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Clutch System – Civic ’92-95

by NinjaX on June 21, 2010

1992-1995 Honda Civic clutch assembly is a single-disc type with a diaphragm spring pressure plate. All models use a hydraulically-controlled clutch system consisting of a master cylinder, release cylinder, release lever and release bearing.
BLEEDING CLUTCH HYDRAULIC SYSTEM

Attach hose to bleeder fitting located on clutch release cylinder, next to hydraulic line. Submerge other end of hose in container half full of clean brake fluid. Fill reservoir with DOT 3 or DOT 4 brake fluid. Open bleeder fitting. Have assistant press clutch pedal to full release position. Close bleeder fitting. Release clutch pedal. Repeat until air bubbles no longer emerge from hose. Refill reservoir.

CLUTCH PEDAL ADJUSTMENT

1. Loosen lock nut “A”, and back off clutch pedal switch “A” until it breaks contact with clutch pedal. See image. Loosen lock nut “C”, and turn clutch pedal push rod until correct pedal height is obtained. Tighten lock nut “C” to specification.

  • Honda 1992-1995 EG Civic
    • Pedal Height In. (mm): .47-.83 (12-21)
    • Pedal Free Play In. (mm): 6.50 (164)

2. Turn clutch pedal switch “A” in until it contacts clutch pedal. Turn switch another 3/4-1 turn. Tighten lock nut “A” to specification. Loosen lock nut “B” and clutch pedal switch “B”. Measure clearance between floor board and clutch pedal with clutch pedal fully depressed.

  • DISENGAGEMENT HEIGHT
    • Height From Floor In. (mm): 3.27 (83)

3. Release clutch pedal .6-.8″ (15-20 mm) from fully depressed position, and hold it there. Adjust position of clutch pedal switch “B” so engine will start with clutch pedal in this position. Turn clutch pedal switch another 3/4-1 turn. Tighten lock nut “B” to specification.

REMOVAL AND INSTALLATION

If vehicle has anti-theft radio, obtain code number before disconnecting battery. After service, turn radio on. When CODE appears, enter code to restore radio operation.

CLUTCH ASSEMBLY REMOVAL

  1. Disconnect negative and positive battery cables. Remove battery base, and air cleaner and tube assembly. Disconnect starter and transmission ground cables. Remove engine harness clamp. Disconnect speedometer sensor connector. Disconnect back-up light switch.
  2. Remove clutch pipe bracket and clutch release cylinder. Drain transaxle fluid. Remove starter. Remove engine and right wheelwell splash shields. Separate lower control arms from ball joints. Remove right radius rod. Using 2 large screwdrivers, pry both drive shaft inner CV joints out of tranny. Protect drive shaft ends.
  3. Remove header pipe and bracket. Remove shift and extension rods. Remove front stopper bracket. Remove engine stiffeners and clutch cover. Install hoist at proper places on engine, and lift engine slightly to unload engine mounts.
  4. Place a jack under tranny, and slightly raise jack to take weight off transaxle mounts. Remove front transaxle mount. Remove rear transaxle mount bracket. Remove side transaxle mount. Remove transaxle housing mount bolts. Pull transaxle away from engine, and remove transaxle.

CLUTCH ASSEMBLY INSPECTION

  1. Check pressure plate diaphragm spring fingers for wear and unevenness on release bearing contact area. Check spring finger height using feeler gauge and Clutch Disc Aligner Assembly (07JAF-PM7012A and 07936-3710100 ).
  2. Verify clearance between tool flange and finger. See clutch specs on bottom of this page. If necessary, install Ring Gear Holder Assembly (07924-PD20003 or 07LAB-PV00100 ) to hold flywheel stationary while removing pressure plate and clutch disc.
  3. With pressure plate and clutch disc removed, inspect pressure plate surface for wear, cracks, burning and runout. Maximum face warpage is .006″ (.15 mm). Measure warpage using straightedge and feeler gauge at several points.
  4. Inspect clutch disc lining for slipping, excessive wear, burning and oil contamination. Measure disc thickness and rivet depth. Check for loose rubber torsion dampers. Replace disc if any dampers are loose. Check disc runout. See clutch specs on bottom of this page.
  5. Inspect flywheel ring gear teeth for excessive wear and damage. Inspect flywheel surface for wear, burning and cracks. Check flywheel runout, flywheel pilot bearing and release bearing. Resurface or replace as necessary.

CLUTCH ASSEMBLY INSTALLATION

  1. Align 2 flywheel dowels with dowel holes in clutch cover. Using clutch alignment tool and ring gear holder, install disc and pressure plate. Tighten pressure plate and flywheel bolts evenly in a crisscross pattern. See figure 1 and figure 2. Tighten transaxle mount nuts and bolts in sequence as illustrated. See figure Align transaxle breather cap as illustrated. See figure. New spring clips must be used on both axle shafts. Slide axles in until spring clips engage differential.
  2. Use NEW self-locking nuts on front end of radius rod and header pipe bracket. Use NEW through-bolt on firewall side transaxle mount. To install transaxle, reverse removal procedure. Clean release bearing sliding surface. Apply molybdenum grease to release bearing sliding surface. Apply a light amount of grease to input shaft splines. DO NOT allow grease or dirt on clutch disc or pressure plate surfaces.
  3. To complete installation, reverse removal procedure. Tighten bolts to specification. See torque specs on bottom of page. Refill fluid to proper level. Adjust clutch pedal height and free play.

