Acura Coupes and Sedans 1994-2000 Repair Information

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



The radio may have a coded theft protection circuit. Make sure you have the code before disconnecting the battery, removing the radio fuse, or removing the radio.

Integra

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the manual transaxle assembly from the vehicle.
  6.  

See Figure 1

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Fig. Fig. 1: View of the transaxle, once it is separated from the engine

  1. Insert the a suitable clutch alignment shaft with the suitable clutch alignment disc part and handle part. Use a feeler gauge and measure the clearance between the pressure plate spring fingers and the clutch alignment disc. There should be a maximum of 0.02 in. (0.6mm) of clearance for a new pressure plate with 0.03 in. (0.8mm) limit for a used pressure plate.
  2.  
  3. Remove the clutch alignment disc.
  4.  
  5. Install a suitable flywheel holder tool to aid in the removal of the pressure plate and clutch disc.
  6.  
  7. Matchmark the flywheel and pressure plate for easy reassembly. Remove the pressure plate bolts in a criss-cross pattern 2 turns at a time to prevent warping the plate.
  8.  

See Figure 2

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Fig. Fig. 2: Loosen the pressure plate bolts in a criss-cross pattern. This will prevent the plate from bending during the removal procedure

  1. Remove the pressure plate, then the clutch disc with the alignment shaft
  2.  

See Figures 3, 4 and 5

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Fig. Fig. 3: Remove the pressure plate and clutch disc from the flywheel



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Fig. Fig. 4: Clutch disc and alignment tool removal



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Fig. Fig. 5: Inspect the clutch disc for signs of uneven wears

To install:

See Figures 6, 7 and 8

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Fig. Fig. 6: Always check the rear main seal for oil leaks that may contaminate the friction surface of the clutch disc. Replace the seal if a leak is detected



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Fig. Fig. 7: Notice the surface of this flywheel. Surface irregularities such as these are caused by constant overheating of the flywheel surface. While machining the surface may be possible, it is advised that the clutch be replaced



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Fig. Fig. 8: This is how the clutch alignment tool should appear after it has been inserted into the pilot bearing

  1. If the flywheel was removed, align the hole in the flywheel with the crankshaft dowel pin and install the mounting bolt finger-tight.
  2.  
  3. Install the flywheel holder, then tighten the flywheel mounting bolts in a criss-cross pattern in several steps. The mounting bolt final torque should be 76 ft. lbs. (103 Nm).
  4.  
  5. Apply a suitable high temperature grease part to the splines of the clutch disc, then install the clutch disc using the clutch alignment shaft.
  6.  
  7. Install the pressure plate, tighten the mounting bolts to 19 ft. lbs. (25 Nm), in the proper sequence shown in the accompanying figure.
  8.  

See Figure 9

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Fig. Fig. 9: Pressure plate bolt tightening sequence-Integra shown

  1. Remove the flywheel holding tool and the clutch alignment shaft
  2.  
  3. Insert the clutch alignment shaft with the clutch alignment disc and handle. Use a feeler gauge and measure the clearance between the pressure plate spring fingers and the clutch alignment disc. There should be a maximum of 0.02 in. (0.6mm) of clearance for a new pressure plate with 0.03 in. (0.8mm) limit for a used pressure plate.
  4.  
  5. Install the transaxle assembly.
  6.  
  7. Connect the negative battery cable and enter the radio security code.
  8.  

2.2L, 2.3L CL

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the starter motor.
  4.  
  5. Disconnect the hydraulic coupling for the slave cylinder at the transaxle by sliding the sleeve on the tube towards the slave cylinder and applying a slight pulling force to the tube.
  6.  
  7. Remove the transaxle.
  8.  
  9. Mark the assembled position of the clutch and pressure plate to the flywheel if it is to be reinstalled.
  10.  

The clutch pressure plate is only held in place by the retaining bolts. No dowel pins are used, therefore the pressure plate must be supported when removing the retaining bolts.

  1. Loosen the pressure plate bolts evenly until the pressure plate spring pressure is released, then finish removing the bolts while supporting the clutch and pressure plate assembly.
  2.  

See Figures 10, 11 and 12

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Fig. Fig. 10: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 11: ... then carefully removing the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 12: Exploded view of the clutch disc, pressure plate and related component mounting

  1. Remove the clutch and pressure plate from the vehicle.
  2.  
  3. Inspect the flywheel, slave cylinder and other components for wear or damage.
  4.  

See Figures 13 and 14

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Fig. Fig. 13: Check the pressure plate for excessive wear



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Fig. Fig. 14: Be sure that the flywheel surface is clean, before installing the clutch

To install:
  1. Clean the pressure plate and flywheel surfaces.
  2.  
  3. Install the clutch disc using an appropriate clutch aligning tool.
  4.  

See Figure 15

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Fig. Fig. 15: Insert an alignment tool through the clutch disc to ensure that it is centered after the pressure plate is installed

If the clutch disc and pressure plate are being reused, align the marks made during disassembly.

