Clutch System — Acura TL III (2003-2006)

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Scheme 1: Special Tools

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Scheme 2: Component Location Index

Function

On ordinary clutches, the clutch pedal load increases as the clutch disc wears. The self-adjusting clutch is designed so the clutch pedal load will not increase even when the clutch disc wears. This is done by automatically adjusting the fulcrum of the diaphragm spring in accordance with the wear of the clutch disc. The clutch pedal load stays consistent even when the clutch disc is worn.

Construction

The self-adjusting clutch consists of a pressure plate, a sensor spring, a diaphragm spring, an adjusting ring, three coil springs, a pressure plate cover, and a compensation spring. They are riveted together and must not be disassembled. If there is problem with any part of the pressure plate or clutch disc, they must be replaced as a set.

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Scheme 3: Construction

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Scheme 4: Operation

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When the clutch disc wears slightly. As the clutch begins to wear, the release load increases slightly. However, this does not affect the operation of the clutch because the release load does not exceed that of the sensor.
When the clutch disc wears considerably. The sensor spring starts to deflect as the clutch disc is worn further and the release load exceeds that of the sensor.

The fulcrum then moves following the amount of sensor spring deflection. As this takes place, the fulcrum of the diaphragm spring is adjusted, keeping the release load consistent.

Scheme 6

Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment

Note. Check the clutch pedal position switch (see CLUTCH PEDAL POSITION SWITCH TEST ). Check the clutch interlock switch (see CLUTCH INTERLOCK SWITCH TEST ). Remove the driver's floor mat before adjusting the clutch pedal. The clutch is self-adjusting to compensate for wear. If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems.

Scheme 7

Scheme 7: Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment

Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C).
Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. Clutch Pedal Stroke: 130-140 mm (5.12-5.51 in.) Clutch Pedal Free Play: 10-18 mm (0.39-0.71 in.) Clutch Pedal Height: 191 mm (7.52 in.) Clutch Pedal Disengagement Height: 90.5 mm (3.56 in.)
Tighten the clutch pushrod locknut (D).
With the clutch pedal released, turn in the clutch pedal position switch (B) until it contacts the clutch pedal (C).
Turn in the clutch pedal position switch (B) an additional 3/4 to 1 turn.
Tighten the clutch pedal position switch locknut (A).
Loosen the clutch interlock switch locknut (J).
Press the clutch pedal to the floor.
Release the clutch pedal 3-8 mm (0.39-0.63 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so the engine will start with the clutch pedal in this position.
Tighten the clutch interlock switch locknut (J).

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Scheme 8: Clutch Pedal Replacement

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Remove the driver's dashboard under cover (see «DRIVER'S DASHBOARD UNDER COVER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/exteriorinterior-trim/#dashboard) ).
Disconnect the clutch pedal position switch connector (A) and clutch interlock switch connector (B).
Pry out the lock pin (C), and pull the pedal pin (D) out of the yoke.
Remove the master cylinder mounting nuts (E) and clutch pedal mounting bolt (F).
Remove the clutch pedal (G).
Install the clutch pedal (A).
Install the clutch pedal mounting bolt (B) and master cylinder mounting nuts (C).
Apply grease to the pedal pin (D), and slide it into the yoke, then install a new lock pin (E).
Connect the clutch pedal position switch connector (F) and clutch interlock switch connector (G).
Adjust the clutch pedal, clutch pedal position switch, and clutch interlock switch (see «CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT»(/acura/tl/iii-2003-2006/remont/clutches-manual-hydraulic/#clutch-system__clutch-pedal-clutch-pedal-position-switch) ).
Reinstall the driver's dashboard under cover (see «DRIVER'S DASHBOARD UNDER COVER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/exteriorinterior-trim/#dashboard) ).

Clutch Master Cylinder Replacement

Note. Use fender covers to avoid damaging painted surfaces. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

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Scheme 10: Clutch Master Cylinder Replacement

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Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
Make sure you have the anti-theft codes for the radio and the navigation system, then write down the customer's audio presets. Make sure the ignition switch is OFF. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
Remove the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
Remove the battery base.
Remove the underhood fuse/relay box.
Remove the driver's dashboard under cover (see «DRIVER'S DASHBOARD UNDER COVER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/exteriorinterior-trim/#dashboard) ).
Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C).
Remove the reservoir mounting bolt (A).
Disconnect the clutch line (B) from the bracket (C).
Remove the clutch line from the clamp (D).
Remove the clutch master cylinder (E).
Disconnect the reservoir hose (A), then remove the retaining clip (B), and remove the clutch line (C) from the clutch master cylinder (D). Plug the end of the reservoir hose and clutch line with a shop towel to prevent brake fluid from coming out.
Remove the O-ring (E) and clutch master cylinder seal (F) from the clutch master cylinder.
Install the clutch master cylinder in the reverse order of removal, and note these items: Apply brake assembly lube to the clutch line, and install a new O-ring. Tighten the master cylinder mounting nuts to 13 N.m (1.3 kgf.m, 9.4 lbf.ft). Install the driver's dashboard lower cover. Install the underhood fuse/relay box. Install the battery base (see step 46 on «TRANSMISSION INSTALLATION»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__transmission-installation) ). Install the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ). Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion. Install the left rear engine compartment cover and the left side engine compartment cover. Enter the radio and navigation system anti-theft codes, then enter the customer's audio presets, and set the clock.
Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown.
To prevent the retaining clip (A) from coming off, pry apart the tip of the retaining clip (B) with a screwdriver.
Bleed the clutch master hydraulic system (see step 10 ).
Refill the brake fluid in the reservoir to the MAX (upper) level line (see step 11 ).

