M/T - Clutch Hard to Disengage

TSB: 05-004/06

2004-2006 RX-8

MANUAL TRANSMISSION - CLUTCH HARD TO DISENGAGE

APPLICABLE MODEL(S)/VINS

2004-2006 RX-8 vehicles with VINs lower than JM1 FE**** ** 206481 (produced before May 1, 2006)

DESCRIPTION

Some vehicles may experience that the free play on the clutch pedal increases and the clutch is hard to disengage.

At hot ambient temperatures or approx. 85 F (30 C), ethanol used during installation of the clutch release cylinder boot becomes vaporized and expands. As the pressure in the boots increases, the piston is pushed back into the release cylinder body. As a result, a gap appears between the piston and the push rod, resulting in excessive free play and the clutch hard to disengage.

As a mass production change, ethanol is no longer used during clutch release cylinder assembly.
Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the clutch release cylinder. Refer to Workshop Manual section 05-10 - CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.

3. Disassemble the clutch release cylinder. Refer to Workshop Manual section 05-10 - CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY.

4. Using brake fluid, wash the rod, inside of the boot and piston rubber.

NOTE:
Use care when washing rubber parts. Do not allow brake cleaner or any volatile grease to remain inside of the boot when assembling or condition may re-occur.

5. Reassemble and install the clutch release cylinder.

6. Bleed the clutch release cylinder. Refer to Workshop Manual section 05-10 - CLUTCH FLUID REPLACEMENT.

7. Verify repair.





WARRANTY INFORMATION

NOTE:

^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.

^ Additional diagnostic time cannot be claimed for this repair.





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