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Discussion Starter #61
Another year nct passed first time. Had to get 2 brake calipers greased and new wipers and that was it.

In it's fugly nct spec....

20181222_113810 by davemx-5, on Flickr

20181222_113825 by davemx-5, on Flickr

The clutch has let go in the car. Does any of the other mx-5 owners have any experience of the ebay XTD clutches? They look like extremely good back for buck. This one: https://www.ebay.co.uk/itm/XTD-STAGE-3-PADDLE-CLUTCH-KIT-90-93-MIATA-1-6L-MX5-MX-5-FREE-SHIP/113407734369?hash=item1a67a0b261:g:10cAAOxyjLNSO1dx:rk:3:pf:0

Some mx-5 owners I've seen rate them very highly.
 

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Discussion Starter #62
Well with the good weather now here can't look at the car sitting in the garage anymore. I'm pretty skint with getting married in 3 months, so decided what better time to learn how to change a clutch than now. I have most of the tools anyway such as torque wrench, and clutch/brake bleeder etc anyway.

Started with removing the console and taking out the seal on top of the gearbox. I've a new one there to replace it anyway. Couldn't believe the state of it, wasn't even attached anymore.

20190421_212725 by davemx-5, on Flickr

20190421_212736 by davemx-5, on Flickr

I had a crack in the manifold which needed to be welded up so it needed to come out anyway. I've dropped it up to the local engineering place to weld up.

20190421_212743 by davemx-5, on Flickr

Started to unbolt the ppf, the bolts on the diff are pretty much seized. My impact gun took one off and going to buy a long breaker bar tomorrow. So will hopefully have the ppf off tomorrow evening.



I started to remove the propshaft and again bolts were pretty much seized, if it wasn't for the impact gun I wouldn't have got them off.

20190421_235823 by davemx-5, on Flickr

20190421_235829 by davemx-5, on Flickr

20190421_235731 by davemx-5, on Flickr

That's where I left it for the night. Just waiting to pick up the rear main seal and gearbox oil, and clutch/brake fluid. I just need to unbolt the starter, speedo sensor, and reverse switch and then the gearbox will come out.
 

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Discussion Starter #63
Cheers folks! Thanks for taking the time to comment!

Right I tried to remove the heat shield near the gearbox and snapped one bolt. I can drill it out and retap it later and its in an easy enough spot.

I then started removing the clutch lines, clutch slave cylinder, electric lines, speedo sensor, neutral switch etc.

Quite a few of the bolts were an absolute bugger to get to. Had to scratch the head a few times trying to figure out access to get the clutch lines bolt off. in the end most of it was accessible underneath the car.

Anyway about 1 in the morning had the gearbox out.

Had one minor hiccup, the line for the speedo sensor snapped. I couldnt see it wrapped up on top of the gearbox. But for the first time replacing a clutch and removing a gearbox I'm pretty happy with that.

You can see the rear crank seal was leaking quite badly.

20190426_003203 by davemx-5, on Flickr

20190426_003224 by davemx-5, on Flickr

20190426_003141 by davemx-5, on Flickr

20190426_003238 by davemx-5, on Flickr

2019-04-26_12-47-58 by davemx-5, on Flickr
 

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Discussion Starter #64
So as I said earlier, I got the manifold back from the engineer. They did a great job sealing up the seams, and getting rid of the bird :D:D:D:D.

20190426_200242 by davemx-5, on Flickr

20190426_200248 by davemx-5, on Flickr

20190426_200251 by davemx-5, on Flickr

20190426_200253 by davemx-5, on Flickr

20190426_200256 by davemx-5, on Flickr

20190426_200258 by davemx-5, on Flickr

So here was the starting point last night.
20190426_204108 by davemx-5, on Flickr

I got the clutch and pressure plate off.
20190426_204826 by davemx-5, on Flickr

I had a look at the clutch and it didn't look anywhere near worn, but one of the springs had broken and came out. If you look at the top spring, you will see a bit of metal above it broken off. Not sure how that would have happened. This car really doesn't see any abuse or card driving.

