Yandex MC
2004-08 TRANSMISSION Clutch - TSX <meta name="InColGX" content=""> </head> <body bgcolor="white" text="black"> <h1>2004-08 TRANSMISSION</h1> <h1>Clutch - TSX</h1><a name="S14066752772008080900000"></a><h2 class="clsHeadOne">Special Tools</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490899" name="S03990906232008080900000">Fig. 1: Identifying Special Tools</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p><a name="S02559332022008080900000"></a><h2 class="clsHeadOne">Component Location Index</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490900" name="S29164848032008080900000">Fig. 2: Identifying Clutch Component Location</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p><a name="S10931444582008080900000"></a><h2 class="clsHeadOne">Clutch Hydraulic System Bleeding</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not reuse the drained fluid. Always use Acura DOT 3 Brake Fluid from an unopened container. Use a non-Acura brake fluid can cause corrosion and shorten the life of the system.</li> <li>Do not mix different brands of brake fluid; they may not be compatible.</li> <li>Make sure not dirt or other foreign matter is allowed to contaminate the brake fluid.</li> <li>Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water.</li> <li>If may be necessary to limit the movement of the release fork with a block of wood to remove all the air from the system.</li> <li>Use fender covers to avoid damaging painted surfaces.</li> </ul> </td> </tr> </table></span></p> <ol class="clsARABICNUM"> <li>Make sure the brake, fluid level in the reservoir is at the MAX (upper) level line (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490901" name="S27949632902008080900000">Fig. 3: Identifying Fluid Level Marks</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Attach one end of a clear tube to the bleeder screw (A), and the other end to the container of brake fluid. Loosen the bleeder screw to allow air to escape from the system.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490902" name="S41950903732008080900000">Fig. 4: Identifying Bleeder Screw w/Torque Specification</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Make sure there is an adequate supply of fluid in the reservoir, then slowly pump the clutch pedal until no more bubbles appear at the clear tube.</li> <li>Tighten the bleeder screw securely.</li> <li>Refill the brake fluid in the reservoir to the MAX (upper) level line.</li> </ol><a name="S09900754782008080900000"></a><h2 class="clsHeadOne">Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Check the clutch pedal position switch (see <a class="clsExtHyperlink" id="A00293837_S08756171682008080900000">CLUTCH PEDAL POSITION SWITCH TEST</a> ).</li> <li>Check the clutch interlock switch (see <a class="clsExtHyperlink" id="A00293830_S30930725442008080900000">CLUTCH INTERLOCK SWITCH TEST</a> ).</li> <li>Remove the driver's floor mat before adjusting the clutch pedal.</li> <li>The clutch is self-adjusting to compensate for wear.</li> <li>If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems.</li> </ul> </td> </tr> </table></span></p> <ol class="clsARABICNUM"> <li>Lift up the carpet (A). At the insulator cutout, measure pedal height from the right side of the pedal pad (B).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490903" name="S01012743142008080900000">Fig. 5: Identifying Carpet And Pedal Pad</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490904" name="S36816797172008080900000">Fig. 6: Identifying Clutch Pedal Position Switch Locknut, Clutch Pedal Position Switch And Clutch Pedal w/Torque Specifications</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal.<p><span class="clsEmphBOLD">Clutch Pedal Stroke: 130-140 mm (5.12-5.51 in.)</span> </p> <p><span class="clsEmphBOLD">Clutch Pedal Free</span> </p> <p><span class="clsEmphBOLD">Play: 10-18 mm (0.39-0.71 in.)</span> </p> <p><span class="clsEmphBOLD">Clutch Pedal Height: 191 mm (7.52 in.)</span> </p> <p><span class="clsEmphBOLD">Clutch Pedal</span> </p> <p><span class="clsEmphBOLD">Disengagement</span> </p> <p><span class="clsEmphBOLD">Height: 95 mm (3.74 in.)</span> </p> </li> <li>Tighten the clutch pushrod locknut.</li> <li>With the clutch pedal released, turn in the clutch pedal position switch until it contacts the clutch pedal.</li> <li>Turn in the clutch pedal position switch an additional 3/4 to 1 turn.</li> <li>Tighten the clutch pedal position switch locknut.</li> <li>Loosen the clutch interlock switch locknut (J).</li> <li>Press the clutch pedal to the floor.</li> <li>Release the clutch pedal 9-12 mm (0.35-0.47 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so the engine will start with the clutch pedal in this position.</li> <li>Tighten the clutch interlock switch locknut.</li> </ol><a name="S15230278122008080900000"></a><h2 class="clsHeadOne">Clutch Pedal Replacement</h2> <ol class="clsARABICNUM"> <li>Disconnect the clutch pedal position switch connector (A) and clutch interlock switch connector (B).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490905" name="S05774877392008080900000">Fig. 7: Identifying Clutch Pedal Position Switch Connector And Clutch Interlock Switch Connector</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Pry out the lock pin (C), and pull the clevis pin (D) out of the yoke.</li> <li>Remove the master cylinder mounting nuts (E) and clutch pedal mounting bolt (F).</li> <li>Remove the clutch pedal (G).</li> <li>Install the clutch pedal (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490906" name="S39019952652008080900000">Fig. 8: Identifying Clutch Pedal, Clutch Pedal Mounting Bolt And Master Cylinder Mounting Nuts w/Torque Specifications</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the clutch pedal mounting bolt (B) and master cylinder mounting nuts (C).</li> <li>Apply grease to the clevis pin (D), and slide it into the yoke, then install a new lock pin (E).</li> <li>Connect the clutch pedal position switch connector (F) and clutch interlock switch connector (G).