Mazda Trucks 1972-1986 Repair Guide

Adjustments

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See Figure 1

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Fig. Fig. 1: Clutch pedal adjustment points

CLUTCH PEDAL FREE-PLAY 1972-75 Vehicles



The free-play of the clutch pedal before the pushrod contacts the piston in the master cylinder should be 0.5-3.0mm (0.0197-0.1181 in.). To adjust the free-play, loosen the locknut and turn the pushrod until the proper adjustment is obtained. Tighten the locknut after the adjustment is complete.

1976-86 Vehicles

The clutch pedal free-play is measured from the top of the pedal pad at rest to the point at which it stops when the pushrod hits the master cylinder piston. Free-play is adjusted by loosening the locknut on the pushrod and adjusting the pushrod length by rotating the rod. The clutch should have a free travel, measured at the pedal pad, of 0.6-3.0mm (0.0236-0.1181 in.) for 1976-84, 5-13mm (0.197-0.512 in.) for 1986 trucks. Tighten the locknut when the adjustment is complete.

PEDAL HEIGHT



Pedal height is measured from the top of the pedal at rest, to the floor board, horizontally behind the pedal. Adjustment is made by loosening the locknut on the pedal stopper and turning the adjusting bolt. Pedal height should be:



1972-81215mm (8.465 in.)
 
1982-84
 

Gasoline engine205mm (8.071 in.) Diesel engine215mm (8.465 in.)



1986215mm (8.465 in.)
 

CLUTCH RELEASE LEVER1972-75 Vehicles



This adjustment must be maintained to prevent release bearing and clutch damage.

  1. Raise and support the truck.
  2.  
  3. Disconnect the release lever return spring at the lever.
  4.  
  5. Loosen the locknut and rotate the adjusting nut until a clearance of 3.5-4.5mm (0.138-0.177 in.) is obtained between the bullet nosed end of the adjusting nut and the release lever.
  6.  
  7. Tighten the locknut and hook the return spring.
  8.  
  9. Lower the truck.
  10.  

1976-86 Vehicles

No adjustment is possible on 1976 and later trucks. Instead, the stroke can be checked by raising the truck and moving the release rod. If the stroke measures less than 5mm (0.197 in.), the clutch pedal should be replaced.

 
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