mazda rx8车间手册英文版5transmissions

1、TRANSMISSION (MANUAL & AUTO)CLUTCHCLUTCH LOCATION INDEX(w)(w)RX-8 Transmission (Manual & Auto)Page 11Clutch pipe2Clutch fluid3Clutch pedal4Clutch master cylinder5Clutch release cylinder6Clutch unit7Clutch cover8Clutch discGENERAL PROCEDURES (CLUTCH)CAUTION:Fluid will damage painted surfaces.

2、 Be careful not to spill any on painted surfaces.If fluid does get on painted surfaces, wipe it off immediately.·NOTE:· If any hydraulic related parts of the clutch sytem are removed during the procedure, add brake fluid,bleed the system and inspect for leakage after the proceduas been com

3、pleted.1. Remove the clutch pipe using the SST (49 0259 770B).2. Install the clutch pipe using a torque wrench and the SST (49 0259 770B).CLUTCH FLUIDCLUTCH FLUID INSPECTION1. Inspect whether the fluid level in the reserve tank is between MIN and MAX.CLUTCH FLUID REPLACEMENTCAUTION:·Fluid will

4、damage painted surfaces. Be careful not to spill any on painted surfaces. If fluid does get on painted surfaces, wipe it off immediately.Keep the fluid level in the reserve tank at 3/4 full or more during air bleeding.·NOTE:· When replacing the fluid, drain the old fluid, fill the reserve

5、tank with new fluid and then perform Steps 1¾6 below.Specified fluido SAE J1703, FMVSS 116 DOT-3(w)RX-8 Transmission (Manual & Auto)Page 29Clutch release collar10Pilot bearing11Flywheel1.2.Remove the bleeder cap from the clutch release cylinder, and connect a vinyl hose to the bleeder plug.

6、 Place the other end of the vinyl tube in a clear container, and fill fluid in the container during air bleeding.Working with two people, one should depress the clutch pedal a few times and then depress and hold the pedal down.3.4.While the clutch pedal is being held down, the othershould loosen the

7、 bleeder screw using theSST , and bleed any fluid containing air bubbles. Once completed, tighten the bleeder screw. Continue to perform Steps 3 and 4 until no air comes from the vinyl hose.5.6.Tighten the bleeder screw using the SST .Tightening torqueo 5.9¾8.8 N·m61¾89 kgf·cm, 5

8、3¾77 in·lbf7.8.Fill the reserve tank to MAX with the recommended fluid. Perform the following inspections:Brake operation Fluid leakage Fluid level···(w)RX-8 Transmission (Manual & Auto)Page 3CLUTCH PEDALCLUTCH PEDAL ADJUSTMENTClutch Pedal Stroke Inspection/Adjustment1.M

9、easure the clutch pedal stroke.If there is any malfunction, loosen locknut A and adjust the pedal stroke with adjusting bolt B. Tighten locknut A after adjustment.·Standard pedal stroke130 mm 5.12 inoClutch Pedal Play Inspection/Adjustment1. Lightly depress the clutch pedal by hand until clutch

10、is felt and then measure the pedal play.(w)RX-8 Transmission (Manual & Auto)Page 4Standardo Clutch pedal play5¾15 mm 0.20¾0.59 ino Clutch pedal push rod playAt push rod setting line :0.1¾0.5 mm 0.004¾0.020 in(Reference value)At pedal pad :0.5¾2.9 mm 0.020¾0.110 in2.

11、 If it is not within the specification, loosen locknut C and turn push rod D to adjust the pedal play.3. Remeasure the pedal play and, if it is within the specification, tighten locknut C.Clutch Disengagement Point Inspection1.2.Start the engine.Without depressing the clutch pedal, move the shift le

12、ver slowly to the reverse position until gear noise is heard and hold the lever in that position.Slowly depress the clutch pedal and hold at the point where the gear noise stops (clutch disengagement point).Measure distance A (from pedal not depressed to clutch disengagement point) and verify that i

13、t is within the specification.3.4.(w)RX-8 Transmission (Manual & Auto)Page 5Clutch disengagement stroke (Reference value)o A: 111.8 mm 4.402 inClutch Switch Inspection.5.Remove the engine cover. Remove the battery cover.Disconnect the negative battery cable. Disconnect the clutch switch c

14、onnector. Verify continuity as indicated in the table.· If there is any malfunction, replace the clutch switch.(w)RX-8 Transmission (Manual & Auto)Page 6CLUTCH PEDAL REMOVAL/INSTALLATION1.2.3.Remove in the order indicated in the table. Install in the reverse order of removal.Inspect and adj