20190426_205642 by davemx-5, on Flickr

20190426_205637 by davemx-5, on Flickr

When I took the clutch and pressure plate out, the pilot bearing came straight out with it. So it must have been in pretty bad shape as it wasn't even in the flywheel anymore.

20190426_205657 by davemx-5, on Flickr

Flywheel off, definitely think I had a leaky rear main seal.
20190426_210722 by davemx-5, on Flickr

Cleaned up all the fresh oil and grease, and installed the new rear main seal.

20190426_215908 by davemx-5, on Flickr

I put on a new shifter bushing, new 75w90 gl4 oil in the turret and a new lower shifter seal while the gearbox was out.

20190426_220032 by davemx-5, on Flickr

New throwout bearing in place and all greased up with high temp grease.

20190426_220042 by davemx-5, on Flickr

Got the speedo sensor wiring fixed and ready to go back in.

20190426_222144 by davemx-5, on Flickr

Gave the flywheel a rub down with brake cleaner. I checked for any imperfections, dimples etc and the flywheel looks perfect so I didn't see the need to get it resurfaced. New pilot bearing installed also. Torqued up all of the bolts.
 

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Discussion Starter #65
20190426_225646 by davemx-5, on Flickr

So this is the new clutch and pressure plate.

20190426_232117 by davemx-5, on Flickr

Clutch aligned, pressure plate installed and all torqued up.

20190426_234936 by davemx-5, on Flickr

The next part was an absolute nightmare. I found the gearbox very hard to align. At 3 in the morning, I got the top two bolts in and the gearbox started to come together with the engine.

I left the gearbox jacked and held with a few bolts. Hopefully I'll have a bit of time next week and get it finished. On the home straight now. Can't wait to see what the exhaust manifold sounds like now. I thought the car was always a bit tappety but I think it's actually exhaust leak from the cracks in the manifold.
 

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Discussion Starter #66
Thanks for all the tips and advice.

Bit of a lack of pictures now as I just wanted the car finished and to start driving it again.

Put new gearbox oil in with 75w90 GL-4.

20190505_192055 by davemx-5, on Flickr

First time I used one of the oil syringes for the first time and it's such a messy job, gearbox oil goes everywhere.

20190505_192059 by davemx-5, on Flickr

I then got the exhaust in, I used a bit of silicone instant gasket to try seal it as I noticed it was leaking before the cat and the back box.

20190505_200952 by davemx-5, on Flickr

20190505_200957 by davemx-5, on Flickr

Got the ppf and gearbox aligned and torqued up.

Then replaced the upper gearbox shifter seal.

2019-05-06_09-16-16 by davemx-5, on Flickr

Also bled the clutch at this point.

Then did a nut and bolt check and finished off installing the centre console and shifter.

Took the car off the stands and started it up. It works! The clutch works perfect. Little bit of a smell off it as the car heated up. Took it out for a drive and it drives amazing. The shifter is so much smoother than before and no gearbox lash from the ppf.

I was under the impression that the clutch was supposed to be very harsh. I have an exedy clutch in my Altezza and it is much much harsher. The XTD is very easy and feels almost like a standard car. Delighted with it.
 

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Discussion Starter #67
Got in the car today for a drive and the wipers are only working now on the fastest setting. Anyone got any ideas?
 

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Discussion Starter #68
I dropped the car off on monday to get the wiring problems fixed with an auto electrician.

The central locking and wipers are now fixed.

However the high warm idle is not. The rear coolant temp sensor was replaced by a blueprint brand. It is still idling at 1500rpm when warm. It idles about 800rpm when cold.

When resistance is added to the coolant temp sensor the warm idle drops to about 800rpm. So the ecu is fine but the coolant temp sensor is not sending the ecu the correct reading.

Anyone got any suggestions? All earths etc seem fine. The idle control valve etc seems fine as the low idle adjusts with resistance.

Really confused.
 

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I was having a similar issue with strange idle and throttle issues and I did all the same things, checking sensors and wiring and it ended up being the ECU. It wouldn't hurt to crack it open and take a look at the board just to cross that off the list.

