I disassembled my clutch master cyl and cleaned the casting a few weeks ago. Tonight when i went to install the new spring/piston etc I noticed the new washer that sits underneath the snap ring is too big. I have all the old internals except for this washer. Can someone post a picture of a typical washer installed so I can make a new one?

Large washer from the rebuild kit:


Thanks

 

If you mean that it is to thick and the snap ring won't fit just push the plunger in enough with a screwdriver and install the snap ring . Check the FSM for your car and see what it has .. Lots of times the kit is for more than one application ..Go here and look Foxed.ca - Mazda RX-7 Manuals The FSM for your car shows the washer so just push the plunger in until the clip fits . Gerald m.

 

Gerald, thanks for the comments. If i just install the snap ring, there is nothing to retain the piston in the bore. The ring does not overlap the face of the piston. I guess I need to make a thinner washer that also has a smaller od than the one shown.

 

Maybe take a few pic and post them so we can see better what is going on .Something doesn't seem right .With the thicker washer It might just be a way to put a little extra pressure on the spring to make the piston return proper . Is there a lip between the bore and where the washer goes to keep the washer from going into the bore ??

 

The washer that comes in rebuild kits won't fit right. Too thick, as you discovered. I don't use them. Just the snap ring is all it takes to hold the piston in.

 

Hmm i must have a different style snap ring because it doesnt overlap the piston. This section view is bad bc the ring isnt modeled correctly but i just turned a little step washer to retain the piston.


thanks for the insight guys.

 

My experience as well. It's dumb, but it has been effective for almost a year for me so I'm fine leaving it alone.