Warning! Remember that dust generated during wear of the clutch slave disk friction linings 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 wipe clutch components – use only special brake cleaners or pure methyl alcohol. Place used rags in a hermetically sealed container.
Removal
1. In order to provide access to the clutch assembly, the gearbox is usually removed, leaving the engine in the car. If the engine has already been removed for general or major repairs, the condition of the clutch components must be checked without fail. Considering the relatively low cost of the parts and the fairly high volume of mechanical 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 car.
2. Remove the gearbox (see 5-speed manual transmission). Support the engine with a jack or hang it from above with a winch (preferably the latter). If you use a jack, remember to place a wooden block between its head and the oil pan to distribute the load.
Attention! The oil intake of the oil pump is located very close to the bottom of the oil pan and can easily be damaged if the latter is deformed.
3. The clutch release fork and release bearing can be left in place in the transmission housing.
4. To prevent the driven disk from falling out when removing the basket, insert a special clutch centering tool 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 painted in white). 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, in several steps, evenly loosen the bolts securing the clutch basket to the flywheel (see accompanying illustration), completely unloading the spring. While securely supporting the clutch assembly, remove the bolts completely, 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 wear of the friction linings of the driven disk. However, it is necessary to carefully examine the condition of all components of the assembly.
2. Examine the flywheel working surface for cracks, traces of overheating, grooves and other damage. Minor defects can be eliminated by turning in a car service workshop (it is recommended to perform turning regardless of the surface condition). A description of the flywheel removal and installation procedures is given in the corresponding Section of the Chapter Engine.
3. Assess the degree of wear of the friction linings of the driven clutch disc. The surface of the linings should rise above the rivet heads by at least 1.6 mm. Make sure that all rivets are tightly seated, check the torsion springs/dampers for cracks, signs of deformation and other mechanical damage (see accompanying illustration). As mentioned above, it is wise to replace clutch components every time they are removed, so pay attention to the slightest errors.
4. The release bearing is always replaced together with the driven disk (see Removal, condition check and installation of the release bearing and clutch release fork). While you're at it, check the condition of the guide bearing in the crankshaft journal (see Checking the condition and replacing the guide bearing).
5a. Assess the condition of the machined surfaces and petals of the diaphragm spring of the pressure plate (see accompanying illustrations).
5b. Check the friction surface for damage. If any defects are found, replace the basket assembly. Light polishing marks can be removed with fine-grained sandpaper. A reconditioned assembly can always be purchased on an exchange basis from Honda 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. Touch the components only with clean hands.
2. Press the basket assembly with the tool for centering the components inserted and fixed into it with the driven disk to the flywheel. Make sure that the clutch disks are turned towards the flywheel and marked with the appropriate marking (like "flywheel side") sides. If there is no marking, remember that the driven disk must be installed with torsion springs/dampers to the gearbox.
3. Hand tighten the assembly-to-flywheel mounting bolts.
4. Center the clutch assembly components. A special tool is inserted through the driven disk hub and inserted into a pocket in the end of the crankshaft journal (see accompanying illustration). To align the components, move the tool in different directions in the vertical plane. Moving diagonally, tighten the assembly mounting bolts tightly in several steps, then tighten them to the required force. Remove the clutch centering tool.
5. Pack the inner groove of the release bearing with high-melting grease (see Removal, condition check and installation of the release bearing and clutch release fork). Also lubricate the contact surfaces of the clutch release lever and the gearbox input shaft bearing holder.
6. Install the release bearing (see Checking the condition and replacing the guide bearing).
7. Install the gearbox and all components removed for access.
[Refer to the original source on the website Hondabook.ru]