Download MAZDA RX-8 Service & Repair Manual (2003 2004 2005 2006) – ! –

Posted on February 2, 2025 by Repair Manual

Replacing the clutch release bearing on a Mazda RX-8 involves several steps and requires specific tools. click here for more details on the download manual…..

Below is a detailed guide to help you through the process:

### Tools and Equipment Needed:

– **Jack and Jack Stands**: To lift the vehicle safely.
– **Socket Set**: Including various sizes to remove bolts, typically metric sizes.
– **Wrench Set**: For additional leverage on stubborn bolts.
– **Torque Wrench**: To ensure bolts are tightened to the manufacturer’s specifications.
– **Screwdrivers**: Flathead and Phillips for various fasteners.
– **Pliers**: For removing clips or securing components.
– **Clutch Alignment Tool**: To help align the clutch disc during reassembly.
– **Pry Bar**: For removing stuck parts.
– **Hammer**: For tapping parts into place if necessary.
– **Grease**: High-temperature grease for lubricating the bearing.
– **Shop Manual**: For specific torque specs and detailed diagrams of the assembly.

### Replacement Procedure:

– **Preparation**:
– Park the vehicle on a level surface and engage the parking brake.
– Disconnect the battery to prevent any electrical issues during the process.

– **Lifting the Vehicle**:
– Use the jack to lift the front of the RX-8 and support it securely with jack stands.

– **Remove the Transmission**:
– Begin by removing the driveshaft by unbolting it from the differential and sliding it out of the transmission.
– Disconnect any electrical connectors and fluid lines attached to the transmission.
– Remove the transmission mounting bolts.
– Support the transmission with a transmission jack and carefully lower it to remove it from the engine.

– **Access the clutch Assembly**:
– Once the transmission is removed, you will have access to the clutch assembly mounted to the flywheel.
– Remove the pressure plate bolts in a crisscross pattern to avoid warping the plate.
– Carefully remove the pressure plate and clutch disc from the flywheel.

– **Removing the old Release Bearing**:
– The release bearing is typically located on the input shaft of the transmission.
– If the bearing is held in by clips or pins, use pliers to remove them.
– Slide the old release bearing off the input shaft.

– **Install the New Release Bearing**:
– Before installing the new bearing, apply a small amount of high-temperature grease to the contact points of the bearing.
– Slide the new release bearing onto the input shaft, ensuring it is seated correctly.
– Reattach any clips or pins that hold the bearing in place.

– **Reassemble the clutch Assembly**:
– Place the new or existing clutch disc onto the flywheel, ensuring it is oriented correctly.
– Use a clutch alignment tool to center the disc for proper installation.
– Position the pressure plate over the clutch disc and hand-tighten the bolts before using a torque wrench to tighten them to the manufacturer’s specifications.

– **Reinstall the Transmission**:
– Carefully lift the transmission back into place using the transmission jack.
– Align the input shaft with the pilot bearing in the flywheel while sliding the transmission into position.
– Reinstall the transmission mounting bolts download MAZDA RX 8 workshop manual and reconnect any electrical connectors or fluid lines that were disconnected.

– **Reattach the Driveshaft**:
– Reinstall the driveshaft to the transmission and differential, ensuring it is secured properly.

– **Final Steps**:
– Reconnect the battery and check all connections to ensure everything is secure.
– Lower the vehicle from the jack stands using the jack.
– Test the clutch operation by pressing the pedal before starting the vehicle.
– Start the engine and test drive the vehicle to ensure proper function of the clutch engagement and release.

### Safety Precautions:

– always ensure the vehicle is securely lifted and supported before working underneath it.
– Wear safety glasses and gloves to protect yourself from debris and sharp edges.
– Dispose of the old release bearing and any other waste materials properly.

By following these detailed steps, you should be able to successfully replace the clutch release bearing on your Mazda RX-8. If you’re unsure about any step, consult a professional mechanic or refer to the vehicle’s service manual for further guidance.
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