Clutch removal HONDA INTEGRA 1998 4.G Workshop Manual

Engine Removal/lnstallation
{cont'dl
7. Install the left front mount, then tighten the bolts in
the numbered sequence shown (O - @).
O t2 x '1.25 mm83 N.m 18.5 kgt.m,61 lbl.ft)Fleplace.
@ 12 x 1.25 mm59 N.m 16.0 kgf.m,43 lbf.frlReplace.
O 10 x 1.25 mmil4 N.m 14.5 kgt'm,33 lbt.ft)
,5-16
. Check that the spring clip on the end of each
driveshaft clicks into place.
CAUTION: Use new spring clips.
. Bleed air {rom the cooling system at the heater
valve open (see page 10-6).
. Adjust the throttle cable (see section 1 1).
. Check the clutch pedalfree play (see section 12).
. Check that the transmission shifts into gear
smoothlY.
. Adjust the tension of the following drive belts.
Alternator belt {see section 23).
P/S pump belt (see section 171.
A/C comDressor belt (see section 22).
! Inspect for tuel leakage (see section 1ll.. After assembling fuel line parts, turn on the
ignition switch (do not operate the staner) so
that the fuel pump operates for approximately
two seconds and the fuel line pressurizes.
Repeat this operation two or three times and
check for tuel leakage at any point in the {uel
line.

Clutch
Speciaf Tools ........ .'--"" 12-2
lflustrated Index ........ ".' 12-3
Clutch Pedal
Adjustment "..".""'...' 12-4
Clutch Master Cylinder
Removal/lnstallation -'.' 12-5
Slave Cylinder
Removal/lnstallation '..' 12-6
Pressure Plate
Removal/lnspection .'-.' 12-7
Clutch Disc
Removal/lnspection '...' 12-a
Flywheel, Flywheel Bearing
fnspection ' 12-9
Replacement .................'............. 1 2-9
Clutch Disc, Pressure Plate
lnstallation ................. 12-10
Release Bearing
Removal/lnspection "'.' 12-11
fnstaffation ".""".-'."'. 12-12

lllustrated Index
NOTE:
a Whenever the transmission is removed, clean and grease the release bearing sliding surface'
a lf the Darts marked with an asterisk (*) are removed, the clutch hydraulic system must be bled (see page 12-6).
a lnspect the hoses for damage, leaks, interference, and twisting.
*RESERVOIR
HOSE
.RESERVOIR
ASSIST SPRING
PEDAL PIN
CLUTCH PEDAL
Removal/lnspecrion, page 12 1 1fnstalfation, p,age 12 12
6 x 1.0 mm9.8 N.m 11.0 kst.m, 7 lbt'ftl
'15 N.m (1 .5 kgt.m,11 tbf.tr)
*CLUTCH MASTER CYLINDERRemoval/lnstallation, page 12-5
Adjustment,page 12 4
19 N.m 11.9 kgl.m,14 tbf.ft)
R€LEASE BEARING
15 N.m (1.5 kgf.m,11 lbf.fr)
ICLUTCH PIPE
.CLUTCH PIPE
FLYWHEELInspection, page 12-9Replacement, page 12-9
JOINT
I x 1.25 mm25 N.m {2.6 kgf.m,19 tbf.frl
I
TRANSMISSIONRemoval, see
CLUTCH DISCRemoval/lnspection, page 12-8lnstalfation, page 1 2 1O
section 1312 x 1.0 mm'103 N.m (10.5 kgl.m,76 tbf.fr)
PRESSURE PLATERemoval/lnspection, page 12 7Installation, page 12 10
8 x 1.25 mrr|22 N.m 12.2 kgt.n,16 lbf.ft)
24 N.m (2.4 kgf.m,17 tbf.tr)
15 N. m {1 .5 kgf.m,11 lbf.tr)
COTTERReplace.
I
WInl
9l
v.^- fl
*CLUTCH HOSE