15、ust the clutch pedal.(w)RX-8 Transmission (Manual & Auto)Page 71Clutch switch connector2Clutch switch3Starter interlock switch connector4Starter interlock switch5Nut cap6Nut7Retaining ring8Joint pin9Bush10Nut11Push rod12Fork13Pedal padStarter Interlock Switch Installation NoteCAUTION:·If th

16、e rod is pushed in, it may not operate properly. Be careful not to push the rod in when installing the starter interlock switch.1.2.3.Insert a new starter interlock switch into the pedal bracket hole in direction A.While pushing the starter interlock switch in direction A, slide it in direction B un

17、til it locks securely.Move the clut switch.fully open stroke in direction C and securely fit the terminal of the starter interlock(w)RX-8 Transmission (Manual & Auto)Page 814Clutch pedal componentCLUTCH MASTER CYLINDERCLUTCH MASTER CYLINDER REMOVAL/INSTALLATIONCAUTION:Fluid will damage painted s

18、urfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.·.Remove in the order indicated in the table. Install in the reverse order of removal.Bleed the air from the system. Inspect and adjust the clutch pedal.(w)RX-8 Transmission (Manual &

19、Auto)Page 91Hose clip2Clutch pipe3Nut4Clutch master cylinder5PackingCLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY1.2.Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly.(w)RX-8 Transmission (Manual & Auto)Page 101Hose clip2Reserve tank hose3Joint4Bushing5B

20、olt6Packing7Connector8Packing9Snap ring10Piston, secondary cup component11Spacer12Primary cup13Return springSnap Ring Disassembly/Assembly Note1.While pressing the piston in with a cloth-wrapped pin punch to protect the push rod contacting surface, remove/install the snap ring.(w)RX-8 Transmission (

21、Manual & Auto)Page 1114Clutch master cylinder bodyCLUTCH RELEASE CYLINDERCLUTCH RELEASE CYLINDER REMOVAL/INSTALLATIONCAUTION:Fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If fluid does get on painted surfaces, wipe it off immediately.·.Remove in

22、 the order indicated in the table. Install in the reverse order of removal.Bleed the air from the system. Inspect and adjust the clutch pedal.(w)RX-8 Transmission (Manual & Auto)Page 121Clip2Clutch pipe, clutch hoseCLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY1.2.Disassemble in the order indicate

23、d in the table. Assemble in the reverse order of disassembly.(w)RX-8 Transmission (Manual & Auto)Page 131Boot2Push rod3Piston, piston cup component4Return spring5Bleeder cap6Bleeder screw7Clutch release cylinder body3Clutch pipe4Bolt5Clutch release cylinderCLUTCH UNITCLUTCH UNIT REMOVAL/INSTALLA

24、TION1.2.Remove in the order indicated in the table. Install in the reverse order of removal.(w)RX-8 Transmission (Manual & Auto)Page 141Clutch release cylinder2Manual Transmission3Boot4Clutch release collar5Clutch release fork6Clutch cover7Clutch discClutch Cover, Clutch Disc Removal Note1.Insta

25、ll the SSTs .2.3.In criss-cross pattern, loosen the bolts one rotation at a time until there is no remaining spring pressure. Remove the clutch cover and the clutch disc.Oil Seal, Pilot Bearing Removal NoteNOTE:· Remove the pilot bearing only if there is a malfunction.1. Remove the pilot bearin

26、g and the oil seal together using the SST .Flywheel Removal Note1. Install the SST to the flywheel.2. Remove the locknut using the SST .(w)RX-8 Transmission (Manual & Auto)Page 158Oil seal9Pilot bearing10Locknut11FlywheelNOTE:·Inspect the eccentric shaft for oil leakage after removing the f

27、lywheel. If necessary, replace the oil seal.3. Remove the flywheel using the SST .4. Remove the key from the eccentric shaft.Flywheel Installation Note1.2.Install the key to the eccentric shaft.Align the flywheel key groove with the eccentric shaft key and install.3.4.Install the SST to the flywheel

28、.Apply silicoalant to the locknut th.(w)RX-8 Transmission (Manual & Auto)Page 165.Tighten the locknut using the SST .Tightening torqueo 392¾490 N·m40.0¾49.9 kgf·m, 289¾361 ft·lbfCAUTION:· Remove the seal protruding from the ths without it becocaught in the pilo

29、t bearing.Pilot Bearing, Oil Seal Installation Note1.Install the pilot bearing using the SSTs .NOTE:Bearing outer diameter: 20 mm 0.787 inPress-in depth:··(w)RX-8 Transmission (Manual & Auto)Page 1711.5¾12.25 mm 0.453¾0.482 in2. Install a new oil seal using the SSTs .Clutch D

30、isc Installation Note1.2.3.Clean the splines of the clutch disc and the main drive gear with a brush.Spa thin layer of clutch grease on the splines.Secure the clutch disc to the flywheel using the SSTs .Clutch Cover Installation Note1.2.Align the clutch cover with the flywheel knock pin and install.

