 Nm).
     
    2005-2006 vehicle years: 21 ft. lbs. (29 Nm).
     

  4.  
  5. Remove special tools 308-020 and 303-673.
  6.  
  7. Install transaxle.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies, if equipped.

  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the transaxle from the vehicle.
  8.  
  9. Remove the pressure plate bolts by loosening them evenly.
  10.  
  11. Remove the clutch pressure plate and disc.
  12.  
  13. Clean the pressure plate and inspect it for burn marks, scores, flatness or ridges, replace if damaged.
  14.  
  15. Inspect the pressure plate diaphragm finger for wear, replace if damaged.
  16.  
  17. Measure the depth of the rivet heads. Minimum depth is 0.012 inch (0.3mm).
  18.  
  19. Inspect the clutch disc for signs of wear and replace if needed.
  20.  
  21. Check the clutch disc runout. Replace the disc if not with specification: 0.027 inch (0.7mm).

    Click image to see an enlarged view

    Fig. Clutch and related components

  22.  

To install:

Click image to see an enlarged view

Fig. Pressure plate bolt torque sequence

  1. Install or connect the following:

    Clutch disc to the flywheel
     
    Pressure plate to the flywheel. Torque the bolts in sequence to 21 ft. lbs. (29 Nm).
     
    Transaxle
     
    Negative battery cable
     

  2.  
  3. Check the transaxle fluid level and top off if necessary.
  4.  

 
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