</li> <li>Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see <a class="clsHyperlink" href="#S09900754782008080900000">CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT</a> ).</li> <li>Check the clutch operation.</li> </ol><a name="S10709507672008080900000"></a><h2 class="clsHeadOne">Clutch Master Cylinder Replacement</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use fender covers to avoid damaging painted surfaces.</li> <li>Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water.</li> </ul> </td> </tr> </table></span></p> <ol class="clsARABICNUM"> <li>Remove the brake fluid from the clutch master cylinder reservoir with a syringe.</li> <li>Make sure you have the anti-theft codes for the audio system and navigation system (if equipped), then write down the audio presets.</li> <li>Disconnect the negative cable from the battery, then disconnect the positive cable.</li> <li>Remove the battery.</li> <li>Remove the air cleaner assembly (see <a class="clsExtHyperlink" id="A00293824_S15330112032008080900000">AIR CLEANER REMOVAL/INSTALLATION</a> ).</li> <li>Remove the battery base (see <a class="clsExtHyperlink" id="A00293841_S11248732182008080900000">ENGINE REMOVAL</a> ).</li> <li>Pry out the lock pin (A), and pull the clevis pin (B) out of the yoke. Remove the master cylinder mounting nuts (C).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490907" name="S37861477382008080900000">Fig. 9: Identifying Lock Pin, Clevis Pin And Master Cylinder Mounting Nuts</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the reservoir mounting bolt (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490908" name="S22639610032008080900000">Fig. 10: Identifying Reservoir Mounting Bolt, Clutch Line Bracket, Clips And Clutch Master Cylinder</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the clutch line bracket (B).</li> <li>Remove the clutch line clips (C).</li> <li>Remove the clutch master cylinder (D).</li> <li>Disconnect the reservoir hose (A), then remove the retaining clip (B), and clutch line (C) from the clutch master cylinder (D). Plug or wrap the end of the reservoir hose and clutch line with a shop towel to prevent brake fluid from coming out.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490909" name="S13462750092008080900000">Fig. 11: Identifying Reservoir Hose, Retaining Clip, Clutch Line And Clutch Master Cylinder</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the O-ring (E) and clutch master cylinder seal (F) from the clutch master cylinder.</li> <li>Install the new O-ring (A) and clutch master cylinder seal (B) to the clutch master cylinder (C).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490910" name="S23178226512008080900000">Fig. 12: Identifying O-Ring, Clutch Master Cylinder Seal And Clutch Master Cylinder</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the clutch line (D), then instill the new retaining clip (E). Connect the reservoir hose (F).</li> <li>To prevent the retaining clip (A) from coming off, pry apart the tip of the retaining clip (B) with a screwdriver.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490911" name="S35691804712008080900000">Fig. 13: Identifying Clip</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the clutch master cylinder (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490912" name="S22522537672008080900000">Fig. 14: Identifying Clutch Master Cylinder, Clutch Line Clips And Clutch Line Bracket w/Torque Specifications</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the clutch line clips (B) and clutch line bracket (C).</li> <li>Install the reservoir mounting bolt (D).</li> <li>Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490913" name="S31372338932008080900000">Fig. 15: Identifying Hose Clamps, Master Cylinder And Reservoir</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the master cylinder mounting nuts (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490914" name="S35682324862008080900000">Fig. 16: Identifying Master Cylinder Mounting Nuts w/Torque Specification</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Apply grease to the clevis pin (6), and slide it into the yoke, then install a new lock pin (C).</li> <li>Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see <a class="clsHyperlink" href="#S09900754782008080900000">CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT</a> ).</li> <li>Bleed the clutch hydraulic system (see <a class="clsHyperlink" href="#S10931444582008080900000">CLUTCH HYDRAULIC SYSTEM BLEEDING</a> ).</li> <li>Install the battery base (see <a class="clsExtHyperlink" id="A00293841_S40647650432008080900000">ENGINE INSTALLATION</a> ).</li> <li>Install the air cleaner assembly (see <a class="clsExtHyperlink" id="A00293824_S15330112032008080900000">AIR CLEANER REMOVAL/INSTALLATION</a> ).</li> <li>Install the battery. Clean the posts and cable terminals. Connect the positive cable to the battery, then connect the negative cable, and apply multipurpose grease to prevent corrosion.</li> <li>Enter the anti-theft codes for the audio system and navigation system (if equipped), then enter the audio presets.</li> <li>Set the clock (on vehicles without navigation).</li> <li>Check the clutch operation, and check for leaks.</li> <li>Test-drive the vehicle.</li> </ol><a name="S21668516002008080900000"></a><h2 class="clsHeadOne">Slave Cylinder Replacement</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use fender covers to avoid damaging painted surfaces.</li> <li>Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water.</li> </ul> </td> </tr> </table></span></p> <ol class="clsARABICNUM"> <li>Make sure you have the anti-theft codes for the audio system and navigation system (if equipped), then write down the audio presets.</li> <li>Disconnect the negative cable from the battery, then disconnect the positive cable.</li> <li>Remove the battery.</li> <li>Remove the air cleaner assembly (see <a class="clsExtHyperlink" id="A00293824_S15330112032008080900000">AIR CLEANER REMOVAL/INSTALLATION</a> ).