31、Tighten the bolts evenly and gradually in the order shown in the figure.Tightening torqueo 17.6¾26.5 N·m1.80¾2.70 kgf·m, 13.0¾19.5 ft·lbf(w)RX-8 Transmission (Manual & Auto)Page 18CLUTCH COVERCLUTCH COVER INSPECTION1.2.Remove the clutch cover.Measure the wear of the

32、 diaphragm spring fingers using a vernier caliper.um wear0.6 mm 0.024 inIf it exceeds theo·um specification, replace the clutch cover.3.Measure the pressure plate flatness using a straight edge and a feeler gauge.NOTE:· Measure the pressure plate flatness across the center.um flatnesso 0.5

33、 mm 0.020 in· If it exceeds theum specification, replace the clutch cover.4.Attach a dial gauge to the rear housing, rotate the flywheel, then inspect for height difference between the diaphragm spring fingers.(w)RX-8 Transmission (Manual & Auto)Page 19um height difference1.0 mm 0.039 inIf

34、it exceeds theo·um specification, replace the clutch cover.CLUTCH DISCCLUTCH DISC INSPECTION.Remove the clutch disc.Inspect the lining surface for discoloration and grease adhesion. Inspect the torsion spring for weakness and the rivet for looseness.Using a vernier caliper, measure the d

35、epth between the lining surface and the rivet head.Minimum deptho 0.3 mm 0.012 in· If it is less than the minimum specification, replace the clutch disc. Measure the clutch disc runout using a dial gauge.5.um runouto 0.7 mm 0.028 in· If it exceeds the Install the clutch disc.um specificati

36、on, replace the clutch disc.6.(w)RX-8 Transmission (Manual & Auto)Page 20CLUTCH RELEASE COLLARCLUTCH RELEASE COLLAR INSPECTIONCAUTION:Do not clean the clutch release collar with cleaning fluids or a steam cleaner because it is filled with grease.·1.2.Remove the clutch release collar.Turn th

37、e collar while applying force in the axial direction, and inspect for sticking, excessive and an abnormal noise.· If there is any malfunction, replace the clutch release collar.,3.Install the clutch release collar.PILOT BEARINGPILOT BEARING INSPECTIONNOTE:·Inspect the pilot bearing when it

38、 is installed to the eccentric shaft.1.2.Remove the clutch unit so that the pilot bearing can be inspected. Inspect the pilot bearing for damage, wear, and proper rotation.· If there is any malfunction, replace the pilot bearing. Install the clutch unit.3.(w)RX-8 Transmission (Manual & Auto

39、)Page 21FLYWHEELFLYWHEEL INSPECTION1.Remove the flywheel.NOTE:· Correct slight scratches and discoloration using sandpaper.· Inspect the runout of the surface that contacts the clutch disc with the flywheel installed to the eccentric shaft..Inspect the surface that contacts the clut

40、ch disc for scratches, Inspect the ring gear teeth for damage and wear.Install the flywheel.s, and discoloration.Measure the runout of the surface that contacts the clutch disc using a dial gauge.um runouto 0.2 mm 0.008 in· If it exceeds theum specification, replace the flywheel.(w)RX-8 Transmi

41、ssion (Manual & Auto)Page 22MANUAL TRANSMISSION Y16M-D TRANSMISSION/TRANSAXLEMANUAL TRANSMISSION LOCATION INDEXNEUTRAL SWITCH REMOVAL/INSTALLATION1.Remove the neutral switch.2.Install the neutral switch to the transmission case.Tightening torqueo 30¾39 N·m3.1¾3.9 kgf·m, 23

42、90;28 ft·lbf(w)RX-8 Transmission (Manual & Auto)Page 231Transmission oil2Oil seal (extension housing)3Neutral switch4TransmissionTRANSMISSION/TRANSAXLE OILTRANSMISSION OIL INSPECTION1.2.Position the vehicle on level ground. Remove oil filler plug.3.Verify that the oil is near the brim of th

