group 12 clutch

8/6/2019 Group 12 Clutch

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8 G V U 8 C Q @ 9 6 G Q P T D U D P I T X D U 8 C Adjustment, page 12-4! 8 G V U 8 C Q @ 9 6 G Adjustment, page 12-4" 8 G V U 8 C H 6 T U @ S 8 ` G D I 9 @ S Replacement, page 12-5 ; Overhaul, page 12-6# 8 G V U 8 C 9 D T 8 Removal, page 12-11 ; Installation, page 12-14$ S @ G @ 6 T @ 7 @ 6 S D I B Replacement, page 12-15% T G 6 W @ 8 ` G D I 9 @ S Replacement, page 12-8 ; Overhaul, page 12-10& Q S @ T T V S @ Q G 6 U @ Removal, page 12-11 ; Installation, page 12-14' A G ` X C @ @ G Inspection, page 12-13 ; Replacement, page 12-13

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NOTE:To check the clutch pedal position switch (see page 04-49) .Remove the drivers side floor mat before adjusting theclutch pedal.The clutch is self-adjusting to compensate for wear.If there is no clearance between the master cylinderpiston and push rod, the release bearing will be heldagainst the diaphragm spring, which can result in clutchslippage or other clutch problems.

Loosen locknut (A), and back off the clutch pedalposition switch or clutch pedal adjusting bolt (B)until it no longer touches the clutch pedal (C).

Loosen locknut (D), and turn the push rod (E) in orout to get the specified height (F), stroke (G), freeplay (H) and disengagement height (I) at the clutchpedal.8 y p u Q r q h y T x r ) ! $ " $ # ( ! $ " v

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Tighten locknut (D).

With the clutch pedal released, turn the clutchpedal position switch or clutch pedal adjusting bolt

(B) in until it contacts the clutch pedal (C).Turn the clutch pedal position switch or clutchpedal adjusting bolt (B) in an additional 3/4 to 1turn.

Tighten locknut (A).

Press the clutch pedal to the floor.

Release the clutch pedal 10 - 16 mm (0.39 - 0.63in.) from the fully depressed position, and hold itthere. Adjust the position of the clutch interlockswitch (K) so that the engine will start with theclutch pedal in this position.

Tighten locknut (J).
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NOTE: Do not spill brake fluid on the vehicle; it maydamage the paint; if brake fluid does contact the paint,wash it off immediately with water.

Remove the brake fluid from the clutch mastercylinder reservoir with a syringe.

Remove the retaining clip (A). Disconnect theclutch line (B). Plug the end of the clutch line with ashop towel to prevent brake fluid from coming out.

Disconnect the reservoir hose (C) from the clutchmaster cylinder reservoir. Plug the end of thereservoir hose with a shop towel to prevent brakefluid from coming out.

Pry out the lock pin (A), and pull the pedal pin (B)out of the yoke. Remove the master cylindermounting nuts (C).

Remove the clutch master cylinder (A).

Remove the O-ring (B) and the clutch master

cylinder seal (C) from the master cylinder.Install the clutch master cylinder in the reverseorder of removal. Install a new O-ring. Tighten themaster cylinder mounting nuts to 13 N m(1.3 kgf m, 9.4 lbf ft). Make sure the tabs on themaster cylinder hose clamps are pointed in thedirections shown.

To prevent the retaining clip (A) from coming off,pry to open the tip of the retaining clip (B) with ascrewdriver.

Bleed the clutch master hydraulic system (see step11 on page 12-9 ).NOTE: The reservoir filling is covered in the bleedingprocedure.


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NOTE:

When attaching the reservoir hose, align the yellow mark on the hose to the rib on reservoir connection area.When attaching the reservoir hose, align the blue mark on the hose to rip on the clutch master cylinder connection area.

Clip catches shall beon arrow marked side

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Check for damageand bending.

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Check for scoring and wear.

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Check the cylinder wall forscoring and wear.

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Clip catches shall be onarrow marked side.

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Inspect for damage,

leaks interference, andtwisting.

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NOTE:Use fender covers to avoid damaging painted surfaces.Do not spill brake fluid on the vehicle; it may damage thepaint; if brake fluid does contact the paint, wash it offimmediately with water.

Write down the frequencies for the radios presetbuttons. Disconnect the negative (-) cable first,then the positive (+) cable from the battery.Remove the battery.

Remove the air cleaner housing (see step 5 onpage 05-3 ).

Remove the intake air duct (see step 6 on page 05-3).

Remove the battery tray.

Remove the clutch line bracket (A).

Remove the mounting bolts (A) and the slavecylinder (B).