</li> <li>Remove the battery base (see <a class="clsExtHyperlink" id="A00293841_S11248732182008080900000">ENGINE REMOVAL</a> ).</li> <li>Remove the clutch line bracket.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490915" name="S16173305572008080900000">Fig. 17: Identifying Clutch Line Bracket And Bolt</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the mounting bolts (A) and the slave cylinder (B).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490916" name="S21455992022008080900000">Fig. 18: Identifying Mounting Bolts, Slave Cylinder, Roll Pins And Clutch Line</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the roll pins (C). Disconnect the clutch line (D), and remove the O-ring (E). Plug or wrap the end of the clutch line with a shop towel to prevent brake fluid from coming out.</li> <li>Install the slave cylinder in the reverse order of removal. Install a new O-ring (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490917" name="S30517781162008080900000">Fig. 19: Identifying O-Ring, Boot And Slave Cylinder Rod w/Torque Specification</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Pull back the boot (B), and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot.</li> <li>Apply super high temp urea grease (P/N 08798-9002) to the pushrod of the slave cylinder. Tighten the slave cylinder mounting bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).</li> <li>Bleed the clutch hydraulic system (see <a class="clsHyperlink" href="#S10931444582008080900000">CLUTCH HYDRAULIC SYSTEM BLEEDING</a> ).</li> <li>Install the battery base (see <a class="clsExtHyperlink" id="A00293841_S40647650432008080900000">ENGINE INSTALLATION</a> ).</li> <li>Install the air cleaner assembly (see <a class="clsExtHyperlink" id="A00293824_S15330112032008080900000">AIR CLEANER REMOVAL/INSTALLATION</a> ).</li> <li>Install the battery. Clean the posts and cable terminals. Connect the positive cable to the battery, then connect the negative cable, and apply multipurpose grease to prevent corrosion.</li> <li>Enter the anti-theft codes for the audio system and navigation system (if equipped), then enter the audio presets.</li> <li>Set the clock (on vehicles without navigation).</li> <li>Check the clutch operation, and check for leaks.</li> <li>Test-drive the vehicle.</li> </ol><a name="S07312085682008080900000"></a><h2 class="clsHeadOne">Clutch Replacement</h2> <p><span class="clsEmphBOLD">Special Tools Required</span> </p> <ul class="clsBULLET"> <li>Clutch alignment disc 07JAF-PM7011A</li> <li>Ring gear holder 07LAB-PV00100 or 07924-PD20003</li> <li>Clutch alignment shaft 07ZAF-PR8A100</li> <li>Sliding hammer weight 07741-0010201</li> <li>Attachment, 22 x 24 mm 07746-0010800</li> <li>Driver 07749-0010000</li> <li>Bearing remover shaft handle 07936-3710100</li> <li>Bearing remover shaft set, 17 mm 07936-3710300</li> </ul><a name="S35647437562008080900000"></a><h2 class="clsHeadTwo">Pressure Plate and Clutch Disc Removal</h2> <ol class="clsARABICNUM"> <li>Check the height of the diaphragm spring fingers using the clutch alignment disc (A), clutch alignment shaft (B), 17 mm bearing remover shaft set (C), and a feeler gauge (D). If the height is more than the service limit, replace the pressure plate.<p><span class="clsEmphBOLD">Standard (New): 0.6 mm (0.02 in.) max.</span> </p> <p><span class="clsEmphBOLD">Service Limit: 0.8 mm (0.03 in.)</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490918" name="S41101048392008080900000">Fig. 20: Identifying Clutch Alignment Disc, Clutch Alignment Shaft, 17 mm Bearing Remover Shaft Set And Feeler Gauge</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the ring gear holder (A), clutch alignment shaft (B), and 17 mm bearing remover shaft set (C).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490919" name="S32682460952008080900000">Fig. 21: Identifying Ring Gear Holder, Clutch Alignment Shaft, And 17 mm Bearing Remover Shaft Set</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>To prevent warping, unscrew the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).</li> <li>Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490920" name="S39099450612008080900000">Fig. 22: Identifying Diaphragm Spring</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Inspect the pressure plate surface (A) for wear, cracks, and burning.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490921" name="S22597526502008080900000">Fig. 23: Identifying Pressure Plate Surface</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.<p><span class="clsEmphBOLD">Standard (New): 0.03 mm (0.001 in.) max.</span> </p> <p><span class="clsEmphBOLD">Service Limit: 0.15 mm (0.006 in.)</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490922" name="S24408415502008080900000">Fig. 24: Identifying Straight Edge, Feeler Gauge And Pressure Plate</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the clutch disc (A), clutch alignment shaft (B), and 17 mm bearing remover shaft set (C).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490923" name="S22665658942008080900000">Fig. 25: Identifying Clutch Disc, Clutch Alignment Shaft, And 17 mm Bearing Remover Shaft Set</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is oil soaked, replace it. If the clutch disc is oil soaked, find and repair the source of the oil leak.</li> <li>Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.<p><span class="clsEmphBOLD">Standard (New): 8.2-8.9 mm (0.32-0.35 in.)</span> </p> <p><span class="clsEmphBOLD">Service Limit: 6.0 mm (0.24 in.)</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490924" name="S24044452212008080900000">Fig. 26: Measuring Clutch Disc Thickness</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc.<p><span class="clsEmphBOLD">Standard (New): 1.2-1.7 mm (0.047-0.067 in.)</span> </p> <p><span class="clsEmphBOLD">Service Limit: 0.2 mm (0.008 in.)