Mazda run around on my clutch
 

So 3 1/2 months ago I had my clutch rebuilt at my Mazda dealership.
Complete clutch rebuild kit (+ release bearing) was ordered from Mazmart for this.
The dealership was fine with this as I've done it many times with them (ordering parts from Mazmart and they do the install).
The tranny never worked worked properly from day 1. There was grinding when trying to get it into most of the gears. Mostly second gear, but eventually 3rd, 4th and even 5th and 6th at times.
I took it back and got the "couldn't re-produce the grinding" response when they tested it.
Yesterday I couldn't get the car into any gear while it was running. I could easily get it into all the gears when turned off. When I started it in first gear there was alot of rattling/grinding noise at the tranny and I turned it off immediately.
Had it towed to the dealership.
They want to charge me for a new clutch?!.......wtf???!! They claim no warranty on parts installed that isn't their parts.
Ok, fair enough but at least acknowledge that the OEM parts (from Mazmart) you installed were never installed properly to begin with. A clutch doesn't break after 3 months under normal driving.

Anyways, I will be having it towed to a local tranny shop that was recommended by a mechanic friend. My friend has his own garage and sends all of his tranny work to this shop.
My question is; any suggestions on what to look for as a recommendation to the tranny shop?
I'm thinking new slave cylinder at the very least?
btw, 2005 6 speed MT

Sounds like the clutch isn't / wasn't being fully disengaged.

Possibilities:
- slave cylinder failure
- master cylinder failure
- clutch line wasn't bled correctly
- clutch line fluid contaminated
- pedal assembly broke
- pedal assembly was never adjusted properly

Excellent, Thank you.

Keep in mind that driving like this is going to lead to premature clutch failure for sure, as the disc is going to overheat from never being fully disengaged with speed changes. Flywheel resurfacing is going to be even more important than normal.

I'll know more tomorrow, the owner of the tranny shop will be dropping the tranny to have a look.
crossing my fingers there isn't too much damage.
I feel more comfortable having this guy doing the work.

on a side note: the head of service gave me a courtesy call after he realized I had my RX8 towed off his lot. The dealership has been nothing but professional and first class with me, standing behind me and expediting the two replacement engines under warranty.....as well as all of the other service I have had done there.
I explained that I simply do not feel comfortable with the techs doing transmission work on my RX8, I wouldn't be in this position if the work had been performed properly the first time. I will continue to bring my car there for all other service......but for this job I would prefer to have a specialist do the work.

The RX8 Aisin Transmission ... if your tranny's synchros are shot, u might as well buy another good used one than getting parts for rebuild.

Well this could be one for the books.........
It looks like part of, or all of, the old throw out bearing was not removed when the dealership installed the new clutch.
So what was done was the new throw out bearing was installed on top of what was left of the old throw out bearing.........the transmission mechanic said he has never seen anything like it. He has left it as is until the dealership can come and look at the work that was done. he is taking pictures for the record.
Now here's what is the result: it has pushed a bearing so far up the e-shaft that getting the bearing out may prove to be very difficult.
This may now result in a new e-shaft being needed, add on top of that the fact that my transmission is now cooked.
have a great day everyone.

That's impressive, though I can't say I'm shocked that a dealer tech screwed that up.



(I think you mean transmission input shaft, the e-shaft is the one that runs through the engine, the transmission input shaft is what the release bearing rides around)

I hope so........however he mentioned that the stuck bearing is in the block.
would that still point to the input shaft you think?

There are two bearings in there.

The release bearing (commonly referred to as the throwout bearing, since it should be thrown out at every clutch change) is about 3-4 inches across and sits rearward of the clutch pressure plate, riding around the transmission input shaft. It sits against the clutch fork lever that sticks through the bellhousing for the clutch slave cylinder to push against.
http://ecx.images-amazon.com/images/...500_AA300_.jpg
http://www.landroverweb.com/landrove...se-bearing.jpg

The pilot bearing is maybe an inch across and sits inside the flywheel, the transmission input shaft tip slides through the center of the pressure plate, clutch disc, and flywheel and the tip rests in the pilot bearing, which provides straight line stability to the motion of the input shaft.
http://www.specialtauto.com/delorean...ing-standa.jpg
http://image.mustangmonthly.com/f/mi...n-they-get.jpg


(not RX-8 pics, just randomly grabbed from the web)

the fault
 

So I'm not sure how clear the pics are, but you may be able to see the black part behind the throw out bearing that was left in during the clutch re-build.
the throw out bearing was installed right on top of it.

That's pretty amazing...

Is the dealer accepting responsibility?

They are doing their investigation now.
The head of service has visited the shop I took it to, he has his own pictures and the opinion of the transmission specialist.
I'll be asking for full reimbursement for any work that needs to be done.

wow ... wow ...

dealership ... *facepalm*

i honestly don't know why exedy cheesed out on the RX8 throwout bearing and made it with a nylon sleeve. never would have happened if they were all metal construction.

good luck with the reimbursement, i'm sure they will cover the labor/parts but not much beyond that i doubt.

but another thing to consider is to not try and save a buck if you are going to the dealer for work. if the dealer has the factory backing they will be much less hesitant to do any warranty repairs to find these problems.

My tranny is fixed! I'll be able to pick it up from the shop today.
So it was kind of a win, Mazda stepped up and supplied all the parts required for the repair at no cost.
Pilot bearing, transmission input shaft, pilot seal(?) and throw out bearing.
The work was performed by the Transmission specialist shop.......not Mazda.
looking forward to smooth shifting again..........