'06 Mazda 3, 2.3.
Background: Crankshaft and bearings damaged, due to son running it without oil. First thought of doing the 2.5 swap, but I was able to find an under-$500 Mazda 2.3 engine on LKQ. It was that cheap because it was in Canada, so it would take longer to get here. I wasn't in a hurry, so I ordered it.
I swapped the transmission from the old to the new and mounted the whole thing in the car. Connected the wires all around, the fuel line, the coolant lines (and thermostat), the AC compressor, the alternator, the exhaust header, everything.
The hardest thing so far, has been the insertion of the drive shafts. This was VERY difficult, mostly the one with the clip, the driver side one.
I was getting ready (and very excited) to put in the fluids, connect the battery, and give it a try, but found that the clutch pedal was on the floor. Did the "normal" stuff (check the fluid level, purge it), but when I was purging it I saw that the slave cylinder looked bad. Took it out and yes, it was damaged.
I also tried to move the release fork, but I couldn't. That made me think that I probably did something wrong when I transferred the transmission. However, I can actually actuate it if I use a big ass bar that I have, but it doesn't move it in a 'soft' way. This makes me think that the small slave cylinder is probably too weak to exert the needed force. On the other hand, it makes sense to me that the effort needed is significant, because what it is doing, is pressing the clutch disks together. The 2 ideas don't 'gel' in my head (clutch fork hard to move, and slave cylinder not looking strong enough)
I really hope someone here can shed some light on this for me. According to the workshop manual, there's only the fork and the bearing, and nothing else right there.
My current plan is simply to order a slave cylinder replacement, mount it, and see if it works. If it doesn't, then I suppose I'll have to take the whole thing down again. I don't think I have a way of 'just' taking down the transmission because I'm doing this job in my garage.
Thank you, to anyone that can give me some advise.
Last edited by vasama; 04-26-2019 at 12:20 PM.