Clutch Disc And Cover Removal/Installation

WARNING: This page is about a different variant/trim than selected.

Remove the transmission; see MANUAL TRANSMISSION REMOVAL/INSTALLATION .
CAUTION:
- If the clutch disc and clutch cover are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release.
NOTE:
- If the parts are to be reused, mark the clutch cover and the flywheel.
Remove the bolts, clutch cover and the clutch disc.

Fig 1: Removing Clutch Cover Bolts
Courtesy of MAZDA MOTORS CORP.
Lubricate the transmission input shaft pilot bearing.
1. Use front axle grease.
  CAUTION:
  - To prevent damage do not force the adjusting ring. Additional pressure may be required on the diaphragm fingers if the adjusting ring does not turn readily.
  NOTE:
  - Clean the clutch cover and flywheel with a commercial alcohol based solvent so surfaces are free from oil film. Do not use cleaners with a petroleum base. Do not immerse the clutch cover in the solvent.
    The clutch cover should always be adjusted before installation.
Compress the clutch diaphragm fingers. Position the clutch pressure plate in a press. Use a suitable adapter and press the clutch diaphragm fingers until the adjusting ring moves freely.

Fig 2: Compressing Clutch Diaphragm Fingers
Courtesy of MAZDA MOTORS CORP.
Adjust the clutch cover.
1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
  
  Fig 3: Adjusting Clutch Cover
  Courtesy of MAZDA MOTORS CORP.
Position the clutch disc on the flywheel.
- Use the clutch aligner SST TZ4P-7137-K or equivalent to align the clutch disc.
  
  Fig 4: Aligning Clutch Disc
  Courtesy of MAZDA MOTORS CORP.
  NOTE:
  - If reusing the clutch pressure plate, align using marks made during removal.
Position the clutch cover on the flywheel dowels. Align the clutch cover. Install the bolts and tighten in a star pattern sequence. Remove the SST .

Fig 5: Identifying Tightening Torque Of Clutch Cover Bolts
Courtesy of MAZDA MOTORS CORP.
Install the transmission; see MANUAL TRANSMISSION REMOVAL/INSTALLATION .