Remove the roll pins (C). Disconnect the clutch line(D), and remove the O-ring (E). Plug the end of theclutch line with a shop towel to prevent brake fluidfrom coming out.

Install the slave cylinder in the reverse order ofremoval. Install a new O-ring (A).

Pull the boot (B) back, and apply brake assemblylube to the boot and slave cylinder rod (C).Reinstall the boot.

Apply Urea Grease UM264 (P/N 41211-PY5-305)to the push rod of the slave cylinder. Tighten theslave cylinder mounting bolts to 22 N m (2.2 kgf m,16 lbf ft).

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Bleed the clutch hydraulic system.

Attach a hose to the bleeder screw (A), and suspendedthe hose in a container of brake fluid.

Make sure there is an adequate supply of f luid at theclutch master cylinder, then slowly pump the clutchpedal until no more bubbles appear at the bleeder hose.

Tighten the bleed screw to 8 N m (0.8 kgf m, 6 lbf ft); donot overtighten it.

Refill the clutch master cylinder with fluid when done.

Always use only Genuine Honda DOT 3 or 4 brake fluid.

Install the clutch line bracket and battery tray.

Install the intake air duct (see step 38 on page 05-16 ).

Install the air cleaner housing (see step 39 on page05-17 ).
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Check that it is fitted securelyover the cylinder body.

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Install with small end facing piston.

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Check the cylinder wall forscoring and wear.


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Check the diaphragm spring fingers for heightusing the dial indicater (A). If the height is morethan the service limit, replace the pressure plate.T h q h q I r ) % ! v h

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Install the special tools.

To prevent warping, unscrew the pressure plate

mounting bolts (A) in a crisscross pattern in severalsteps, then remove the pressure plate (B).

Inspect the pressure plate (A) surface for wear,cracks, and burning.

Inspect the fingers of the diaphragm spring (B) forwear at the release bearing contact area.

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Inspect for warpage using a straight edge (A) andfeeler gauge (B). Measure across the pressure

plate (C). If the warpage is more than the servicelimit, replace the pressure plate.T h q h q I r ) " v h

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Remove the clutch disc and special tools.

Inspect the lining of the clutch disc for signs ofslipping or oil. If the clutch disc is burned black oroil soaked, replace it.

Measure the clutch disc thickness. If the thicknessis less than the service limit, replace the clutchdisc.

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Measure the rivet depth from the clutch disc liningsurface (A) to the rivets (B) on both sides. If therivet depth is less than the service limit, replace theclutch disc.T h q h q I r ) % $ ! ! $

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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 dialindicator (B) through at least two full turns with theengine installed. Push against the flywheel eachtime you turn it to take up the crankshaft thrustwasher clearance. If the runout is more than theservice limit, replace the flywheel and recheck therunout. Resurfacing the flywheel is notrecommended.T h q h q I r ) $ ! v h

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Install the special tool.

Remove the flywheel mounting bolts in a crisscross

pattern in several steps, then remove the flywheel.Install the flywheel on the crankshaft, and install themounting bolts finger-tight.

Install the special tool, then torque the flywheelmounting bolts in a crisscross pattern in severalsteps.

(contd)


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Install the ring gear holder.

Apply Urea Grease UM264 (P/N 41211-PY5-305)to the splines (A) of the clutch disc (B), then installthe clutch disc using the special tools.

Install the pressure plate (A) and the mountingbolts (B) finger-tight.

Torque the mounting bolts in a crisscross pattern.Tighten the bolts in several steps to preventwarping the diaphragm spring.

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Remove the special tools.

Make sure the diaphragm spring fingers are all thesame height.


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Remove the release fork boot (A) from the clutchhousing (B).

Remove the release fork (C) from the clutchhousing (B) by squeezing the release fork setspring (D) with pliers. Remove the release bearing(E).

Check the release bearing for play by spinning it byhand. If there is excessive play, replace the releasebearing with a new one.NOTE: The release bearing is packed with grease. Donot wash it in solvent.

Apply Urea Grease UM264 (P/N 41211-PY5-305)to the release fork (A), the release fork bolt (B), therelease bearing (C), and the release bearing guide(D) in the shaded areas.

With the release fork slid between the releasebearing pawls, install the release bearing on themainshaft while inserting the release fork throughthe hole in the clutch housing.

Align the detent of the release fork with the releasefork bolt, then press the release fork over therelease fork bolt squarely.

Install the release fork boot (E), make sure the bootseals around the release fork and clutch housing.

Move the release fork (A) right and left to makesure that it fits properly against the release bearing(B), and that the release bearing slides smoothly.


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group 12 clutch

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