  1. Install an appropriate flywheel holding tool to hold the flywheel.
  2.  

See Figures 16 and 17

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Fig. Fig. 16: Typical clutch alignment tool, note how the splines match the transaxle's input shaft



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Fig. Fig. 17: Use the clutch alignment tool to align the clutch disc during assembly

  1. Install the pressure plate and start the retaining bolts.
  2.  

See Figure 18

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Fig. Fig. 18: The pressure plate-to-flywheel bolt holes should align

  1. Tighten the retaining bolts evenly and in sequence to 13-18 ft. lbs. (18-26 Nm).
  2.  

See Figures 19, 20 and 21

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Fig. Fig. 19: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 20: Be sure to use a torque wrench to tighten all bolts



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Fig. Fig. 21: Tighten the pressure plate bolts gradually and in the sequence shown to ensure correct clutch operation

  1. Remove the clutch aligner tool.
  2.  
  3. Reinstall the transaxle.
  4.  
  5. Reconnect the slave cylinder tube coupling by pushing the male coupling into the slave cylinder female coupling.
  6.  
  7. Lower the vehicle.
  8.  
  9. Reconnect the negative battery cable.
  10.  
  11. Bleed the hydraulic clutch system, if required.
  12.  
  13. Check the clutch system for proper operation.
  14.  

Legend

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the transaxle from the vehicle, as outlined earlier.
  6.  
  7. Matchmark the flywheel and pressure plate for reassembly. Remove the pressure plate bolts in a criss-cross pattern 2 turns at a time to prevent warping the plate.
  8.  
  9. Inspect the pressure plate and clutch disk for signs of wear.
  10.  
  11. Inspect the flywheel for scoring and wear. Use a dial indicator to make sure it is flat and resurface or replace, as necessary.
  12.  

To install:
  1. Make sure the flywheel and the end of the crankshaft are clean before assembly. Tighten the flywheel bolts, in a criss-cross pattern, to 76 ft. lbs. (105 Nm).
  2.  
  3. Apply grease to the splines of the clutch disc, and install the clutch disc using a clutch alignment shaft.
  4.  
  5. Install the release bearing on the pressure plate, then install the pressure plate. When installing the pressure plate, align the mark on the outer edge of the flywheel with the alignment mark on the pressure plate. Failure to align these marks will result in imbalance.
  6.  
  7. Tighten the pressure plate bolts using an alignment shaft to center the friction disc. After centering the disc, tighten the bolts 2 turns at a time, in a criss-cross pattern to avoid warping the diaphragm springs; torque to 19 ft. lbs. (26 Nm).
  8.  
  9. Jack the transaxle into place and make sure the mainshaft is properly aligned with the disc spline and that the aligning pins are in place.
  10.  
  11. Install the transaxle and tighten the mounting bolts to 55 ft. lbs. (75 Nm).
  12.  
  13. Install and connect the slave cylinder and its hydraulic line. Fill the reservoir with fluid.
  14.  
  15. Verify that all wiring harnesses, vacuum lines, and linkages are connected properly.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Check the clutch adjustment and road test the vehicle.
  20.  

Vigor

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the transaxle from the vehicle, as outlined earlier.
  4.  
  5. Remove the slave cylinder with the hydraulic hose still connected. Remove the boot from the clutch case and remove the release fork with the bearing.
  6.  
  7. Matchmark the flywheel and pressure plate for easy reassembly. Remove the pressure plate bolts in a criss-cross pattern 2 turns at a time to prevent warping the plate.
  8.  
  9. Inspect the flywheel for scoring and wear. Use a dial indicator to make sure it is flat and reface or replace, as necessary.
  10.  

To install:
  1. Make sure the flywheel and the end of the crankshaft are clean before assembly. Tighten the flywheel bolts, in a criss-cross pattern, to 76 ft. lbs. (103 Nm).
  2.  
  3. Apply grease to the splines of the clutch disc, and install the clutch disc using a clutch alignment shaft.
  4.  
  5. Install the release bearing on the pressure plate, then install the pressure plate. When installing the pressure plate, align the mark on the outer edge of the flywheel with the alignment mark on the pressure plate. Failure to align these marks will result in imbalance. After installing the pressure plate, make sure the release bearing does not come off.
  6.  
  7. Tighten the pressure plate bolts using a pilot shaft to center the friction disc. After centering the disc, tighten the bolts 2 turns at a time, in a criss-cross pattern to avoid warping the diaphragm springs; tighten to 19 ft. lbs. (26 Nm).
  8.  
  9. Install the transaxle, make sure the mainshaft is properly aligned with the disc spline and the aligning pins are in place, before tightening the case bolts.
  10.  

ADJUSTMENTS Clutch Pedal Free-Play



The clutch is self-adjusting to compensate for wear.

  1. Loosen the locknut at the base of the clutch switch.
  2.  
  3. Loosen the locknut at the rear of the pedal pin.
  4.  
  5. Turn the pushrod in or out to obtain the specified amount of pedal play.
  6.  
  7. Tighten the locknut located to the rear of the pedal pin.
  8.  
  9. Turn the clutch switch until it contacts the pedal shaft.
  10.  
  11. Turn the clutch switch one turn farther.
  12.  
  13. Tighten the locknut on the switch.
  14.  
  15. Loosen the locknut on the clutch interlock switch.
  16.  
  17. Measure the clearance between the clutch pedal and the floor board with the clutch pedal depressed.
  18.  
  19. Allow the clutch pedal to rise from the floor until it is 0.59-0.79 inch. (15-20 mm) above the full bottom measurement.
  20.  
  21. Adjust the interlock switch so that the engine will start from this position.
  22.  
  23. Turn the interlock switch three quarters to one turn further.
  24.  
  25. Tighten the locknut to secure the position of the clutch interlock switch.
  26.  

 
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