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 before disposal.
Removal
Clutch slave disc assembly
1 - Friction linings - in the picture worn below the permissible limit
2 - Rivets - used to secure friction linings and when the latter wear excessively, they begin to leave grooves on the working surface of the flywheel
3 - Torsion springs or dampers - should be checked for cracks and signs of deformation
4 - Splined hub - should slide freely on the splines of the gearbox input shaft, the splines should not be excessively worn
5 - Marking the side of the disc facing the flywheel-usually in the form of an inscription like "Flywheel side"
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 large amount of mechanical work required to provide access to the clutch assembly, it makes sense to replace the latter regardless of the condition of its components. Below is a description of the procedure for removing the clutch without removing the engine from the car.
2. Remove the gearbox (see Removal and installation of manual transmission). Support the engine with a jack or hang it from above with a winch (preferably the latter). If you use a jack, do not forget 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 their original locations, but their condition should also be checked (see section Removal, checking the condition and installing the release bearing and clutch release lever).
4. To prevent the driven disk from falling out when removing the basket, insert a tool designed for clutch centering 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/
6. Working diagonally, in several steps, evenly loosen the bolts securing the clutch basket to the flywheel, completely releasing the diaphragm spring.
7. While supporting the clutch assembly securely, remove the bolts completely, then separate the clutch basket from the flywheel and remove the 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 other components of the assembly.
2. Inspect 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). The procedures for removing and installing the flywheel are described 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. As mentioned above, it is reasonable to replace the clutch components every time the assembly is dismantled, so pay attention to the slightest errors.
4. The release bearing is always replaced together with the driven disk (see section Removal, checking the condition and installing the release bearing and clutch release lever).
5. Assess the condition of the machined surfaces and petals of the diaphragm spring of the pressure plate. If defects are found, replace the basket assembly. Traces of light polishing can be removed using fine-grained sandpaper. A restored clutch assembly can always be purchased on an exchange basis through Honda service stations.
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 a tool inserted into it and fixed for centering the components of the driven disk) to the flywheel. Make sure that the clutch disc is turned towards the flywheel marked with the appropriate marking (like "Flywheel side") side. If there is no marking, remember that the driven disk is always installed with torsion springs/dampers to the gearbox.
3. Hand tighten the assembly-to-flywheel mounting bolts.
4. Center the clutch assembly components. The special tool is passed through the driven disk hub and inserted into the pocket in the end of the crankshaft journal. To align the components, move the tool in different directions in the vertical and horizontal planes. Acting diagonally, tighten the assembly mounting bolts tightly in several steps, then tighten them with the required force. Remove the clutch centering tool.
5. Pack the inner groove of the release bearing with high-melting grease (see section Removal, checking the condition and installing the release bearing and clutch release lever). Also lubricate the contact surfaces of the clutch release lever and the gearbox input shaft journal.
6. Install the release bearing (see section Removal, checking the condition and installing the release bearing and clutch release lever).
7. Install the transmission and all components removed for access. Ensure that all fasteners are tightened to the appropriate torque.