12-1 HONDA CIVIC 1999 6.G Workshop Manual

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Clutch
Speciaf Tools .......... ...........12-2
f lfustrated 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 ...... 12-8
Flywheel
Inspection ....................... 12-9
Replacement ....................................... 12-9
Clutch Disc, Pressure Plate
lnstallation ..................... 12-10
Release Bearing
Removal/lnspection ......12-11
f nstalfation .................,... 12-12
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Special Tools
ItJ
Ref. No. Tool NumberDescriptionOty Page Reterence
o
\31(
@
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OTJAF _ PM7O11A
OTJAF _ PM70124
07LAB - PV00100 or
07924, PD20003
07746 - 0010100
07749 - 00']0000
07936 - 3710100
Clutch Alignment Disc
Clutch Alignment Shaft
Ring Gear Holder
Attachment, 32 x 35 mm
Driver
Hand le
12-7
12-7 ,8, 10, 11't2-7,9,10,11
12 10
12-'tO
12-1 ,8, 10, 11
(r\aU
2-2

lllustrated Index
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NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
. lf the parts marked with an asterisk (*) are removed, the clutch hydraulic system mustbe bled (seepage 12-6)
. Inspect the hoses for damage, leaks, interference, and twisting
'RESERVOIF TANK
ASSIST SPRING
LOCK PIN
5x1,0mm9.8 N.m (1.0 kgf.m,7.2 tbtftl*CLUTCH LINE15 N.m {1.5 kgJ m,11 tbt.ft)
RELEASE BEARINGRemoval/lnspection, page 12-1 1Installation, page 12-'12
*CLUTCH MASTER CYLINDERRemoval/lnstallation, page 12 5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
FLYWHEELInspectaon, page 12IReplacement, Page 12-9
CLUTCH DISCRemoval/lnspection, page 1 2-8
lnstallation, page 12-'10
'12 x 1.0 mm118 N.m {12.0 kgt'm,86.8lbfft)
PBESSURE PLATEBemoval/lnspection, page 12 7Installation, page 12''10
8 x 1.25 mm22 N m (2.2 kgf.m, 16lbf ft)
ISLAVE CYLINDERRemoval/lnstallation, page 12_6
12-3

FlywheelClutch Disc, Pressure Plate
Replacement (cont'dl
4. Drive the new ball bearing into the flywheel using
the special tools as shown.
DRIVER07749-0010000
ATTACHMENT,32x35mm07746-OOIOTOO
FLYWHEEL
BEARING
Align the hole in the flywheel with the crankshaft
dowel pin and install the flywheel. Install the
mounting bolts finger-ti9ht.
Install special tool, then torque the flywheel mount-
ing bolts in a crisscross pattern in several steps as
snown.
5.
6.
MOUNTING BOLTS118 N.m (12.0 kgl.m,87 tbf.ft)
RING GEAR HOLDER07LAB-PV00100ol07924 -PO20003
WVa// ,
12-10
Installation
1. Install the special tool.
Y
07936-3710r00
{P/N 08798-90021
RING GEAR HOLDER07LAB-PVOO100ot07924-PD20003
CLUTCH ALIGNMENT SHAFTOTJAF_PM7012A
2.
3.
Installthe clutch disc using the special tools.
Install the pressure plate.
RING GEAR HOLDERoTLAB PV00'l OO
07924 PD20003
OTJAF_PM70124HANOLE07936-3710100
CLUTCH DISC

Release Bearing
)
4. Torque the mounting bolts in a crisscross pattern as
shown. Tighten them in several steps to prevent
warping the diaPhragm sPring.
19 rbf.ft)
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RING GEAR HOLDERoTLAB-PV00100ot07924-PD20003
CLUTCH ALIGNMENT SHAFT
OTJAF_PM7O12AHANOLE07936-3710100
MOUNTING BOLTS
8 x 1.25 mm
25 N.m (2.6 kgl'm.
Removal/lnspection
1. Remove the release fork boot from the clutch hous-
Ing.
2. Remove the release fork from the clutch housing by
squeezing the release fork set spring with pliers
Remove the release bearing.
Check the release bearing for play by spinning it by
hand.
CAUTION: The releass bearing is packed with
grease. Do not wash it in solvent.
lf there is excessive play, replace the release bear-
ing with a new one.
RELEASE FORK
12-11

Release Bearing
Installation
NOTE: Use only Super High Temp Urea Grease(P/N 08798 - 9002).
1. With the release fork slid between the release bear-
ing pawls, install the release bearing on the main-
shaft while inserting the release fork through the
hole in the clutch housing.
RELEASE FORK BOLT12 x 'l .25 mm
tP/N 0a79a-90021O.3-0.9 s 10.01 -O.03 ozl
Align the detent of the release fork with the release
fork bolt, then press the release fork over the
release fork bolt sequarely.
-Gr08798-9002)
2.
12-12
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3. Move the release fork right and left to make surethat it fits properly against the release bearing, and
that the release bearing slides smoothly.
4. Install the release fork boot; make sure the bootseals around the release fork and clutch housino.