CAUTION:
a Do not 3pill brakefluid on the vehicle; it may damege
th€ paid; if brake fluid do63 contact th€ paint. wa3h
it otf immediately with water.
a Plug the end of the clutch pipe and reservoir hose with
a shop towel to prevent brake fluid from coming out.
1. Remove the brake fluid trom the clutch master
cylinder reservoir with a syringe,
2. Disconnect the clutch pipe and reservoir hose from
the clutch master cylinder.
Remove the clutch master cylinder.
NOTE: Do not spill braketluid ontheclutch master
cylinder damper.
CLUTCH PIPE15 N.m {1 .5 kgf'm,11 lbt.Ir)
5.
cLulcHMASTERCYLINDER
Install the clutch master cylinder in the reverse or-
der of removal.
NOTE: Bleed the clutch hydraulic system {see page
I z-ol.cturcHMASTERCYLINDER
Pry out the cotter pin, and pull the pedal pin out of
the yoke. Remove the nuts.
NUTS13 N.m {1.3 kgt.m,9 rbf.ftl
PEOAL PIN
-6rl(P/N 08798-90021
Clutch Master Cylinder
Removal/lnstallation
2-5

T
fi
;ill
Slave Cylinder
Removal/lnstallation
CAUTION:
a Do not spill brakelluid onthe vehicle; it may dameg€
the paint; if brake fluid does coniaqt the paint, wash
it otf immodiaioly wilh w8ter.
a Plug the end of the clutch pipe with a shop towel to
prevent brake fluid from coming out.
-6|1, Super High Temp Urea Grease (P/N
4==? 08798- 9OO2).-='aii^5Fi: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch pipe from the slave cylinder.
2. Remove the slave cylinder from the clutch housing.
12-6
-Gl
lP/N 08798
Install the slave cylinder in the reverse order of
removal.
NOTE: Make sure the boot is installed on the slave
.wlin.larCLUTCH PIPE15 N.m 11.5 kgt.m, 11 lbf.ttl
SLAVE CYLINDER
*9002t
I x 1.25 rnm22 N.m 12.2 kgl.m,16 lbl.lt)
.'....-..-:::-9!!!!!i
{Brake Assembly '
Lube)
Bleed the clutch hydraulic system.
a Attach a hose to the bleeder screw, and suspend
the hose in a container ot brake fluid.
a lvlake sure there is an adequate supply ot fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
a Refill the clutch master cylinder with fluid when
done.
a Use only DOT 3 or 4 brake tluid.
We recommend Genuine Honda Super Duty
DOT 3.
a Confirm clutch operation. and check for leaking
fluid.

Pressure Plate
Removal/lnspectaon
1. Check the diaphragm spring fingers for height us-
ing the special tools and a feeler gauge.
Standsrd (New): 0.6 mm (0.02 in) max.
Service Limit: 0.8 mm {0.03 in)
07NAF-PR3010007936-3710100
lf the height is more than the service limit, replacethe hro..rr.a nlefe
2. Install the special tools.
CLUTCH ALIGNMENT SHAFT07NAF -PR30100
HANDLE
RING GEAR HOLDER07LAB- PVOo'l0O oro7924-PD20003
07936 - 3710100
PRESSURE PLATE
GEAR HOLDER
ADJUSTER NUT
3.
ADJUSTER BOLT
BOLT
WASHER
To prevent warping, unscrew the pressure plate
moi.rnting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
FEELER GAUGECLUTCH ALIGNMENT DISCOTJAF_PM7011A
5.
6.
Inspect the pressure plate surface for wear, cracks,
and burning.
Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
DIAPHRAGM SPRING
PRESSURE PLATE
Inspect for warpage using a straight edge and teel-
er gauge.
NOTE: Measure across the pressure plate at three
points.
Standard {New}: 0.03 mm {0.001 inl max.
Service Limit:0.15 mm (0.006 in)
lf the warpage is more thah the service limit,
replace the pressure plate.
STRAIGHT EDGE
2-7

rtr
1
Clutch Disc
Removal/lnspection
CLUTCH DISC
1. Remove the clutch disc and special tools.Measure the depth from the lining surface to the
rivets. on both sides.
Standa.d {N.w}: 1.2 - 1.7 mm (0.05 - 0.07 in} min.
Service Limit 0.2 mm (0.01 inl
07LAB- Pv001OO or07924 PD20003
CLUTCH ALIGNMENT SHAFT07NAF-PR30100HANDLE07936- 3710100
Inspect the lining of the clutch disc for signs of slip-ping or oil. lf it is burned black or oil soaked, replace
it.
Measure the clutch disc thickness. lf the thickness is
less than the service limit, replace the clutch disc.
Standard lNew): 8.3 - 9.0 mm 10.33 - 0.35 in)
Sorvica Limit 6.0 mm 10.2i[ inl
CLUTCH DISC
3.
lf the rivet depth is less than the service limit,
reolace the clutch disc.
CLUTCH DISC
LINING SURFACE
12-8

