(1) In 1996, the #2 rotor oil cooling jet came loose from the e-shaft. This resulted in low oil pressure and clanking as the jet tumbled around.

(2) In 1997, the mechanism to open the glove box came loose. Had to cut the metal lock hoop to remove the door. Then I cut open the inner panel of the door to JB Weld and reattach the fallen out screws.
Had to weld the loop back together, and JB Weld the door inner panel back together.

(3) reference#1, 1999, Replaced stock engine #2 because it had an oil consumption problem since day 1.
It was built by a soon after defunct shop and would only get 500-600 miles per quart of oil.

Built modified engine #3 myself this time. Used many new parts or used newer parts. It is still running today perfectly.
But initially it would move the PS and AC belt 1 rib forward on the PS pulley and this would cut off that rib from the belt.
I added a spacer to move the PS pulley forward by 1 rib to fix the problem.
This engine has newer side housings and 1996 rotor housing but used the large original PS and AC compressor bracket.
It has worked perfectly until 2024.

(4) January 2024, just finished installing the JP3 RX8 AC compressor conversion kit. Once again it chewed up the PS/AC belt on the PS pulley.
Using a DAYCO belt alignment tool kit and a straight edge, I discovered that the PS pulley to be out of plane with the main pulley.
Had to use washers to align the PS pump pulley to the engine main pulley. The RX8 compressor pulley aligned perfectly with the main pulley.

(CONCLUSION) Maybe Mazda had a casting problem back in the early days of the FD RX-7 or the bracket warped with age.

 

using the stock FD compressor or the RX8?

 

Stock AC compressor until January 2024 when I completed the JP3 RX-8 conversion.