</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490925" name="S18041579942008080900000">Fig. 27: Measuring Rivet Depth From Clutch Disc Lining Surface</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> </ol><a name="S02611513562008080900000"></a><h2 class="clsHeadTwo">Crankshaft Pilot Bushing Inspection</h2> <ol class="clsARABICNUM"> <li>Inspect the crankshaft pilot bushing for wear and damage.</li> <li>Inspect the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot bushing is not smooth, replace it.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490926" name="S15509920482008080900000">Fig. 28: Inspecting Crankshaft Pilot Bushing</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> </ol><a name="S21617803492008080900000"></a><h2 class="clsHeadTwo">Crankshaft Pilot Bushing Replacement</h2> <ol class="clsARABICNUM"> <li>Remove the crankshaft pilot bushing (A) using the bearing remover shaft handle (B), 17 mm bearing remover shaft set, (C), and the sliding hammer weight (D).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490927" name="S30331588452008080900000">Fig. 29: Removing Crankshaft Pilot Bushing</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Install the new crankshaft pilot bushing (A) into the crankshaft using the driver (B) and 22 x 24 mm attachment (C). Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing surface.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490928" name="S21178455182008080900000">Fig. 30: Installing Crankshaft Pilot Bushing</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> </ol><a name="S35230005202008080900000"></a><h2 class="clsHeadTwo">Flywheel Inspection</h2> <ol class="clsARABICNUM"> <li>Inspect the ring gear teeth for wear and damage.</li> <li>Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.</li> <li>Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel, and recheck the runout.<p><span class="clsEmphBOLD">Standard (New): 0.05 mm (0.002 in.) max.</span> </p> <p><span class="clsEmphBOLD">Service Limit: 0.15 mm (0.006 in.)</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490929" name="S35248706522008080900000">Fig. 31: Measuring Flywheel Runout Using Dial Indicator</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> </ol><a name="S41818760922008080900000"></a><h2 class="clsHeadTwo">Flywheel Replacement</h2> <ol class="clsARABICNUM"> <li>Install the ring gear holder (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490930" name="S29906056112008080900000">Fig. 32: Identifying Ring Gear Holder</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel and ring gear holder.</li> <li>Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.</li> <li>Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490931" name="S31259591562008080900000">Fig. 33: Identifying Ring Gear Holder And Flywheel Mounting Bolts w/Torque Specification</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> </ol><a name="S26052811392008080900000"></a><h2 class="clsHeadTwo">Clutch Disc and Pressure Plate Installation</h2> <ol class="clsARABICNUM"> <li>Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.</li> <li>Install the ring gear holder (A).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490932" name="S23590933462008080900000">Fig. 34: Identifying Ring Gear Holder, Crankshaft Pilot Bushing And Clutch Disc</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (B).</li> <li>Apply super high temp urea grease (P/N 08798-9002) to the splines (C) of the clutch disc (D), then install the clutch disc using the clutch alignment shaft (E) and 17 mm bearing remover shaft set (F).</li> <li>Install the pressure plate (A) and the mounting bolts (B) finger-tight.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490933" name="S35488343232008080900000">Fig. 35: Identifying Pressure Plate And Mounting Bolts</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.<p><span class="clsEmphBOLD">Specified Torque: 25 N.m (2.6 kgf.m, 19 lbf.ft)</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490934" name="S30362728712008080900000">Fig. 36: Identifying Ring Gear Holder, Clutch Alignment Shaft And Remover Handle w/Torque Specification</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the ring gear holder (A), clutch alignment shaft (B), and remover handle (C).</li> <li>Make sure the diaphragm spring fingers are all the same height.</li> </ol><a name="S02554477042008080900000"></a><h2 class="clsHeadTwo">Release Bearing Replacement</h2> <ol class="clsARABICNUM"> <li>Remove the release fork boot (A) from the clutch housing (B).<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490935" name="S02747093482008080900000">Fig. 37: Identifying Release Fork Boot, Clutch Housing, Fork And Fork Set Spring</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).</li> <li>Check the play of the release bearing by spinning it with your hand. If there is excessive play or noise, replace the release bearing.<p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td>The release bearing is packed with grease. Do not wash it in solvent.</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490936" name="S06612844942008080900000">Fig. 38: Checking Play Of Release Bearing</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490937" name="S21369619542008080900000">Fig. 39: Identifying Release Fork, Release Fork Bolt, Release Bearing And Release Bearing Guide</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> <li>With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.</li> <li>Align the detent of the release fork with the release fork bolt, then squarely press the release fork over the release fork bolt.</li> <li>Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.</li> <li>Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly. Wipe off any excess grease.<p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="G05490938" name="S34508012922008080900000">Fig. 40: Identifying Release Fork And Release Bearing</a><br><span class="clsCourtesyNote">Courtesy of AMERICAN HONDA MOTOR CO., INC.</span></span></p> </li> </ol> </body> </html>

