My 91 NA blew a clutch line (the rubber one going to the slave), couldn't fine one anywhere without ordering from Mazda. Went to a hose place, they made me a nice one, new fittings & all. It is twice the diameter of the old hose.
Problem, I have put in new master & slave, will not pump up. I have bled, put in old master & slave, same thing, pedal stays to the floor. Now, the clutch fork (part that engages the slave) doesn't seem to push back hard enough. I can grab and pull it, pedal will go up. I remove the slave, can't push it (the clutch fork) forward, so it's got pressure, big time. I reinstalled the slave, push pedal to the floor (it stays). I loosened the slave bolts, the slave snaps back due to the fork pressure.
Bottom line: The fork pushes the slave back slightly, but not far enough. It the clutch itself the problem. or is the bigger rubber line somehow causing this?
Thanks for the help!

 

You answered your own question
If the clutch line is twice as big, it's too large. If you're still using the stock slave use a diamter hose.

 

Really??Dammitt!!

Anyone 2nd or 3rd the theory??

 

boosted1205 is right.

You increased the size of the hose, which lowered the amount of pressure coming out of it.

Visualize this.

You have your standard green water hose. There is a good amount of pressure coming out of it. What happens if you replace the water hose w/ say...a fireman's water hose? Basically, there will not be enough pressure coming out of the fireman's hose.

Same thing is happening here. The hose is screwing up the amount of fluid that is displaced in your hydraulic system.

Change the hose.

 

Thanks for the tries, guys, but I just replaced the entire unit, hose and all, with a known good one. Same thing. Got to have something to do with the clutch itself.

 

are you bleeding the clutch corectly?

 

God, Have I! Been doing it all day. The last thing I did was install a complete sealed unit (slave, master, & lines) that came right off a working car, no bleeding required. Same crap.
I would have someone pump the pedal a few times with the bleeder closed, then open up (pedal to floor) with small hose from bleeder to cup with small amount of fluid. Close bleeder, have helper pull up pedal. Repeat until no bubbles. Did it literally dozens of times with 3 different slaves and masters, all known good.
Damnest thing I've ever run into.

ATTENTION KEVIN LANDERS..COME GET THIS THING!!

 

Did you properly bench bleed the master cylinder (prior to installation)?

 

Bench-bleed the master..can't say that I did. How's it done, I'll try anything.

 

The one I gave him didnt need bench bleeding. IT was a master, slave and line set off a working 91 with fluid still in it; it worked on that car, and provided he didnt flip it upside down before installation, should have worked on this car.

The only thing I can figure out is a bad throwout bearing that ate into the pressureplate, or a bad pressureplate itself, both are almost unheard of.

FOr clarification, what he is saying is that the slave will push the clutch fork down, but the fork wont push the slave back in...this indicates, to me, an internal problem with teh pressureplate, rather than a hydraulic problem, but Ill look in person soon.

 

What a really odd problem.

 

AHAHAHHHAAAAAAAAAAA!!

LMFAO!

Mike, your boy made a fool out of us all.

I think I found the problem

 

dammmnn, did the whole disk just get eaten up"?


LOL, IS THAT MY ENGINE IN THE BACKGROUND?
nice to see its still apart i can tell from the ACT yellow pressure plate.

 

Sorry guys, but this is my first glimpse in a (I think) clutch st-of-guts.
Please elaborate as to what exactly I'm looking at (and going to have to PAY for!)??

 

the friction surface completely came off the disk, new stock disks are about 80 bux. your lookin at a clutch job basically

 

Well, it's my son's car, he's 16 and thinks every day is a 'fast & furious' day..
I hate when stuff like this happens, 'cause the wife is giving me grief for selling his 'reliable' honda and buying him the 'P.O.S. Rx-7!
Anyone relate?

 

New clutch installed and all is good once again in the land of burned tires and shredded asphalt known as seymour tn

 

Another rotary resurrected by Kevin Landers!

Thanks, Kevin!