Release Bearing
Removal/lnspection
1. Remove the release fork
housrng.
boot from the clutch
5.
6.
Torque the mounting bolts in a crisscross pattern as
shown. Tighten the bolts in several steps to prevent
warping the diaphragm spring.
8 x 1.25 mm25 N.m {2.6 kgf.m,19 tb{.fr}
Remove the special tools.
Recheck the diaphragm spring fingers for height {seepage 12-7).
CLUTCH HOUSING
BELEASE AEAFING
RELEASE FORK
Remove the release fork from the clutch housing by
squeezing the release fork set spring with pliers. Re
move the release bearing.
Check the release bearing for play by spinning it by
hand. lf there is excessive play, replace the release
bearing with a new one.
CAUTION: The release bearing is packed wirhgrease. Do not wash it in solvent.
a;;;:
S",€ r
K4IN/
RELEASE BEARING

Manual Transmission
Special Tools ............. 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Transmission Assembly
Removal ................. 13-4
lllustrated Index ................................... 13-8
Transmission Housing
Removal ................. 13-10
Peverse Change Holder, Reverse ldler Gear
jGlearance Inspection ....................... 13-1 1
Removal ................. 13-12
Change Holder Assembly
Clearance Inspection .....,.,....,,.....,,.. 13-13
Removal ................. 13-15
Disassembly/Reassembly ............... 13-16
Mainshaft, Countershaft, Shift Fork
Removal ................. 13-17
Shift Rod
Removal ................. 13-18
Shift Fork Assembly
Index ................ ...... 13-19
Clearance lnspection ...................,.,. 13-20
Mainshaft Assembly
fndex ................ ......13-21
Clearance f nspection ..,,,.................. 13-22
Disassembly .......... 13-25
Inspection .............. 13-26
Reassembly ........... 13-21
Countershaft Assembly
Index ................ ...... 13-28
Clearance Inspection ....................... 13-29
Disassembly .......... 13-30
Inspestion .............. 13-31
Reassembly ........... 13-32
Synchro Sleeve, Synchro Hub
Inspection .............. 13-34
Installation ............. 13-34
Synchro Ring, Gear
Inspection .............. 13-35
Clutch Housing Bearing
Replacement ......... 13-36
Mainshaft Thrust Clearance
Adiustment ............ 13-38
Transmission
Reassembly ........... 13-41
Transmission Assembly
Installation ............. 13-46
Gearshift Mechanism
Overhaul ................ 13-51

Transmission Assembly
Removal
r@i Make surs iacks and safety stands sro placod propor-
ly (3ee s€ction 1).
. Apply parking brake and block resr whaeb 30 vohicle
will not roll off stands and hll on You whil6 working
under it.
CAUTION: Use fender covers to svoid damaging
paintod surtacos.
1. Disconnect the negative (-) cable from the battery,
then the positive {+) cable.
2. Remove the intake 8ir duct and the air cleaner hous-
ing assembly,
AIR CLEANERHOUSINGASSEMBL
Disconnect the back-up light switch connector and
the transmission ground wire.
BACK.UP LIGHTSWITCH CONNECTOR
TRANSMISSIONTRANSMISSIO
GROUND WIRE HANGEB B
4. Remove tne lowei radiator hose"clamp from the
transmission hsnger B.
INTAKE AIR DUCT
13-4
\-
5. Remove the wire hsrness clamps.
VSS CONNECTOR
Disconnect the starter motor cables and the vehicle
speed sensor (VSS) connector.
Remove the clutch pipe bracket and the slave cylin-
der.
NOT€: Do not operate the clutch pedsl once the
slave cvlinder has been removed.
7.