Mazda Trucks 1972-1986 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 24

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Fig. Fig. 1: 1972-75 piston engine clutch assembly



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Fig. Fig. 2: 1976-84 piston engine clutch assembly



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Fig. Fig. 3: View of the 1986 clutch assembly



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Fig. Fig. 4: Rotary engine clutch assembly



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Fig. Fig. 5: Clutch aligning tool and flywheel holding tool in place



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Fig. Fig. 6: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 7: Removing the clutch and pressure plate assembly



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Fig. Fig. 8: ... then carefully remove the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 9: View of the flywheel once the clutch assembly is removed



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Fig. Fig. 10: Check across the flywheel surface, it should be flat



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Fig. Fig. 11: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 12: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 13: Upon installation, it is usually a good idea to apply a thread-locking compound to the flywheel bolts



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Fig. Fig. 14: Check the pressure plate for excessive wear



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Fig. Fig. 15: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 16: Typical clutch alignment tool, note how the splines match the transmission's input shaft



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Fig. Fig. 17: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 18: Clutch plate installed with the arbor in place



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Fig. Fig. 19: Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Fig. 20: Pressure plate-to-flywheel bolt holes should align



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Fig. Fig. 21: You may want to use a thread locking compound on the clutch assembly bolts



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Fig. Fig. 22: Install the clutch assembly bolts and tighten in steps, using an X pattern



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Fig. Fig. 23: Be sure to use a torque wrench to tighten all bolts



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Fig. Fig. 24: View of the clutch and pressure plate assembly


CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.All Models

  1. Remove the transmission.
  2.  
  3. Remove the four attaching and two pilot bolts holding the clutch cover to the flywheel. Loosen the bolts evenly and a turn or two at a time. If the clutch cover is to be reinstalled, mark the flywheel and clutch cover to show the location of the two pilot holes.
  4.  
  5. Remove the clutch disc.
  6.  
  7. Install the clutch disc on the flywheel. Do not touch the facing or allow the facing to come in contact with grease or oil. The clutch disc can be aligned using a tool made for that purpose, or with an old mainshaft.
  8.  
  9. Install the clutch cover on the flywheel and install the four standard bolts and the two pilot bolts.
  10.  
  11. To avoid distorting the pressure plate, tighten the bolts evenly a few turns at a time until they are all tight.
  12.  
  13. Torque the bolts to 13-20 ft.lbs. using a crossing pattern.
  14.  
  15. Remove the aligning tool.
  16.  
  17. Apply a light film of lubricant to the release bearing, release lever contact area on the release bearing hub and to the input shaft bearing retainer.
  18.  
  19. Install the transmission.
  20.  
  21. Check the operation of the clutch and if necessary, adjust the pedal free-play and the release lever.
  22.  

 
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