Genuine Mazda RX-7 Clutch Master Cylinder

Mazda RX-7 Clutch Master Cylinder Parts and Q&A

• Master Cylinder
  FA66-41-400A
  Q: How to service the clutch master cylinder on Mazda RX-7?

  A:

  Located to the left of the firewall, next to the servo of the brakes, the clutch master cylinder should be serviced in presence of leaks, influx of air into the hydraulic system, or in case of using the wrong fluid. It is either replaceable with a remanufactured unit in the auto supply stores or the Mazda dealers, or it can be serviced and used again. Guard fender areas and cowling of the car, the hydraulic fluid may damage the painted areas and drape these areas with rags or newspaper beneath the master cylinder to absorb the fluid that could leak out on the car when the connection is being disconnected. Perform this procedure by disconnecting the fluid pipe with the master cylinder where a suitable plug is used to avoid leakage and dirt entering. Within the car, unscrew the two nuts that hold the master cylinder to the firewall, these are found near the top of the clutch pedal. In the engine compartment, take all the care to withdraw the master cylinder without spilling excess fluid on painted areas. Prior to re-installation, hydraulic fluids must be used to prime the cylinder, filling it with fresh fluid and running the piston to the point that the fluid is ejected out of the outlet. You should use silicone sealer on the master cylinder flange to ensure that the cylinder is sealed airtight, and the plunger that comes along the clutch pedal should be centered in the cylinder and placed against the firewall. Install the two nuts in the vehicle to make them loose so as to engage the threads of the fluid pipes with ease. Attach the fluid line into the cylinder making sure the connection is not cross threaded and screws easily then screw completely the two attaching nuts on the inside and ensure that the fluid line is screwed in place. Lastly, bleed the hydraulic clutch system.
• Master Cylinder
  FD01-41-990B
  Q: What steps should be taken when disassembling and reassembling the Clutch Master Cylinder on Mazda RX-7?

  A:

  Regardless of whether the master cylinder is to be disassembled, certain components must be replaced, and overhaul kits of the parts required are easily obtained in the auto parts stores and even at the Mazda dealers which must be acquired before disassembly commences. Once all of the fluid is emptied out of the cylinder at the reservoir, the connector bolt holding the reservoir to the cylinder must be taken off after which the reservoir, bolt and associated items must be removed. It is possible to loosen the piston stop ring with the help of a small screwdriver or needle-nose pliers at the back of the cylinder and disassemble the washer. The entire piston and secondary cup system will then drop out of the rear of the cylinder and then the primary piston cup, spacer and the spring back will be pulled out. Washing should be done with clean alcohol or brake fluid, not gasoline or any product of petroleum and blown off with compressed air, where possible. Bearing and piston of the cylinder must be inspected in reference to wear, roughness or scoring, and in case of any of these the parts are to be replaced. The compensating port on the cylinder is to be inspected, a small piece of wire being inserted to test it open, and the clearance between the cylinder bore and piston measurements checked with a feeler gauge, the limit of which is 0.006 in (0.15 mm); the excess of which will cause the piston or the cylinder to contact the cylinder wall, and this effect is also noticeable on the compressor casting. Lastly, the master cylinder ought to be assembled again by using the new pieces of the overhaul kit, and the piston and cups dipped in clean brake fluid are to be used in the process.