Download Mazda RX7 Mk3 1994 Service Repair Manual –

Posted on March 1, 2025 by Repair Manual

Repairing the gearbox output flange on a Mazda RX-7 Mk3 (also known as the RX-7 FC) can be a detailed process that involves several steps. click here for more details on the download manual…..

The output flange is a critical component that connects the gearbox to the driveshaft, and any issues with it can lead to vibrations, leaks, or even complete failure of the driveline. Below are detailed steps and components necessary for repairing or replacing the output flange.

### Tools and Materials Required:

#### Tools:
1. **Jack and Jack Stands** – To safely lift and support the vehicle.
2. **Socket Set** – Including various sizes; commonly 10mm, 12mm, and 14mm sockets for the bolts.
3. **Torque Wrench** – For ensuring bolts are tightened to manufacturer specifications.
4. **Pry Bar** – For prying off the flange if it’s stuck.
5. **Hammer** – To tap the flange if necessary.
6. **Seal Puller** – To remove the old seal without damaging the housing.
7. **Wrenches** – Various sizes to accommodate different bolts.
8. **Drill and Drill Bits** – For any necessary modifications or repairs.
9. **Rags and Brake Cleaner** – For cleaning surfaces.
10. **Grease or Lubricant** – To lubricate components during reassembly.

#### Materials:
1. **Replacement Output Flange** – Ensure it’s compatible with the RX-7 Mk3.
2. **New Seals** – Transmission output seal and any other gaskets that might need replacement.
3. **Thread Locker** – Optional, for added security on bolt threads.
4. **Oil or Fluid** – To top up the transmission if any fluid is lost during the process.

### Steps for Repairing the Gearbox Output Flange:

#### 1. Preparation:
– **Disconnect the Battery**: Always disconnect the negative terminal to prevent electrical shorts.
– **Lift the Vehicle**: Use a jack to lift the rear of the car, and secure it with jack stands.

#### 2. Remove the Driveshaft:
– **Locate the Driveshaft**: The driveshaft connects the output flange to the rear differential.
– **Unbolt the Driveshaft**: Using the socket set, remove the bolts that hold the driveshaft to the output flange. Keep track of the bolts and their orientation.
– **Slide the Driveshaft Off**: Carefully slide the driveshaft off the output flange. You may need to gently tap it with a hammer if it’s stuck.

#### 3. Remove the Output Flange:
– **Inspect for Retaining Bolts**: Check if there are any bolts retaining the output flange. Remove them using the socket set.
– **Remove the Flange**: If the flange is stuck, use a pry bar carefully to pop it off. Avoid damaging the gearbox housing.
– **Inspect the Seal**: Once the flange is removed, inspect the output seal for damage. If the seal is worn or leaking, it will need to be replaced.

#### 4. Replace the Seal:
– **Remove the Old Seal**: Use a seal puller to carefully remove the old output seal from the gearbox.
– **Clean the Area**: Clean the sealing surface thoroughly with brake cleaner and a rag to ensure a good seal for the new one.
– **Install the New Seal**: Lubricate the outer edge of the new seal with a bit of transmission fluid and carefully tap it into the housing until it is flush.

#### 5. Install the New Output Flange:
– **Prepare the Flange**: If applicable, apply a bit of thread locker to the bolts.
– **Position the Flange**: Align the new output flange with the splines in the gearbox download Mazda RX7 Mk3 workshop manual and gently push it onto the shaft.
– **Secure the Flange**: Tighten all retaining bolts to the manufacturer’s recommended torque specification using a torque wrench.

#### 6. Reattach the Driveshaft:
– **Align the Driveshaft**: line up the driveshaft with the output flange. If it has a specific orientation (like a specific angle), make sure to match it.
– **Bolt the Driveshaft**: Reinstall the bolts securing the driveshaft to the output flange and tighten them to the specified torque.

#### 7. Lower the Vehicle:
– **Check Everything**: Before lowering the car, double-check all bolts and connections to ensure nothing is loose.
– **Remove Jack Stands**: Carefully lower the vehicle back to the ground.

#### 8. Reconnect the Battery:
– **Reconnect the Battery**: Reattach the negative battery terminal.

#### 9. Test the Repair:
– **Take the Car for a Drive**: Start the vehicle and drive it around the block, listening for any unusual noises and checking for leaks under the vehicle.

### Conclusion:
Repairing the gearbox output flange on a Mazda RX-7 Mk3 requires attention to detail and the right tools. By following these steps and ensuring that all components are properly installed and torqued, you can effectively repair the output flange, ensuring the reliability and performance of your RX-7. Always refer to the vehicle’s service manual for specific torque specifications and additional guidance tailored to your specific model.
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