Mazda Trucks 1987-1993 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION




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.

Pickup and MPV

See Figures 1 through 8



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Fig. Fig. 1: Exploded view of the clutch and pressure plate assembly



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Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 3: ... then carefully remove the pressure plate and clutch assembly from the flywheel



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Fig. Fig. 4: Check the flywheel surface for flatness and, if necessary, remove it from the engine for truing

  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.  



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Fig. Fig. 5: Be sure that the flywheel surface is clean before installing the clutch



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Fig. Fig. 6: Typical clutch alignment tool, note how the splines match the transmission's input shaft



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Fig. Fig. 7: Use the clutch alignment tool to align the clutch disc during assembly.



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Fig. Fig. 8: Be sure to use a torque wrench to tighten all of the bolts

  1. Tighten the bolts to 13-20 ft.lbs. (18-27 Nm). using a crossing pattern.
  2.  
  3. Remove the aligning tool.
  4.  
  5. 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.
  6.  
  7. Install the transmission.
  8.  
  9. Check the operation of the clutch and if necessary, adjust the pedal free-play and the release lever.
  10.  

Navajo

See Figures 9 and 10



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Fig. Fig. 9: Exploded view of the clutch components

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the clutch hydraulic system master cylinder from the clutch pedal and remove.
  4.  
  5. Raise the vehicle and support it safely.
  6.  
  7. Remove the starter.
  8.  
  9. Disconnect the hydraulic coupling at the transmission.
  10.  

Clean the area around the hose and slave cylinder to prevent fluid contamination.

  1. Remove the transmission from the vehicle.
  2.  
  3. Mark the assembled position of the pressure plate and cover the flywheel, to aid during re-assembly.
  4.  
  5. Loosen the pressure plate and cover attaching bolts evenly until the pressure plate springs are expanded, and remove the bolts.
  6.  
  7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Remove the pilot bearing only for replacement.
  8.  

To install:
  1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft Tool T74P-7137-K or equivalent can enter the clutch pilot bearing and align the disc.
  2.  



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Fig. Fig. 10: Pressure plate bolt torque sequence

  1. When reinstalling the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to 15-25 ft.lbs. (21-35 Nm) in the proper sequence. Remove the clutch disc pilot tool.
  2.  
  3. Install the transmission into the vehicle.
  4.  
  5. Connect the coupling by pushing the male coupling into the slave cylinder.
  6.  
  7. Connect the hydraulic clutch master cylinder pushrod to the clutch pedal.
  8.  

ADJUSTMENTS



Free-Play/Pedal Height
EXCEPT NAVAJO

See Figure 11



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Fig. Fig. 11: Clutch pedal adjustment points

  1. Measure the distance from the top of the clutch pedal pad to the carpet. The distance should be as follows:

    B2200: 7.13-7.52 inches (181-191mm)
     
    B2600: 7.52-7.91 inches (191-201mm)
     
    MPV: 8.19-8.58 inches (208-218mm)
     

  2.  
  3. If the distance is not within specification, loosen the clutch switch locknut and turn the switch until the distance is correct. Tighten the lock nut.
  4.  
  5. Check the free-play by pressing the pedal by hand until clutch resistance is felt. The free-play should be 0.02-0.12 inch (0.6-3.0mm).
  6.  
  7. If the free-play is not within specification, loosen the locknut on the actuator rod and turn the actuator rod until the free-play is correct.
  8.  
  9. Check that the disengagement height from the upper surface of the pedal height to the carpet is correct when the pedal is fully depressed. The disengagement height should be as follows:

    B2200: 2.60 inches (66mm)
     
    B2600: 2.80 inches (71mm)
     
    MPV: 1.38 inches (35mm)
     

  10.  
  11. Tighten the actuator rod locknut to 8.7-12.0 ft. lbs. (12-17 Nm).
  12.  
  13. Recheck the pedal height. Certain models are equipped with a clutch assist spring. The spring is mounted on the clutch linkage, and is adjustable. The correct length should be between 1.33-1.37 inches (33.8-34.8mm). Adjust by turning the locknut.
  14.  

NAVAJO

The hydraulic clutch system provides automatic adjustment. No adjustment of clutch linkage or pedal position is required.

 
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