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.
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- 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.
- 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.
- 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.
- Tighten the bleeder screw securely.
- 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.
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- 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
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- 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.
- 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.)
- Tighten the clutch pushrod locknut.
- With the clutch pedal released, turn in the clutch pedal position switch until it contacts the clutch pedal.
- Turn in the clutch pedal position switch an additional 3/4 to 1 turn.
- Tighten the clutch pedal position switch locknut.
- Loosen the clutch interlock switch locknut (J).
- Press the clutch pedal to the floor.
- 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.
- Tighten the clutch interlock switch locknut.
Clutch Pedal Replacement
- 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.
- Pry out the lock pin (C), and pull the clevis pin (D) out of the yoke.
- Remove the master cylinder mounting nuts (E) and clutch pedal mounting bolt (F).
- Remove the clutch pedal (G).
- 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.
- Install the clutch pedal mounting bolt (B) and master cylinder mounting nuts (C).
- Apply grease to the clevis pin (D), and slide it into the yoke, then install a new lock pin (E).
- Connect the clutch pedal position switch connector (F) and clutch interlock switch connector (G).
- Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT
).
- 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.
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- Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
- Make sure you have the anti-theft codes for the audio system and navigation system (if equipped), then write down the audio presets.
- Disconnect the negative cable from the battery, then disconnect the positive cable.
- Remove the battery.
- Remove the air cleaner assembly (see
AIR CLEANER REMOVAL/INSTALLATION
).
- Remove the battery base (see ENGINE REMOVAL
).
- 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.
- 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.
- Remove the clutch line bracket (B).
- Remove the clutch line clips (C).
- Remove the clutch master cylinder (D).
- 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.
- Remove the O-ring (E) and clutch master cylinder seal (F) from the clutch master cylinder.
- 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.
- Install the clutch line (D), then instill the new retaining clip (E). Connect the reservoir hose (F).
- 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.
- 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.
- Install the clutch line clips (B) and clutch line bracket (C).
- Install the reservoir mounting bolt (D).
- 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.
- Install the master cylinder mounting nuts (A).
Fig. 16: Identifying Master Cylinder Mounting Nuts w/Torque Specification
Courtesy of AMERICAN HONDA MOTOR CO., INC.
- Apply grease to the clevis pin (6), and slide it into the yoke, then install a new lock pin (C).
- Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT
).
- Bleed the clutch hydraulic system (see CLUTCH HYDRAULIC SYSTEM BLEEDING
).
- Install the battery base (see ENGINE INSTALLATION
).
- Install the air cleaner assembly (see
AIR CLEANER REMOVAL/INSTALLATION
).
- 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.
- Enter the anti-theft codes for the audio system and navigation system (if equipped), then enter the audio presets.
- Set the clock (on vehicles without navigation).
- Check the clutch operation, and check for leaks.
- 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.
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- Make sure you have the anti-theft codes for the audio system and navigation system (if equipped), then write down the audio presets.
- Disconnect the negative cable from the battery, then disconnect the positive cable.
- Remove the battery.
- Remove the air cleaner assembly (see
AIR CLEANER REMOVAL/INSTALLATION
).
- Remove the battery base (see ENGINE REMOVAL
).
- Remove the clutch line bracket.
Fig. 17: Identifying Clutch Line Bracket And Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
- 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.
- 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.
- 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.
- Pull back the boot (B), and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot.
- 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).
- Bleed the clutch hydraulic system (see CLUTCH HYDRAULIC SYSTEM BLEEDING
).
- Install the battery base (see ENGINE INSTALLATION
).
- Install the air cleaner assembly (see
AIR CLEANER REMOVAL/INSTALLATION
).
- 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.
- Enter the anti-theft codes for the audio system and navigation system (if equipped), then enter the audio presets.
- Set the clock (on vehicles without navigation).
- Check the clutch operation, and check for leaks.
- 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
- 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.
- 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.
- To prevent warping, unscrew the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
- 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.
- Inspect the pressure plate surface (A) for wear, cracks, and burning.
Fig. 23: Identifying Pressure Plate Surface
Courtesy of AMERICAN HONDA MOTOR CO., INC.
- 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.
- 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.
- 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.
- 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.
- 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
- Inspect the crankshaft pilot bushing for wear and damage.
- 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
- 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.
- 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
- Inspect the ring gear teeth for wear and damage.
- Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
- 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
- Install the ring gear holder (A).
Fig. 32: Identifying Ring Gear Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
- Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel and ring gear holder.
- Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
- 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
- Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
- 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.
- Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (B).
- 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).
- 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.
- 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.
- Remove the ring gear holder (A), clutch alignment shaft (B), and remover handle (C).
- Make sure the diaphragm spring fingers are all the same height.
Release Bearing Replacement
- 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.
- Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).
- 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.
- 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.
- 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.
- Align the detent of the release fork with the release fork bolt, then squarely press the release fork over the release fork bolt.
- Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.
- 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.