Mazda 3 since 2003
1. Operation and maintenance of the car
2. Engine
3. Transmission
3.1. Coupling
3.1.1. General information
3.1.2. Check and adjustment of a pedal of coupling
3.1.2.1. Adjustment of height of provision of a pedal
3.1.2.2. Check and adjustment of a free wheeling of a pedal of coupling
3.1.2.3. Verification of the provision of switching off of coupling
3.1.2.4. Removal and installation of a pedal of coupling
3.1.2.5. Removal and installation of tubes of a hydraulic actuator of coupling
3.1.2.6. Removal and installation of the main cylinder of the drive of switching off of coupling
3.1.2.7. Removal, check and installation of coupling
3.2. Mechanical transmission
3.3. Automatic transmission
3.4. Driving mechanism
3.5. Tables
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
 








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3.1.2.7. Removal, check and installation of coupling

Removal
Remove the transmission in the block with the main transfer.
Remove a coupling switching off fork cover.
Remove a coupling switching off fork assembled.
Remove a coupling switching off bearing coupling clip.
Remove a support of a fork of switching off of coupling from the transmission.

Fig. 3.11. Removal and installation of coupling: 1 – working cylinder of the drive of switching off of coupling; 2 – gear shifting box; 3 – fork cover; 4 – release bearing; 5 – coupling switching off fork; 6 – coupling casing; 7 – the conducted clutch plate; 8 – flywheel


Turn off each bolt at one time, on one turn, before easing of effort of a spring.

Fig. 3.12. Removal of a casing of coupling


Turn off bolts and a casing of coupling (fig. 3.12).

ATTENTION
Preserve a clutch plate, surfaces of a press disk and a flywheel against hit on them of oil and foreign objects.

Using special adaptation, remove the basic bearing of a main shaft of the transmission.

NOTE
Do not remove the basic bearing of a main shaft of the transmission if you do not replace it.

Install the special device for deduction of a flywheel from a provorachivaniye.

Fig. 3.13. Removal of a flywheel of coupling


Turn off bolts of fastening of a flywheel in the sequence specified in the figure 3.13.

Check
Check a coupling casing.

Fig. 3.14. Measurement of depth of wear of petals of a diaphragm spring


Using a caliper, measure depth of wear of petals of a diaphragm spring (fig. 3.14).
Maximum permissible wear on depth And: 0,6 mm.

Fig. 3.15. Measurement of a gap between a press disk and a ruler


Using a ruler and the probe, measure a gap between a press disk and a ruler, as shown in the figure 3.15.
Maximum gap: 0,5 mm.
Install the arrow indicator on the block of cylinders.

Fig. 3.16. Measurement of a deviation of tops of petals of a diaphragm spring


Rotating a flywheel, measure a deviation of tops of petals of a diaphragm spring (fig. 3.16).
The maximum deviation from the plane: 0,6 mm.
If one of the measured values does not meet the established standard, replace a coupling casing.
Check the conducted clutch plate.

Fig. 3.17. Measurement of frictional overlays of the conducted clutch plate


By means of a caliper check thickness of frictional slips on both sides of a release disk in relation to heads of rivets (fig. 3.17).
Minimum thickness of a slip: 0,3 mm.
If thickness of slips is less than minimum, replace a disk.

Fig. 3.18. Check of an axial beating of a disk


By means of the arrow indicator check an axial beating of a disk (fig. 3.18).
Maximum axial beating: 0,7 mm.
If the axial beating exceeds the established norms, replace a disk.

Fig. 3.19. Check of the release bearing


Putting the axial pressure upon the release bearing, turn its (fig. 3.19).
If the bearing jams or there is considerable resistance to rotation, replace the bearing.

NOTE
The pressurized bearing does not demand washing or lubricant.

Putting the axial pressure upon the basic bearing of a main shaft of the transmission, turn it.
If the bearing jams or there is considerable resistance to rotation, replace the bearing.

Fig. 3.20. Check of an axial beating of a flywheel


By means of the arrow indicator check an axial beating of a flywheel (fig. 3.20).
Maximum axial beating: 0,2 mm.
If the axial beating exceeds the established norms, replace a flywheel.

Installation
Establish a flywheel on a bent shaft.
When using old bolts remove the remains of old sealant from carving openings under bolts of fastening of a flywheel in cranked to a shaft and from bolts of fastening of a flywheel. Apply sealant on bolts of fastening of a flywheel and establish them.

NOTE
If you establish a new bolt, you do not apply on it sealant.

Wrap by hand bolts of fastening of a flywheel.
Record a flywheel from a provorachivaniye by means of special adaptation.

Fig. 3.21. Order of tightening of bolts of fastening of a flywheel


Tighten fastening bolts for two or three passes to the sequences, specified in the figure 3.21.
Inhaling moment: 108–115 N · m.
Using special adaptation, install the new basic bearing of a main shaft of the transmission.

Fig. 3.22. Installation of the conducted clutch plate


Establish the conducted clutch plate and record its situation with the help of device for centering of disks (3.22).
Establish a coupling casing.
Install special adaptation.

Fig. 3.23. Order of tightening of bolts of fastening of a press disk


Evenly and gradually tighten bolts of fastening of a press disk in the sequence specified in the drawing (fig. 3.23).
Inhaling moment: 18,6–25,5 N · m.
Install a support of a fork of switching off of coupling in the transmission.
Install a clip of the coupling of the bearing of switching off of coupling on the bearing.
Apply jellied lubricant on the surfaces of contact of the coupling and a fork of switching off of coupling, a fork and a pusher and a point of support of a fork.
Apply jellied lubricant for shlitsevy connections of coupling and on vents of the leading shaft.
Install a fork of switching off of coupling with the bearing of switching off of coupling in the transmission.

NOTE
After installation move a fork for check of smoothness of movement of the release bearing forward and back.

Establish a coupling switching off fork cover.
Install the transmission.

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3.2. Mechanical transmission