Mitchell onDemand(proDemand) web-online. Is free

DATACENTER ERROR!!! Внимание! Авария в датацентре!!


Subscribe to the telegram channel https://t.me/kolhosniki_en

Place for your advertisement

predsedatel@kolhosniki.ru
Click for start

MANUAL TRANSMISSION CLUTCH

  • HEADINGS
    • Special Tools
    • Component Location Index
    • Clutch Hydraulic System Bleeding
    • Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment
    • Clutch Pedal Replacement
    • Clutch Master Cylinder Replacement
    • Slave Cylinder Replacement
    • Clutch Replacement
      • Pressure Plate and Clutch Disc Removal
      • Crankshaft Pilot Bushing Inspection
      • Crankshaft Pilot Bushing Replacement
      • Flywheel Inspection
      • Flywheel Replacement
      • Clutch Disc and Pressure Plate Installation
      • Release Bearing Replacement
  • FIGURES
    • Fig. 1: Identifying Special Tools
    • Fig. 2: Identifying Clutch Component Location
    • Fig. 3: Identifying Fluid Level Marks
    • Fig. 4: Identifying Bleeder Screw w/Torque Specification
    • Fig. 5: Identifying Carpet And Pedal Pad
    • Fig. 6: Identifying Clutch Pedal Position Switch Locknut, Clutch Pedal Position Switch And Clutch Pedal w/Torque Specifications
    • Fig. 7: Identifying Clutch Pedal Position Switch Connector And Clutch Interlock Switch Connector
    • Fig. 8: Identifying Clutch Pedal, Clutch Pedal Mounting Bolt And Master Cylinder Mounting Nuts w/Torque Specifications
    • Fig. 9: Identifying Lock Pin, Clevis Pin And Master Cylinder Mounting Nuts
    • Fig. 10: Identifying Reservoir Mounting Bolt, Clutch Line Bracket, Clips And Clutch Master Cylinder
    • Fig. 11: Identifying Reservoir Hose, Retaining Clip, Clutch Line And Clutch Master Cylinder
    • Fig. 12: Identifying O-Ring, Clutch Master Cylinder Seal And Clutch Master Cylinder
    • Fig. 13: Identifying Clip
    • Fig. 14: Identifying Clutch Master Cylinder, Clutch Line Clips And Clutch Line Bracket w/Torque Specifications
    • Fig. 15: Identifying Hose Clamps, Master Cylinder And Reservoir
    • Fig. 16: Identifying Master Cylinder Mounting Nuts w/Torque Specification
    • Fig. 17: Identifying Clutch Line Bracket And Bolt
    • Fig. 18: Identifying Mounting Bolts, Slave Cylinder, Roll Pins And Clutch Line
    • Fig. 19: Identifying O-Ring, Boot And Slave Cylinder Rod w/Torque Specification
    • Fig. 20: Identifying Clutch Alignment Disc, Clutch Alignment Shaft, 17 mm Bearing Remover Shaft Set And Feeler Gauge
    • Fig. 21: Identifying Ring Gear Holder, Clutch Alignment Shaft, And 17 mm Bearing Remover Shaft Set
    • Fig. 22: Identifying Diaphragm Spring
    • Fig. 23: Identifying Pressure Plate Surface
    • Fig. 24: Identifying Straight Edge, Feeler Gauge And Pressure Plate
    • Fig. 25: Identifying Clutch Disc, Clutch Alignment Shaft, And 17 mm Bearing Remover Shaft Set
    • Fig. 26: Measuring Clutch Disc Thickness
    • Fig. 27: Measuring Rivet Depth From Clutch Disc Lining Surface
    • Fig. 28: Inspecting Crankshaft Pilot Bushing
    • Fig. 29: Removing Crankshaft Pilot Bushing
    • Fig. 30: Installing Crankshaft Pilot Bushing
    • Fig. 31: Measuring Flywheel Runout Using Dial Indicator
    • Fig. 32: Identifying Ring Gear Holder
    • Fig. 33: Identifying Ring Gear Holder And Flywheel Mounting Bolts w/Torque Specification
    • Fig. 34: Identifying Ring Gear Holder, Crankshaft Pilot Bushing And Clutch Disc
    • Fig. 35: Identifying Pressure Plate And Mounting Bolts
    • Fig. 36: Identifying Ring Gear Holder, Clutch Alignment Shaft And Remover Handle w/Torque Specification
    • Fig. 37: Identifying Release Fork Boot, Clutch Housing, Fork And Fork Set Spring
    • Fig. 38: Checking Play Of Release Bearing
    • Fig. 39: Identifying Release Fork, Release Fork Bolt, Release Bearing And Release Bearing Guide
    • Fig. 40: Identifying Release Fork And Release Bearing
  • TABLES

