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. Place used rags in a sealed container before disposal.
Removing
Assembling the clutch disc
1 - Friction lining - worn below the permissible limit in the picture
2 - Rivets - used to fasten friction linings and, if the latter are worn 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 - must slide freely over the splines of the gearbox input shaft, the splines must 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 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. Given the relatively low cost of parts and the rather large amount of locksmith work 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 vehicle.
2. Remove the gearbox (see Removal and installation of manual transmission). 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 clutch release fork and release bearing can be left in their original places, but their condition should also be checked (see Section Removing, 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, thread a tool designed to center 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 /
6. Working diagonally, evenly loosen the bolts securing the clutch basket to the flywheel in several stages, completely unloading the diaphragm spring.
7. While firmly supporting the clutch assembly, finally remove the bolts, then separate the basket from the flywheel and remove the assembly from the vehicle.
Examination
1. Most often, a malfunction in the functioning of the clutch turns out to be associated with wear of the friction linings of the driven disk. However, you should carefully examine the status of all other assembly components.
2. Inspect the flywheel running surface for cracks, overheating, gouges or 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 the torsion springs / dampers for cracks, signs of deformation and other mechanical damage. As mentioned above, it is reasonable to replace clutch components every time the assembly is dismantled, so pay attention to the slightest errors.
4. Together with the driven disk, the release bearing is also always replaced (see Section Removing, checking the condition and installing the release bearing and clutch release lever).
5. Estimate a condition of the processed surfaces and petals of a diaphragm spring of a pressure disk. If defects are found, replace the basket assembly. Light polishing marks can be removed with fine sandpaper. A remanufactured clutch assembly is always available through Honda Authorized Service Stations on an exchange basis.
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 nested and fixed tool for centering the components of the driven disk) to the flywheel. Make sure that the clutch disc is turned to the flywheel marked with the appropriate marking (type "Flywheel side") side. If there is no marking, remember that the driven disc is always 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 at the end of the crankshaft trunnion. To align the components, move the tool in different directions in the vertical and horizontal planes. Working diagonally, tighten the assembly mounting bolts firmly in several steps, then tighten them to the required torque. Remove the clutch centering tool.
5. Fill the inner groove of the release bearing with refractory grease (see Section Removing, 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 trunnion.
6. Install the release bearing (see Section Removing, checking the condition and installing the release bearing and clutch release lever).
7. Establish a transmission and all components removed for the purpose of providing access. Make sure all fasteners are tightened to the correct torque.