Master23

To see the original article with images check it out here: Integra DC2 Clutch Assembly. Garage411.com

Clutch Master Cylinder Removal and Installation

Remove brake fluid from master cylinder. Disconnect fluid lines and reservoir hose from master cylinder. Plug end of line from fluid reservoir. Remove cotter pin from master cylinder push rod at clutch pedal. Remove mounting nuts and master cylinder. To install, reverse removal procedure . Bleed hydraulic system.

Clutch

Removal
1. Remove battery and battery tray. Remove air cleaner housing and air inlet duct as an assembly. Disconnect ground cable from transaxle. Remove lower radiator hose clamp from transaxle hanger.
2. Unplug connector from back-up light switch. Drain transaxle fluid. Remove vehicle speed sensor connector. Disconnect cables and wiring harness clamp from starter. Remove hydraulic hose bracket and clutch slave cylinder.
3. Remove 3 upper transaxle mounting bolts and lower starter bolts. Remove engine splash shield. Disconnect oxygen sensor connector. Remove exhaust pipe from catalytic converter and manifold. On models with VTEC engines, remove catalytic converter. On all models, separate lower right ball joint from control arm. Remove right damper fork. Remove axle shafts and intermediate shafts.
4. Remove heat shield. Disconnect shift rod and torque rod from transaxle. Remove front and rear engine braces. Remove clutch housing cover. Remove right front transaxle mount/bracket. Place floor jack under transaxle. Support engine with jack stands. Remove transaxle mount.
5. Remove rear transaxle mount bracket and mount bolts from side of transaxle. Check for wires, hoses, or any other components that may still be attached. Move transaxle away from engine until shaft clears clutch. Lower transaxle to remove from vehicle.
6. Before removing clutch from flywheel, measure diaphragm spring fingers wear with feeler gauge, Handle (07936-3710100), Clutch Alignment Shaft (07NAF-PR30100), and Clutch Alignment Disc (07JAFPM7011A). Wear limit is 0.03" (0.8 mm). Install flywheel holder. If reusing clutch, mark pressure plate and flywheel for installation reference. Unscrew pressure plate bolts 2 turns at a time in a crisscross pattern, to prevent warpage.

Inspection
1. Inspect pressure plate surface for wear, cracks, burning or warpage in excess of .006" (.15 mm). Measure warpage with straightedge and feeler gauge at several points. Inspect clutch pilot and release bearing for smooth operation and looseness. Replace bearings if necessary.
2. Inspect clutch disc lining for excessive wear and burned or oil-soaked condition. Measure disc thickness and rivet depth. Inspect clutch disc for loose torsion dampers. Measure clutch disc and flywheel runout. Replace clutch disc if not within specifications.
3. Inspect flywheel ring gear teeth for wear and damage. Inspect flywheel for wear, cracks and burned condition. When measuring flywheel runout, push against flywheel to take up crankshaft thrust washer clearance.

Use new set rings (spring clips) on both axle shafts. Slide axles in until set rings engage differential.

Installation
1. Tighten flywheel bolts to specification in a crisscross pattern. Align dowel holes in pressure plate with flywheel dowels. Using clutch alignment tool and ring gear holder, install disc and pressure plate. Tighten pressure plate bolts to specification in a crisscross pattern.
2. Ensure both dowel pins are installed in clutch housing. Clean release bearing sliding surface. Apply molybdenum disulfide grease to surface. Apply a light coat of grease to input shaft splines. Keep clutch disc and pressure plate surfaces free of grease and dirt.
3. To complete installation, reverse removal procedure. Tighten transmission mount bolts in sequence as illustrated. Refill all fluids to proper level. Adjust clutch pedal height and free play.

Clutch Specifications - In. (mm)

• Diaphragm Spring Finger Wear
  o Standard: (New) 0.02 (0.5)
  o Service Limit: 0.03 (0.8)
• Disc Thickness
  o Standard (New): 0.33-0.35 (8.4-9.0)
  o Service Limit: 0.24 (6.1)
• Disc Runout
  o Standard (New): 0.002 (0.05)
  o Service Limit: 0.006 (0.15)
• Flywheel Runout
  o Standard (New): 0.002 (0.05)
  o Service Limit: 0.006 (0.15)
• Pressure Plate Runout
  o Standard (New): 0.002 (0.05)
  o Service Limit: 0.006 (0.15)
• Rivet Depth
  o Standard (New): 0.05-0.07 (1.3-1.8)
  o Service Limit: 0.01 (0.3)

TORQUE SPECIFICATIONS - Ft. Lbs. (N.m)

• Ball Joint Castle Nut: 36-44 (49-59)
• Clutch Housing Cover Bolts
  o 6 mm: (1)
  o 8 mm: 17 (23)
  o 12 mm: 42 (57)
• Damper Fork Pinch Bolt: 47 (64)
• Engine Stiffener Bracket Bolts
  o 8 mm: 17 (23)
  o 12 mm: 42 (57)
• Exhaust Pipe-To-Catalyst Nuts
  o Rear: 24 (33)
  o Front: 12 (16)
• Exhaust Pipe-To-Manifold Nuts: 40 (54)
• Flywheel-To-Crankshaft Bolt: 76 (103)
• Intermediate Shaft Support Bolt: 29 (39)
• Master Cylinder Mounting Nuts: 10 (14)
• Pressure Plate-To-Flywheel Bolt: 19 (26)
• Right Front Transaxle Mount
  o Mounting Bolt: 32 (44)
  o Through-Bolt: 61 (83)
• Rear Transaxle Mount
  o Mounting Bolt: 47 (64)
  o Trough-Bolt: 55 (74)
• Release Fork Bolt: 21 (29)
• Slave Cylinder-To-Housing Bolt: 16 (22)
• Starter Bolt 32: (44)
• Transaxle-To-Engine Mounting Bolts
  o 12 mm: 47 (64)
  o 14 mm: 87 (118)
• Transaxle Torque Rod Bolt: 16 (22)

To see the original article with images check it out here: Integra DC2 Clutch Assembly. Garage411.com