Brandon1048
Member
I'm working on my girlfriends 2003 mazda protege LX 2.0l. I'm replacing the clutch and several things that need attention. I got the clutch kit an exedy KMZ08.
The problem is that when I got the transmission on and went to install the slave cylinder, I noticed the release fork was near the end of its travel. I suspected the throwout bearing being in backwards, that wasn't the case. The clutch cover/pressure plate and pilot bearing are identical and spec exactly the same as the stock ones. It seems that the clutch disc is too thick making the diaphragm spring fingers all just about parallel to each other. I got the kit from amazon. I just installed an exedy kit (kmz03) on my mazdaspeed miata with no problems whatsoever.
With it all together, I can move the fork back and forth by hand. By the time the TOB comes in contact with the pressure plate fingers, the fork is at the end of it's travel.
The p/n listed on the boxes are MZD007US and MZC619 which both show the 2003 protege LX 2.0 as an application. So I took it apart and checked the P/N on the clutch disc and pressure plate; they were the same as listed on the box, mfr. website, and everything else I've found. The only difference I can find is clutch plate thickness, but I can't find a spec on new thickness anywhere. The FSM only lists minimum depth of rivets. The throwout bearing has the same part number a the one that came out of the car and is identical.
Has anyone ran into a problem like this? What looks like would fix it is a thicker TOB or longer clutch fork pivot stud.
The problem is that when I got the transmission on and went to install the slave cylinder, I noticed the release fork was near the end of its travel. I suspected the throwout bearing being in backwards, that wasn't the case. The clutch cover/pressure plate and pilot bearing are identical and spec exactly the same as the stock ones. It seems that the clutch disc is too thick making the diaphragm spring fingers all just about parallel to each other. I got the kit from amazon. I just installed an exedy kit (kmz03) on my mazdaspeed miata with no problems whatsoever.
With it all together, I can move the fork back and forth by hand. By the time the TOB comes in contact with the pressure plate fingers, the fork is at the end of it's travel.
The p/n listed on the boxes are MZD007US and MZC619 which both show the 2003 protege LX 2.0 as an application. So I took it apart and checked the P/N on the clutch disc and pressure plate; they were the same as listed on the box, mfr. website, and everything else I've found. The only difference I can find is clutch plate thickness, but I can't find a spec on new thickness anywhere. The FSM only lists minimum depth of rivets. The throwout bearing has the same part number a the one that came out of the car and is identical.
Has anyone ran into a problem like this? What looks like would fix it is a thicker TOB or longer clutch fork pivot stud.