2004-08 TRANSMISSION

Clutch - TSX

Special Tools

Fig. 1: Identifying Special Tools
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Component Location Index

Fig. 2: Identifying Clutch Component Location
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Clutch Hydraulic System Bleeding

NOTE:
  • Do not reuse the drained fluid. Always use Acura DOT 3 Brake Fluid from an unopened container. Use a non-Acura brake fluid can cause corrosion and shorten the life of the system.
  • Do not mix different brands of brake fluid; they may not be compatible.
  • Make sure not dirt or other foreign matter is allowed to contaminate the brake fluid.
  • Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water.
  • If may be necessary to limit the movement of the release fork with a block of wood to remove all the air from the system.
  • Use fender covers to avoid damaging painted surfaces.

  1. Make sure the brake, fluid level in the reservoir is at the MAX (upper) level line (A).

    Fig. 3: Identifying Fluid Level Marks
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Attach one end of a clear tube to the bleeder screw (A), and the other end to the container of brake fluid. Loosen the bleeder screw to allow air to escape from the system.

    Fig. 4: Identifying Bleeder Screw w/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  3. Make sure there is an adequate supply of fluid in the reservoir, then slowly pump the clutch pedal until no more bubbles appear at the clear tube.
  4. Tighten the bleeder screw securely.
  5. Refill the brake fluid in the reservoir to the MAX (upper) level line.

Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment

NOTE:
  • Check the clutch pedal position switch (see CLUTCH PEDAL POSITION SWITCH TEST ).
  • Check the clutch interlock switch (see CLUTCH INTERLOCK SWITCH TEST ).
  • Remove the driver's floor mat before adjusting the clutch pedal.
  • The clutch is self-adjusting to compensate for wear.
  • If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems.

  1. Lift up the carpet (A). At the insulator cutout, measure pedal height from the right side of the pedal pad (B).

    Fig. 5: Identifying Carpet And Pedal Pad
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C).

    Fig. 6: Identifying Clutch Pedal Position Switch Locknut, Clutch Pedal Position Switch And Clutch Pedal w/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  3. Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal.

    Clutch Pedal Stroke: 130-140 mm (5.12-5.51 in.)

    Clutch Pedal Free

    Play: 10-18 mm (0.39-0.71 in.)

    Clutch Pedal Height: 191 mm (7.52 in.)

    Clutch Pedal

    Disengagement

    Height: 95 mm (3.74 in.)

  4. Tighten the clutch pushrod locknut.
  5. With the clutch pedal released, turn in the clutch pedal position switch until it contacts the clutch pedal.
  6. Turn in the clutch pedal position switch an additional 3/4 to 1 turn.
  7. Tighten the clutch pedal position switch locknut.
  8. Loosen the clutch interlock switch locknut (J).
  9. Press the clutch pedal to the floor.
  10. Release the clutch pedal 9-12 mm (0.35-0.47 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so the engine will start with the clutch pedal in this position.
  11. Tighten the clutch interlock switch locknut.

Clutch Pedal Replacement

  1. Disconnect the clutch pedal position switch connector (A) and clutch interlock switch connector (B).

    Fig. 7: Identifying Clutch Pedal Position Switch Connector And Clutch Interlock Switch Connector
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Pry out the lock pin (C), and pull the clevis pin (D) out of the yoke.
  3. Remove the master cylinder mounting nuts (E) and clutch pedal mounting bolt (F).
  4. Remove the clutch pedal (G).
  5. Install the clutch pedal (A).

    Fig. 8: Identifying Clutch Pedal, Clutch Pedal Mounting Bolt And Master Cylinder Mounting Nuts w/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  6. Install the clutch pedal mounting bolt (B) and master cylinder mounting nuts (C).
  7. Apply grease to the clevis pin (D), and slide it into the yoke, then install a new lock pin (E).
  8. Connect the clutch pedal position switch connector (F) and clutch interlock switch connector (G).
  9. Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT ).
  10. Check the clutch operation.

Clutch Master Cylinder Replacement

NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water.

  1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
  2. Make sure you have the anti-theft codes for the audio system and navigation system (if equipped), then write down the audio presets.
  3. Disconnect the negative cable from the battery, then disconnect the positive cable.
  4. Remove the battery.
  5. Remove the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
  6. Remove the battery base (see ENGINE REMOVAL ).
  7. Pry out the lock pin (A), and pull the clevis pin (B) out of the yoke. Remove the master cylinder mounting nuts (C).

    Fig. 9: Identifying Lock Pin, Clevis Pin And Master Cylinder Mounting Nuts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  8. Remove the reservoir mounting bolt (A).

