A car with a manual transmission is equipped with a single-disc diaphragm clutch

Pressure plate in a stamped steel casing attached by six bolts to the flywheel of the engine

The driven disc is mounted on the slots of the primary shaft of the gearbox and is clamped by a diaphragm spring between the flywheel and the pressure plate

Feature of the clutch design of the Mazda 6

The clutch release bearing is mounted on a guide sleeve pressed into the clutch housing and moves along the sleeve with a fork, which in turn drives the working cylinder of the clutch release hydraulic drive

Feature of the Mazda clutch design 6

The hydraulic clutch release drive consists of a master cylinder installed in the engine compartment, a working cylinder combined with a clutch release bearing, a pipeline including a tube and hose, a clutch pedal, the bracket of which is attached with nuts to the front panel of the body

The pedal is returned to its original position by a spring

Feature of the clutch design of the Mazda 6

The working cylinder on cars with a five-speed gearbox is located on the clutch housing, and on cars with a six-speed gearbox - inside the clutch housing

Feature of the clutch design of the Mazda 6

The main cylinder is connected by a hose to the tank mounted on the main brake cylinder (the tank is common to both main cylinders)

Brake fluid is used in the hydraulic clutch release drive

Adjustment of the clutch release drive is provided

In order for the clutch to serve for a long time and reliably, do not keep your foot on the clutch pedal all the time. This bad habit is often acquired while learning to drive in driving schools for fear of not having time to turn off the clutch when the car stops. In addition to the rapid fatigue of the foot, which is always above the pedal, the clutch turns out to be at least a little, but squeezed out, while the driven disk slips and wears out. In addition, despite the fact that the release bearing is designed to operate in a constant rotation mode, it is under increased load when the pedal is pressed even a little bit and its resource is reduced. For the same reason, we do not recommend keeping the clutch off for a long time (for example, in traffic jams). If you do not have to start immediately, it is better to turn on the neutral position of the gearbox and release the pedal.

Checking the clutch pedal stroke

Check the clutch pedal stroke to assess the condition of the clutch

Checking the clutch pedal stroke

We measure the height of the clutch pedal, it should be 210-216 mm

If the measured state does not correspond to the nominal value, adjust it

To adjust, loosen the lock nut (A) and, rotating the bolt (B), achieve the desired value

To determine the free movement of the clutch pedal, we measure the distance from the initial position of the pedal to the position in which an increase in resistance is felt when pressing the pedal with your hand

Nominal free stroke of the clutch pedal 1-3 mm

Checking the clutch pedal stroke

If the free stroke differs from the nominal value, adjust the length of the pusher of the clutch master cylinder

To do this, loosen the tightening of the lock nut (C) and, rotating the pusher (D) by the toe, adjust the free stroke of the pedal

Checking the clutch pedal stroke

Check the pedal stroke (B) until the clutch is engaged, it should be 20 mm, the full pedal stroke (C) should be 140 mm

Measure the distance (A) (from the position of the clutch pedal at the moment of turning on the clutch to the position of the pedal in the fully squeezed position)

If the pedal stroke before turning on the clutch is less than or greater than the specified value, check the following:

- free running of the clutch pedal

If necessary, we adjust it;

- full pedal stroke. With a smaller pedal stroke, you need to adjust it and check the condition of the clutch drive

- the presence of air in the clutch hydraulic drive. If necessary, you need to pump the hydraulic drive

Possible clutch malfunctions and solutions

Incomplete clutch activation (clutch leads)

- reduced the full stroke of the clutch pedal

Adjust the clutch release drive

- warping of the driven disk (end runout of more than 0.5 mm)

Straighten the slave disk or replace

- irregularities on the surface of the friction pads of the driven disk

Replace the slave disk assembly

- loosening of rivets or breakage of friction linings of the driven disk

Replace the pads, check the end runout of the disc

- jamming of the driven disk hub on the slots of the primary shaft of the gearbox

Clean the slots, cover with LCC-15 grease. If the cause of jamming is crumpling or wear of the slots, replace the primary shaft or the driven disk

- air in the hydraulic drive system

Upgrade the system

- leakage of fluid from the main or working cylinder of the clutch drive

Replace the clutch master or working cylinder

- loosening of the rivets of the pressure spring attachment

Replace the clutch cover with the pressure plate assembly

- misalignment or warping of the pressure plate

Replace the clutch discs

Increased noise when the clutch is switched off

- wear, damage or leakage of lubricant from the clutch release bearing

Replace the bearing

Increased noise when the clutch is engaged

- breakage of the plates connecting the pressure plate to the casing

Replace the clutch cover with the pressure plate assembly

Incomplete engagement of the clutch (the clutch is slipping)

- increased wear or burning of the friction pads of the driven disc

Replace the slave disk

- oiling of the driven disk, the surfaces of the flywheel and the pressure disk

Eliminate oiling and rinse the parts with white spirit

- damage or jamming of the clutch release drive

Eliminate the cause of jamming

Jerks during clutch operation

- jamming of the driven disk hub on the slots of the primary shaft

Clean the slots and lubricate with LCC-15 grease

- breakage or decrease in the elasticity of the springs of the damper of the driven disk

Replace the slave disk

- oiling of the friction linings of the driven disc, the surfaces of the flywheel and the pressure disc

Eliminate oiling and rinse the parts with white spirit

- jamming in the clutch release drive mechanism

Replace the deformed parts. Eliminate the causes of jamming

- increased wear of the friction pads of the driven disk

Replace the pads with new ones

- loosening of the rivets of the friction pads of the driven disk

Replace the faulty rivets, and replace the pads if necessary