You can see some or the traces we're corroded. I put a new ECU in the car and it instantly fixed the problem.

Sent from my Pixel 3 XL using Tapatalk
 

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Discussion Starter #70
I was having a similar issue with strange idle and throttle issues and I did all the same things, checking sensors and wiring and it ended up being the ECU. It wouldn't hurt to crack it open and take a look at the board just to cross that off the list.

You can see some or the traces we're corroded. I put a new ECU in the car and it instantly fixed the problem.

Sent from my Pixel 3 XL using Tapatalk
That kind of makes sense that this problem is the same. I have kept the car in doors and barely used so I'd hope its not the problem but would make sense if it was.

The auto electrician is leaning to thinking the temp sensor is faulty so I've bought a new genuine from Mazda. It will be here next week hopefully.
 

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Discussion Starter #71
The genuine mazda sensor is in and the problem is still the same. The next thing to try is the ecu. The autoelectrician says he cant see a problem with my own but ive bought a second hand one to double check it.
 

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Discussion Starter #73
Cheers its a right pain in the ass!ha I'm getting married in 2 weeks and was hoping to use it as our wedding car but not looking likely now.

The new ecu should be here tomorrow so fingers crossed it fixes the issue.
 

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Discussion Starter #74
I replaced the ecu and it brought the warm idle to 1500rpm. Still not sorted but it's a lot better now thankfully.

I picked up some Zoom mx5 cup holders on yahoo auctions.

20191002_192601 by davemx-5, on Flickr

Also got a bluetooth stereo, it's pretty much the same as my old one except with bluetooth.

The old wiring never saved the stations and was always annoying, but I never investigated it. When I pulled the stereo out, I switched the power cables and that was problem solved with the new one going in. This is the new one, looks the exact same.

20191002_204318 by davemx-5, on Flickr

So i've picked up some new wheels, the central locking stopped working again, but hope to get that sorted again when I get more time. Wired my old stereo into my fathers mx5, the wiring in it was a complete mess.

20191003_195613 by davemx-5, on Flickr

20191004_191959 by davemx-5, on Flickr

20191004_194227 by davemx-5, on Flickr
 

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Discussion Starter #76
On that syringe...were you saying it made the fluid swap less messy or that it was still a very messy job?
Ah it was running out of the top as well, when you put pressure on it to put oil into the gearbox. Just make sure and wear gloves and dirty clothes because it will go all over your hands and arms.

I'll just leave this here...new wheels arrived today. 15x9 et0. Going to be interesting to fit.

20191015_194443 by davemx-5, on Flickr
 

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Ah it was running out of the top as well, when you put pressure on it to put oil into the gearbox. Just make sure and wear gloves and dirty clothes because it will go all over your hands and arms.
No smell quite like tranny and diff fluid smell.


Hadn't thought about accidentally blowing fluid out of the turret. Wouldn't that normally mean you're overfilling slightly?
 

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Discussion Starter #78
Ah it was running out of the top as well, when you put pressure on it to put oil into the gearbox. Just make sure and wear gloves and dirty clothes because it will go all over your hands and arms.
No smell quite like tranny and diff fluid smell.


Hadn't thought about accidentally blowing fluid out of the turret. Wouldn't that normally mean you're overfilling slightly?
Ah no I meant out the top of the syringe. As your pushing the handle up to push the fluid in. A bit of fluid comes out around the handle each time you push more in.
 

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Discussion Starter #80
BLACK IS BEAUTIFUL FOR SURE!!! I respect it, just don't want to keep it clean!!! Beautiful car!!!
Cheers! Yeah I know, black can get full of swirl marks so easy.

I was always one for driving a car not worrying so much about the paint. But I did a 3 stage polish and fusso wax on this. I bought prewash, snow foam and shampoo and wax, and since I've done that I've zero problems at all. I also have a black Saab 9-3, and a black ford transit custom for work. They're a pain to keep. But look so well when they're clean.
 
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