43、e plug port.· If the oil is not near the brim of the plug port, add the specified amount and type of oil.Specified oil gradeo API Service GL-4 or GL-5Specified oil viscosityo SAE 75W-90Install oil filler plug and a new washer.4.Tightening torqueo 27¾48 N·m 2.8¾4.9 kgf·m, 20&

44、#190;35 ft·lbfTRANSMISSION OIL REPLACEMENT1.2.Position the vehicle on level ground.Remove oil filler plug and drain plug, and then drain the oil.3.4.Clean drain plug.Install drain plug and a new washer.(w)RX-8 Transmission (Manual & Auto)Page 24Tightening torqueo 27¾48 N·m 2.8

45、0;4.9 kgf·m, 20¾35 ft·lbfAdd the specified amount and type of oil through the plug port for oil filler plug to near the brim of the port.5.Specified oil gradeo API Service GL-4 or GL-5Specified oil viscosityo SAE 75W-90Capacity (approx. quty)o 1.75 L 1.85 US qt, 1.54 lmp qt Install oi

46、l filler plug and a new washer.6.Tightening torqueo 27¾48 N·m 2.8¾4.9 kgf·m, 20¾35 ft·lbf(w)RX-8 Transmission (Manual & Auto)Page 25OIL SEAL (EXTENSION HOUSING)OIL SEAL (EXTENSION HOUSING) REPLACEMENT1.2.Drain the transmission oil. Remove the following parts:a.b.c.d

47、.e.Front tunnel member Rear tunnel memberCatalytic converter, middle pipe, main silencer Heat insulatorPropeller shaft3.Remove the oil seal using a flathead screwdriver.4.Tap a new oil seal into the case using the SSTs .5.6.7.Apply the specified oil to the oil seal lip. Install in the reverse order

48、of removal.Add transmission oil.MANUAL TRANSMISSIONTRANSMISSION REMOVAL/INSTALLATION.5.6.7.Remove the engine cover. Remove the battery cover.Disconnect the negative battery cable. Drain the transmission oil.Remove in the order indicated in the table. Install in the reverse order of removal.Ad

49、d transmission oil.(w)RX-8 Transmission (Manual & Auto)Page 268.Perform the 'INSPECTION AFTER TRANSMISSION INSTALLATION', and verify that there is no malfunction.(w)RX-8 Transmission (Manual & Auto)Page 271Shift lever knob2Upper panelExhaust Manifold Stay Removal Note1. Remove the ex

50、haust manifold stay from the transmission.2. Rotate the exhaust manifold stay and place it on the transverse member.Power Plant Frame Removal Note1. Support the transmission using a transmission jack.(w)RX-8 Transmission (Manual & Auto)Page 283Shift insulator component (outer)4Shift insulator co

51、mponent (inner)5Shift lever component6Front tunnel member7Rear tunnel member8Heated oxygen sensor connector9Heated oxygen sensor connector bracket10Catalytic converter, middle pipe, main silencer11Exhaust manifold stay12Heat insulator13Starter14Clutch release cylinder15Power plant frame16Propeller s

52、haft17Back-up light switch connector18Neutral switch connector19Wire20Transmission installation bolt21Transmission22Stopper23Bolt24Dynamic damper2. Remove the power plant frame.Propeller Shaft Removal Note1.Install the SST to the main shaft.2.Insert a slab of woodthe rear differential, and remove th

53、e propeller shaft.Transmission Removal NoteWARNING:· Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged or cause injury.1. Support the transmission securely using a transmission jack.(w)RX-8 Transmission (Manual & Auto)Page 292. Remove the tr

54、ansmission installation bolt.3. Remove the transmission.Transmission Installation Note1.2.Shift to any gear position.Install the SST to the main shaft.WARNING:Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged or cause injury.·3.Place the transmi

55、ssion on the transmission jack and raise it.NOTE:·Slowly rotate the SST to engage the clutch with the main drive gear spline, and install the transmission.4.5.Install the transmission.Tighten the transmission installation bolt.(w)RX-8 Transmission (Manual & Auto)Page 30Bolt lengtho A: 55 mm

56、 2.1 ino B: 90 mm 3.5 inTightening torqueo 37¾52 N·m 3.8¾5.3 kgf·m, 28¾38 ft·lbfPower Plant Frame Installation Note1.Support the transmission using a transmission jack.2.3.Install the power plant frame.Temporarily tighten the nuts in the order shown in the figure.4.5.6.Tighten nut 1 until the power plant frame is seated in the rear differential.Install the heat insulator, exhaust manifold stay, exhaust pipe, silencer and front tunnel member.Raise the front end of the power plant frame (transmi