CLUTCH MASTER CYLINDER REMOVAL AND INSTALLATION

Pry out cotter pin, and pull pedal pin out of yoke. Drain brake fluid. Disconnect and plug hydraulic line. Remove nuts and bolts attaching master cylinder to firewall. To install, reverse removal procedure. Refill master cylinder, and bleed air from system.

CLUTCH RELEASE CYLINDER REMOVAL AND INSTALLATION

Disconnect clutch pipe from release cylinder. Remove release cylinder from transaxle clutch housing. To install, reverse removal procedure. Refill master cylinder, and bleed air from system.

OVERHAUL

Manufacturer recommends replacement of faulty clutch master and release cylinders. Overhaul procedures not available at time of publication.

CLUTCH SPECIFICATIONS

  • Diaphragm Spring Finger Wear
    • Standard (New): 0.02 (0.5)
    • Service Limit: 0.04 (1.0)
  • Disc Runout
    • Standard (New): 0.002 (0.05)
    • Service Limit: 0.006 (0.15)
  • Disc Thickness
    • Standard (New): 0.33-0.35 (8.4-9.0)
    • Service Limit: .24 (6.1)
  • Flywheel Runout
    • Standard (New): 0.002 (0.05)
    • Service Limit: 0.006 (0.15)
  • Pressure Plate Runout
    • Standard (New): 0.001 (0.03)
    • Service Limit: 0.006 (0.15)
  • Rivet Depth
    • Standard (New): 0.05 (1.3)
    • Service Limit: 0.01 (0.3)

TORQUE SPECIFICATIONS Ft. Lbs. (N.m)

  • Battery Base Mounting Bolts: 16 (22)
  • Cable Stay Bolts: 20 (27)
  • Castle Nut: 36-43 (49-59)
  • Center Beam Bolts: 37 (50)
  • Damper Fork: Nut 47 (64)
  • Damper Pinch Bolt: 32 (43)
  • Engine Stiffener Bolts
    • 8 mm 17 (24)
    • 10 mm 33 (45)
  • Flywheel Housing-To-Engine Bolts: 47 (64)
  • Flywheel-To-Crankshaft Bolt: 87 (118)
  • Front Engine Mount Bracket Bolts
    • 10 mm 33 (45)
    • 12 mm 47 (64)
  • Front Stopper Bracket Bolts
    • 10 mm 33 (45)
    • 12 mm 47 (64)
  • Intake Manifold Bracket Bolts: 16 (22)
  • Intermediate Shaft Support Bolt: 28 (38)
  • Header Pipe
    • Nuts 16 (22)
    • Bolts 12 (16)
  • Lower Transaxle-To-Engine Bolts
    • 12 mm 47 (64)
    • 14 mm 61 (83)
  • Pedal Adjuster Lock Nut “C”: 13 (18)
  • Pressure Plate-To-Flywheel Bolts: 18 (25)
  • Radius Rod
    • Nut 40 (54)
    • Bolts 76 (103)
  • Rear Mount-To-Transmission Bolts
    • 10 mm 28 (38)
    • 12 mm 47 (64)
    • Through-Bolt 54 (74)
  • Rear Mount-To-Transmission Bracket Bolts: 61 (83)
  • Release Fork Bolt: 21 (29)
  • Speed Sensor Mounting Bolts: 14 (19)
  • Starter Mounting Bolts: 32 (43)
  • Upper Transaxle-To-Engine Bolts
    • 10 mm 33 (45)
    • 12 mm 47 (64)
  • Wheel Lug Nuts: 81 (110)

TORQUE SPECIFICATIONS INCH Lbs. (N.m)

  • Master Cylinder Mounting Nuts: 115 (13)
  • Pedal Adjuster Lock Nut “A”: 89 (10)
  • Pedal Adjuster Lock Nut “B”: 89 (10)

Got questions and comments on 1992-1995 Honda Civic clutch system? Leave them below!

{ 2 comments… read them below or add one }

craig hezel September 9, 2011 at 1:51 am

im installing a new clutch, pressure plate & throwout bearing on a 94 honda civic. my question is when im tightning the pressure plate bolts is it normal for the springs on the pressure plate to go flat, the springs the throwout bearing press on

Jeff Barlow May 18, 2012 at 12:21 am

After looking at pictures on another website the flywheel appears to have a “deck height” ( the pressure plate bolts on a higher plane than the clutching surface). Is this true and if so what is the limit for this difference?

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