    Fig. 10: Identifying Reservoir Mounting Bolt, Clutch Line Bracket, Clips And Clutch Master Cylinder
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  9. Remove the clutch line bracket (B).
  10. Remove the clutch line clips (C).
  11. Remove the clutch master cylinder (D).
  12. Disconnect the reservoir hose (A), then remove the retaining clip (B), and clutch line (C) from the clutch master cylinder (D). Plug or wrap the end of the reservoir hose and clutch line with a shop towel to prevent brake fluid from coming out.

    Fig. 11: Identifying Reservoir Hose, Retaining Clip, Clutch Line And Clutch Master Cylinder
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  13. Remove the O-ring (E) and clutch master cylinder seal (F) from the clutch master cylinder.
  14. Install the new O-ring (A) and clutch master cylinder seal (B) to the clutch master cylinder (C).

    Fig. 12: Identifying O-Ring, Clutch Master Cylinder Seal And Clutch Master Cylinder
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  15. Install the clutch line (D), then instill the new retaining clip (E). Connect the reservoir hose (F).
  16. To prevent the retaining clip (A) from coming off, pry apart the tip of the retaining clip (B) with a screwdriver.

    Fig. 13: Identifying Clip
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  17. Install the clutch master cylinder (A).

    Fig. 14: Identifying Clutch Master Cylinder, Clutch Line Clips And Clutch Line Bracket w/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  18. Install the clutch line clips (B) and clutch line bracket (C).
  19. Install the reservoir mounting bolt (D).
  20. Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown.

    Fig. 15: Identifying Hose Clamps, Master Cylinder And Reservoir
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  21. Install the master cylinder mounting nuts (A).

    Fig. 16: Identifying Master Cylinder Mounting Nuts w/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  22. Apply grease to the clevis pin (6), and slide it into the yoke, then install a new lock pin (C).
  23. Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT ).
  24. Bleed the clutch hydraulic system (see CLUTCH HYDRAULIC SYSTEM BLEEDING ).
  25. Install the battery base (see ENGINE INSTALLATION ).
  26. Install the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
  27. Install the battery. Clean the posts and cable terminals. Connect the positive cable to the battery, then connect the negative cable, and apply multipurpose grease to prevent corrosion.
  28. Enter the anti-theft codes for the audio system and navigation system (if equipped), then enter the audio presets.
  29. Set the clock (on vehicles without navigation).
  30. Check the clutch operation, and check for leaks.
  31. Test-drive the vehicle.

Slave Cylinder Replacement

NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water.

  1. Make sure you have the anti-theft codes for the audio system and navigation system (if equipped), then write down the audio presets.
  2. Disconnect the negative cable from the battery, then disconnect the positive cable.
  3. Remove the battery.
  4. Remove the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
  5. Remove the battery base (see ENGINE REMOVAL ).
  6. Remove the clutch line bracket.

    Fig. 17: Identifying Clutch Line Bracket And Bolt
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  7. Remove the mounting bolts (A) and the slave cylinder (B).

    Fig. 18: Identifying Mounting Bolts, Slave Cylinder, Roll Pins And Clutch Line
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  8. Remove the roll pins (C). Disconnect the clutch line (D), and remove the O-ring (E). Plug or wrap the end of the clutch line with a shop towel to prevent brake fluid from coming out.
  9. Install the slave cylinder in the reverse order of removal. Install a new O-ring (A).

    Fig. 19: Identifying O-Ring, Boot And Slave Cylinder Rod w/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  10. Pull back the boot (B), and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot.
  11. Apply super high temp urea grease (P/N 08798-9002) to the pushrod of the slave cylinder. Tighten the slave cylinder mounting bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
  12. Bleed the clutch hydraulic system (see CLUTCH HYDRAULIC SYSTEM BLEEDING ).
  13. Install the battery base (see ENGINE INSTALLATION ).
  14. Install the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
  15. Install the battery. Clean the posts and cable terminals. Connect the positive cable to the battery, then connect the negative cable, and apply multipurpose grease to prevent corrosion.
  16. Enter the anti-theft codes for the audio system and navigation system (if equipped), then enter the audio presets.
  17. Set the clock (on vehicles without navigation).
  18. Check the clutch operation, and check for leaks.
  19. Test-drive the vehicle.

Clutch Replacement

Special Tools Required

  • Clutch alignment disc 07JAF-PM7011A
  • Ring gear holder 07LAB-PV00100 or 07924-PD20003
  • Clutch alignment shaft 07ZAF-PR8A100
  • Sliding hammer weight 07741-0010201
  • Attachment, 22 x 24 mm 07746-0010800
  • Driver 07749-0010000
  • Bearing remover shaft handle 07936-3710100
  • Bearing remover shaft set, 17 mm 07936-3710300

Pressure Plate and Clutch Disc Removal

  1. Check the height of the diaphragm spring fingers using the clutch alignment disc (A), clutch alignment shaft (B), 17 mm bearing remover shaft set (C), and a feeler gauge (D). If the height is more than the service limit, replace the pressure plate.

    Standard (New): 0.6 mm (0.02 in.) max.

    Service Limit: 0.8 mm (0.03 in.)

