Warning! Remember that the dust produced during the wear of the friction linings of the clutch disc may contain asbestos, which is harmful to health. Do not blow off dust with compressed air and try not to inhale it. Do not use petroleum-based solvents to clean clutch components, use only special brake cleaners or pure methanol. Store used rags in a sealed container.
Withdrawal
1. In order to gain access to the clutch assembly, it is common to remove the transmission while leaving the engine on the vehicle. If the engine has already been removed for general or overhaul, the condition of the clutch components must be checked without fail. Bearing in mind the relatively low cost of parts and the rather high amount of locksmith work to provide access to the clutch assembly, it makes sense to replace the latter, regardless of the condition of the components. Below is a description of the procedure for removing the clutch without removing the engine from the vehicle.
2. Remove the gearbox (see 5-speed manual gearbox). Support the engine with a jack, or hang it from above on a winch (preferably the latter). If using a jack, be sure to place a piece of wood between the jack head and the sump to distribute the load.
Attention! The oil pump intake is located very close to the bottom of the oil pan and can easily be damaged if the latter is deformed.
3. The release fork and release bearing can be left in place in the transmission case.
4. To prevent the driven disc from falling out when removing the basket, thread a special tool for centering the clutch into its hub.
5. Carefully inspect the surfaces of the flywheel and clutch basket assembly for markings (usually in the form of letters X or O applied with white paint). If you cannot find the marking, apply it yourself, clearly marking the position of the basket relative to the flywheel (see accompanying illustration).
6. Working diagonally, evenly loosen the clutch basket-to-flywheel bolts in several steps (see accompanying illustration), fully unloading the spring. While firmly supporting the clutch assembly, finally remove the bolts, then separate the basket from the flywheel and remove the entire assembly from the vehicle.
Examination
1. Most often, the malfunction of the clutch is associated with the wear of the friction linings of the driven disk. However, you must carefully examine the status of all assembly components.
2. Examine the working surface of the flywheel for cracks, traces of overheating, grooves and other damage. Minor defects can be eliminated by turning in the conditions of a car service workshop (the groove is recommended to be made regardless of the state of the surface). Description of the procedures for removing and installing the flywheel is given in the relevant Section of the Chapter Engine.
3. Assess the degree of wear of the friction linings of the clutch driven disk. The surface of the overlays must rise above the heads of the rivets by at least 1.6 mm. Make sure that all rivets are firmly seated, check torsion springs / dampers for cracks, signs of deformation and other mechanical damage (see accompanying illustration). As mentioned above, it is reasonable to replace clutch components every time they are removed, so pay attention to the slightest errors.
4. Together with the driven disk, the release bearing is also always replaced (see Removing, checking the condition and installing the release bearing and clutch release fork). Take this opportunity, at the same time check the condition of the pilot bearing in the crankshaft journal (see Checking the condition and replacing the guide bearing).
5a. Evaluate the condition of the machined surfaces and petals of the pressure plate diaphragm spring (see accompanying illustrations).
5b. Check the friction surface for damage. If defects are found, replace the basket assembly. Light polishing marks can be removed with fine sandpaper. You can always purchase a remanufactured assembly on an exchange basis at Honda branded service centers.
Installation
1. Before installation, wipe the machined surfaces of the flywheel and pressure plate with a rag soaked in acetone. It is extremely important to achieve complete degreasing of the working surfaces of the components, as well as the friction linings of the driven disk. Only touch the components with clean, washed hands.
2. Press the basket assembly with the component centering tool inserted and fixed with the driven disk against the flywheel. Make sure that the clutch discs are turned to the flywheel marked with the appropriate marking (type "flywheel side") parties. If there is no marking, remember that the driven disk must be installed with torsion springs / dampers to the gearbox.
3. Hand-tighten the bolts securing the assembly to the flywheel.
4. Center the clutch assembly components. A special tool is threaded through the hub of the driven disk and tucked into a pocket in the end of the crankshaft trunnion (see accompanying illustration). To align the components, move the tool in different directions in a vertical plane. Moving in a diagonal manner, tighten the assembly fastening bolts tightly in several steps, then tighten them with the required force. Remove the clutch centering tool.
5. Fill the inner groove of the release bearing with refractory grease (see Removing, checking the condition and installing the release bearing and clutch release fork). Also lubricate the contact surfaces of the clutch release lever and the transmission input shaft bearing holder.
6. Install the release bearing (see Checking the condition and replacing the guide bearing).
7. Establish a transmission and all components removed for the purpose of providing access.