Same basic scenario happened to me with MNAO when the original factory engine failed. The actual decision making party was the regional factory rep however. Once the regional rep made their decision to leave me hanging out on a limb without a safety net, MNAO suddenly could only pronounce the word NO. I took almost 2 years, but via the extended warranty I eventually got my money back from Mazda.

I would say the eyelashes hanging off that clutch are not a good sign. That may be signs of abuse by the previous owner. Fact is though the springs again are not a wear item. The clutch surface is. I don't understand why any amount of abuse should break the springs? If the clutch mating surface is worn out fine, you own buying a new one, but the springs?? Anyone else know of a reason why the springs would be considered a wear item that should go over time?

Doesnt matter, really. The Stealership Cop-out is "Well, CLEARLY you ABUSED it for it to break like that!!"

Assholes... :(

:-/

Well, they are not calling it wear anymore. They are saying I "abused" it by "dumping the clutch" at "over 6000 RPM" and that subjects the springs to "1200lbs of force" (whereas normal clutch release only puts "100lbs" on them), and they snapped.

Of course, it's my fault that gently letting off the clutch while pulling away from the toll booth in heavy traffic can snap the springs. Springs are made to compress and expand... If they were excessively compressed by excessive force, it would be the mounting points that would have gotten deformed. A spring snapping sounds like metal fatigue or part defect to me...

The shavings ("eyelashes") were apparently generated when the center of the clutch disc became misaligned and machined off the friction material.

I dunno. I don't buy it though. If I'm a clutch engineer sitting in front of my computer in Japan figuring out how to size and pick materials for my spring I'm going to size them using LCF cycles for 100Kmiles and X clutch uses per mile (or whatever they actually use) and clutch drops at 9000rpm at a standstill as a worst case scenario. Understandably you'll need a spring that's soft enough so the clutch pedal pressure is reasonable but really hydraulics can help there. I don't buy it that a 9000RPM clutch dump should exceed the design limits at 50K miles. Anyone from the 7 board see similar things happen? Maybe it's a rotarygod question on what we should expect from clutch springs. :dunno:

Similar situation but did not experience a casualty.

Was going 45mph in 3rd gear. Then let off gas to around 35 mph and decreasing going up a hill, so I performed a double clutch downshift into 2nd gear. Heard a repeating squeak noise akin to squeaky brakes. Came from underneath the footwell, either dead center or left of center.

Felt something was wrong and let off the gas. Was almost back home so I just pulled in and called it a day.

On the way to work that morning, the shifting was rougher than ordinary--I'd say it was being difficult to work with and sort of picky and reluctant in the 1st and 2nd gears.

Since then I've been taking it real easy and hoping the mechanicals settle down and that I won't hear the squeak again. I'm worried that this is an early indication of a 2nd gear casualty or premature clutch wear.

There's a forum member - ACTman or something? He's the president of ACT Clutches. He commented on my clutch exploding. MAYBE he'd be willing to comment on your clutch situation? May be 'ammo'?

Keep in mind - according to LAW, they must PROVE you abused it. Showing a failure is NOT proof of abuse. Ask him if he thinks you REALLY launched at 6,000 rpms +. Your car was towed from 'a' documented location. Do people 'launch' from toll booths? Print out my thread and show him. Show him it was covered - that Mazda service line has RECORDS of repairing similar failures. Maybe question his credibility? He said "The service tech removed the inspection plate (there isn't one, right?) and saw the 'disc was bad'. If the can be WRONG about the disc being bad - when it wasn't, he can be wrong about what is 'abuse' and what is 'part failure'.

At this point, trying to communicate with MNAO is like talking to a brick wall. I am ordeing an ACT clutch and flywheel and I'm gonna pay the dealer to put it in. Then I'm gonna sue their ass to get my money back.

Anyone have any rx7store coupons?

updates?

The parts have been shipped. Should arrive in the next couple of days... I can't wait to get my baby back... (with a lightweight flywheel! :rock: )

Am looking around for a lawyer / looking for other peoples' experience in similar situations... I'll keep you posted so that anyone going through a similar ordeal can hopefully benefit from my experience.

Well, I got my car back today!! Finally.... The Prolite feels great. Makes a huge difference in first and second gear, and I can still feel the effect in third. Taking some getting used to though, especially in traffic. But, it is perfectly streetable.

No updates on the legal end of things yet.

I had the same thing happen........ told me its the clutch....... money coming out of my pocket. Im currently waiting on parts to be shipped myself. Mazda corp brushed me off like i was a mosquito. keep us informed.

This happened more than a year ago for me - how many miles on your car? Did your clutch disc explode as did mine?

I have about 31k on mine right now. It happened roughly 3 weeks ago. They didnt tell me my clutch exploded, but said my clutch was burned out? Stated that was the reason the car stopped shifting into gear. Funny thing though my check engine light came on the same day this happened, but they told me that was because of my mazsports cooling fan mod........

Any updates HERO?

Well, I just joined the busted clutch club. Very little warning. I started it up and it made a noise I hadn't heard before and I think "I need to take it in and get it checked". 15 miles later, I push in the clutch coming to a light and it goes to the floor all the while making a horrible noise. Just had it towed to the dealer. Will see them in the morning.

Just got back from the dealer. The throwout bearing was toast. No other damage. The new bearing won't be in until tomorrow so I called RP at Axialflow and he is having a short shifter overnighted to the dealer for me. The dealer will but it in instead of the stock shifter. Never miss an opportunity for free install of a mod!!

I have my car back now after $368 for an exedy stage 1 and $468.20 for labor........ Warranty will in no way, shape or form cover it. About my check engine light, they initially told me it was due to my mazsports cooling fan mod which doesnt make sense because ive had that on since christmas with no problems. The tech who worked on my car at the time evidentally reset my ECU and then quit, so the new tech told me to just wait until it comes back on for him to check it out. The shifting from gear to gear is a little rough. If that doesnt fix itself out in a couple weeks ill go back in for that. Besides that, the exedy clutch is soooooooo much better than the OE! I'd recommend it.

hows everything going for everyone else?

I have driven manuals for over 15 years, I never experienced such a heartache as my rx-8, seems like my engine light is a whole transmission has eaten itself, the whole second rotor assembly is hoofed into the drive shaft and the whole bottom of the car looks like a scene from die hard 3 after mclaine been through there... car is totaled with less than 55k miles on it, also a 2004, bought in early 04, I think this is my last mazda, they have lost a good customer that bought an rx2, later an rx-7 and then later an rx-8... they treated me good, but not the 8, I am disenchanted by it, could have been such a great car... had it been handled the way the FD3s was, I drove the piss out of my FD, for over 8 years, never, I mean never had a problem with it, my rx-8, has been in the shop 6 times in only 3yrs...

Not The Start I was Hoping For!!
 

Hello guys, I just recently bought this car at the start of November. Mine is a 05 ti Grey with 25000 miles i bought it at 23890. This unfortunately is my first post, as i more of a reader than a poster. I had been reading and getting myself familiar with this car. I have read alot of bad reviews about this car but dont care because of how insanely fun this car is to drive. Intro aside. I was driving in regular traffic to work today when all of a sudden i noticed a loss of power. when i released my clutch it would not engage at all. after about a few hours it was off to dealership. And after reading this and many other posts the next couple of days is gonna be hell at the dealership. If any of you guys have any tips for when I go to the dealer I would very much appreciate it.

You're in Brooklyn ? Please tell me you did NOT took your car to Giuffer Mazda ...

PM me for more info about your problem, Im in Queens.

Yes I did take it there, the roadside assistance said they could only tow it the the nearest dealer. How bad was your experience there?