    Fig. 20: Identifying Clutch Alignment Disc, Clutch Alignment Shaft, 17 mm Bearing Remover Shaft Set And Feeler Gauge
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Install the ring gear holder (A), clutch alignment shaft (B), and 17 mm bearing remover shaft set (C).

    Fig. 21: Identifying Ring Gear Holder, Clutch Alignment Shaft, And 17 mm Bearing Remover Shaft Set
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  3. To prevent warping, unscrew the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
  4. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.

    Fig. 22: Identifying Diaphragm Spring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  5. Inspect the pressure plate surface (A) for wear, cracks, and burning.

    Fig. 23: Identifying Pressure Plate Surface
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  6. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.

    Standard (New): 0.03 mm (0.001 in.) max.

    Service Limit: 0.15 mm (0.006 in.)

    Fig. 24: Identifying Straight Edge, Feeler Gauge And Pressure Plate
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  7. Remove the clutch disc (A), clutch alignment shaft (B), and 17 mm bearing remover shaft set (C).

    Fig. 25: Identifying Clutch Disc, Clutch Alignment Shaft, And 17 mm Bearing Remover Shaft Set
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is oil soaked, replace it. If the clutch disc is oil soaked, find and repair the source of the oil leak.
  9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.

    Standard (New): 8.2-8.9 mm (0.32-0.35 in.)

    Service Limit: 6.0 mm (0.24 in.)

    Fig. 26: Measuring Clutch Disc Thickness
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc.

    Standard (New): 1.2-1.7 mm (0.047-0.067 in.)

    Service Limit: 0.2 mm (0.008 in.)

    Fig. 27: Measuring Rivet Depth From Clutch Disc Lining Surface
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Crankshaft Pilot Bushing Inspection

  1. Inspect the crankshaft pilot bushing for wear and damage.
  2. Inspect the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot bushing is not smooth, replace it.

    Fig. 28: Inspecting Crankshaft Pilot Bushing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Crankshaft Pilot Bushing Replacement

  1. Remove the crankshaft pilot bushing (A) using the bearing remover shaft handle (B), 17 mm bearing remover shaft set, (C), and the sliding hammer weight (D).

    Fig. 29: Removing Crankshaft Pilot Bushing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Install the new crankshaft pilot bushing (A) into the crankshaft using the driver (B) and 22 x 24 mm attachment (C). Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing surface.

    Fig. 30: Installing Crankshaft Pilot Bushing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Flywheel Inspection

  1. Inspect the ring gear teeth for wear and damage.
  2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
  3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel, and recheck the runout.

    Standard (New): 0.05 mm (0.002 in.) max.

    Service Limit: 0.15 mm (0.006 in.)

    Fig. 31: Measuring Flywheel Runout Using Dial Indicator
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Flywheel Replacement

  1. Install the ring gear holder (A).

    Fig. 32: Identifying Ring Gear Holder
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel and ring gear holder.
  3. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
  4. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.

    Fig. 33: Identifying Ring Gear Holder And Flywheel Mounting Bolts w/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Clutch Disc and Pressure Plate Installation

  1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
  2. Install the ring gear holder (A).

    Fig. 34: Identifying Ring Gear Holder, Crankshaft Pilot Bushing And Clutch Disc
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  3. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (B).
  4. Apply super high temp urea grease (P/N 08798-9002) to the splines (C) of the clutch disc (D), then install the clutch disc using the clutch alignment shaft (E) and 17 mm bearing remover shaft set (F).
  5. Install the pressure plate (A) and the mounting bolts (B) finger-tight.

    Fig. 35: Identifying Pressure Plate And Mounting Bolts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.

    Specified Torque: 25 N.m (2.6 kgf.m, 19 lbf.ft)

    Fig. 36: Identifying Ring Gear Holder, Clutch Alignment Shaft And Remover Handle w/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  7. Remove the ring gear holder (A), clutch alignment shaft (B), and remover handle (C).
  8. Make sure the diaphragm spring fingers are all the same height.

Release Bearing Replacement

  1. Remove the release fork boot (A) from the clutch housing (B).

    Fig. 37: Identifying Release Fork Boot, Clutch Housing, Fork And Fork Set Spring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  2. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).
  3. Check the play of the release bearing by spinning it with your hand. If there is excessive play or noise, replace the release bearing.

    NOTE: The release bearing is packed with grease. Do not wash it in solvent.

    Fig. 38: Checking Play Of Release Bearing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.

    Fig. 39: Identifying Release Fork, Release Fork Bolt, Release Bearing And Release Bearing Guide
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

  5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.
  6. Align the detent of the release fork with the release fork bolt, then squarely press the release fork over the release fork bolt.
  7. Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.
  8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly. Wipe off any excess grease.

    Fig. 40: Identifying Release Fork And Release Bearing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

Didn't find what you were looking for? Try to find in:
- Alldata Online (Beta)
Loading...

This project exists mainly due to the display of advertising.

Due to the international situation, making a profit from advertising has become impossible.

If this continues, then the project will either close completely, or become closed and paid.

To support the project, you can Buy a paid subscription


Can be closed in 20