Bp4w & 6 speed conversion into NA 1.6 clutch problem

Sil4ver · Postby **Sil4ver** » Tue Nov 19, 2013 12:24 am

Gday all,

I have recently swapped my 1.6 to a bp4w 99 and 6 speed from a mazdaspeed.

car starts and runs fine however theres a problem...

I resued my 1.6 flywheel and 1.6 clutch as they were pretty much brand new.

However now the clutch fork from the 6 speed seems to have a bit of play as the pin from the slave cylinder seems a little too short.

Is this because the 1.6 pressure plate is thinner causing the fork to have more room to move. Or is it something else?

Would dropping the box and putting 1.8 clutch/fw reduce the play, bringing the fork back in line for the pin from the slave cylinder.

I resued the release bearing from the 5 speed into the 6 speed as the 6 was shot. Would this be also likely to cause an issue ? (the part numbers are the same?)

Any help would be appreciated.

Regards

Sam

Postby **Boyracer** » Tue Nov 19, 2013 7:28 am

You can adjust the rod at the clutch pedal.... Fitting a 1.8 clutch/flywheel won't make any difference.

Sil4ver · Postby **Sil4ver** » Tue Nov 19, 2013 5:07 pm

Cheers!

Ive done that adjusted it so now the slave pin is against the fork.

However clutch feel is weird.

When pressing down for the first half is normal slack, but then its pretty solid and engages. Only for an inch.

As if i have button clutch, which i dont.

And when clutch is engaged it really wants to push my foot back off the pedal?

You hear it clunk when i release my foot off clutch point when off

Sil4ver · Postby **Sil4ver** » Tue Nov 19, 2013 5:51 pm

The slave cylinder was replaced not long ago with a new part. However could these symptoms be master Cylinder fail?

Sil4ver · Postby **Sil4ver** » Tue Nov 19, 2013 6:35 pm

Or because I resused the 5spd release bearing. Its changed the fulcrum point of the clutch fork causing it to have more play within the 6 spd box?

Sil4ver · Postby **Sil4ver** » Fri Nov 22, 2013 8:14 pm

No one has any ideas to why this is happening?

Its not to do with clutch pedal adjustment. Ruled that out.

Now the pin from the slave is almost 'over extended' to put pressure on the clutch fork.

I have ordered new pilot and release bearing.

But I am still wondering if thats going to help as it seems the clutch fork pivot point is out by a fair amount.

Anyone have a clue? No one really on the net seems to have this problem?

geofiz · Postby **geofiz** » Sat Nov 23, 2013 10:46 am

Sam,

All the parts are interchangable, so assuming that the relase bearing and slave/master cylinders are OK, iot all comes down to adjustment.

There are two main adjustments that can be made under the dash, which are summarised very nicely in this post.

http://www.mazdas247.com/forum/showthread.php?123646510-Adjusting-the-clutch-pedal-(works-great!)

read it a few times to makes ure you follow all the hints. If you want to look at a pedal box outside of teh car before trying this, let me know, I have a spare setup with the master cylinder still attached that you can look at to visualise the setup.

Russell