Well, I got the car back today. He must have misspoken, or I have a different recollection of the conversation. They did not replace the flywheel. They did a complete clutch kit replacement - $600 in parts. This included the clutch cover, clutch disc, clutch release collar, pilot bearing, and oil seal. Plus $375 labor.

Here's the lowdown after 41K miles of zero abuse on my clutch - the clutch cover's pressure plate was barely worn - smooth as a baby's bottom. The throwout bearing had some play in it, and that was apparently causing the rattling. The splines of the clutch cover had a groove worn in them where the throwout bearing made contact, and the clutch disc was discolored blue, indicating extreme temperatures.

Pictures to follow:

 

Clutch cover - note groove in splines:

 

Clutch disc and throwout bearing. BTW, I just realized, they didn't give me the pilot bearing back.

This is the first RX-8 clutch that this particular dealership has opened up. However, most of the cars they sell are automatics.

 

It's not a lemon, but I definitely think the clutch should have been problem-free for at least another 50K miles, given how I drive it. I left the parts at the dealership, and they're going to have the district rep take a look at them and maybe he'll authorize reimbursement.

 

I'm fairly certain that that blue colour is normal for this clutch plate. They come new that colour, I believe.

 

TCReedy1

Thanks for the insight on the tranny noise we all (MT) hear.

I wonder, however, about why Mazda might not have tried to cancel the sixth, ninth and twelth orders in the same way reciprocating engines are handled. Are the recip engines second, fourth, eigth orders easier to deal with then those created by a rotary?

 

I used a good synthetic....Redline MT90, it made not one iota of difference in terms of noise reduction. I wasn't trying to get rid of the noise, I was trying to allay the notchiness when shifting from first to second. Didn't help that either.....

 

Maybe so. I'm just regurgitating what I was told by the service tech.

 

Good luck with getting reimbursement......you'll have a good chance, I reckon. Even better chance if you are over 30 and your rear tyres aren't fried.......

 

The way it was explained to me, when the clutch is properly working, the throwout bearing should make no contact with the splines on the clutch cover when the pedal is not depressed. If there is some play in the throwout bearing (as appears to have been the case in my clutch), or something is out of tolerance, it is possible for the bearing to make intermittent contact with the splines. I'm assuming this is how the groove got worn in my splines, and this was the source of the rattle. The rattle appears to be gone now, BTW, so this seems to have some merit. Am I understanding something incorrectly (I'm not exactly an automotive guru)? I'm trying to understand what could have caused the damage shown in the pictures.

I still do have a vibration at idle that shakes the entire seat. I wonder, if the transmission is vibrating, could it have accelerated the clutch wear (maybe causing the bearing to make contact with the splines?

It seems like these noise and vibration problems all started happening shortly after the transmission damper recall was performed. I went to look for the PDF at Rosenthal's site, but it's gone now. Was the damper supposed to reduce vibrations in the drivetrain? Maybe mine never got replaced, or was not replaced properly...

 

All it says is: "On certain RX-8 vehicles, the transmission damper heat insulator, which is installed on the manual transmissions, may be cracked, causing abnormal noise. Should you continue operating the vehicle in this condition, the insulator could come off while driving and could pose a serious hazard to a following vehicle."

"Parts required
Heat Insulator Kit (Y6Y0 22 100) includes:
o-Heat insulator
o-Two (2) bolts"

So the damper itself was not replaced as a part of this recall.

 

Well...my loud bearing went a step further.
I had always heard it was just "normal" noise...until today!

On the commute in this morning, when trying to downshift it simply seized up and I could not engage the gears. Talk about wacky noises and being stranded on the highway...it was nasty.

ANYWAY, I've not heard the prognosis - but I can bet that it had SOMETHING to do with the thrust bearing...

I'll let you know.

Meanwhile, I'll have to suffer driving my '06 MX-5 for a few days.
:p

 

Yikes, that doesn't sound good... Sorry to hear it. Keep us posted.

 

I'll bet it isn't......sounds like complete clutch failure.

 

Yeah, still no word.
They never pulled it in today...but it definitely is some sort of complete clutch failure...which is lame. I never even rode it that hard.

:S

 

Photo....

 

Youch!
I'll have to ask them to call me when they have the parts out of mine. I'll take pics too!

 

Beware, you may be held responsible for the clutch damage...if that is indeed what has happened here. If you are held responsible, you'll be asked to pay for the damage.....no warranty claim. And you won't be the first that has happened to. Haven't done any burnouts lately, have you?

Be prepared.

 

Yes, they are blue

 

New ones too?

 

5,000 miles back when I installed my wheel, so kinda new :o

 

I take very good care of my RX-8 and the local dealer knows it. I expect that a clutch failure in a car with less than 15K mi will be covered under warranty...especially since I complained from when the car was new of odd transmission and clutch noises.

They still have not updated me...so for now, I'll drive the Mazda 6 loaner.

 

Well...as predicted...
it's a clutch failure and NOT covered.
so...I am off to shop for parts
and $1000 for a clutch job is WAY TOO HIGH IMO

 

That is messed up!

 

Hmmmm, sorry mate.