Slave Cylinder Replacement

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Scheme 18: Slave Cylinder Replacement

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Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
Make sure you have the anti-theft codes for the radio and the navigation system, then write down the customer's audio presets. Make sure the ignition switch is OFF. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
Remove the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
Remove the battery base.
Remove the mounting bolts (A), harness bracket (B), and slave cylinder (C).
Remove the roll pins (D). Disconnect the clutch line (E), and remove the O-ring (F). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out.
Install the slave cylinder in the reverse order of removal. Install a new O-ring (A).
Pull back the boot (B), and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot.
Apply super high temp area grease (P/N 08798-9002) to the pushrod of the slave cylinder. Tighten the slave cylinder mounting bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
Bleed the clutch hydraulic system. Attach a hose to the bleeder screw (A), and suspend the hose in a container of brake fluid. Make sure there is an adequate supply of fluid in the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose. It may be necessary to limit the movement of the release fork (B) with a block of wood to remove all the air from the system. Tighten the bleeder screw to 8 N.m (0.8 kgf.m, 5.8 lbf.ft); do not overtighten it. Refill the clutch master cylinder with fluid when done. Use only Acura DOT 3 Brake Fluid, from an unopened container. Make sure the clutch works properly, and check for leaks.
Make sure the fluid level in the reservoir is at the MAX (upper) level line (A).
Install the battery base (see step 46 on «TRANSMISSION INSTALLATION»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__transmission-installation) ).
Install the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion.
Install the left rear engine compartment cover and the left side engine compartment cover.
Enter the radio and navigation system anti-theft codes, then enter the customer's audio presets, and set the clock.

Clutch Replacement

Special Tools Required

Pressure plate compressor 07AAE-P8EA000
Clutch alignment shaft 07AAF-P8EA000
Pressure plate compressor adapter 07AAK-P8EAOOO
Ring gear holder 07LAB-PV00100 or 07924-PD20003
Attachment, 37 x 40 mm 07746-0010200
Driver 07749-0010000

Note. You must use the special tools required to remove and install the clutch pressure plate or you will irreversibly damage it.

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Scheme 24: Pressure Plate and Clutch Disc Removal

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Check the height of the diaphragm spring fingers using the special tools and a feeler gauge. If the height is more than the service limit, replace the pressure plate and clutch disc as a set. Standard (New): 0.6 mm (0.02 in.) max. Service Limit: 0.8 mm (0.03 in.)
Install the special tools.
Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.
Loosen the pressure plate mounting bolts (A) in the pattern shown in several steps, then remove the bolts.
Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure, then install two pressure plate mounting bolts, hand-tight, to hold the pressure plate (B). Remove the special tools and the pressure plate.
Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
Inspect the pressure plate surface (A) for wear, cracks, and burning.
Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate and clutch disc as a set. Standard (New): 0.03 mm (0.001 in.) max. Service Limit: 0.15 mm (0.006 in.)
Remove the clutch disc and special tools.
Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch looks burnt or is oil soaked, replace it and the pressure plate as a set. Find and repair the source of the oil leak if the clutch disc is soaked.
Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc and pressure plate as a set. Standard (New): 8.68-9.53 mm (0.342-0.375 in.) Service Limit: 7.2 mm (0.283 in.)
Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc and pressure plate as a set. Standard (New): 1.0 mm (0.039 in.) Service Limit: 0.2 mm (0.008 in.)

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Scheme 33: Flywheel and Pilot Bearing Inspection

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Inspect the ring gear teeth for wear and damage.
Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is not within the standard, replace the flywheel, and recheck the runout. Resurfacing the flywheel is not recommended. Standard (New): 0.05-0.45 mm (0.002-0.018 in.)
Turn the inner race of the pilot bearing with your finger. The pilot bearing should turn smoothly and quietly. Check that the pilot bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the pilot bearing.

Scheme 35

Scheme 35: Flywheel and Pilot Bearing Replacement

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Install the special tool.
Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.
Remove the pilot bearing (A) from the flywheel (B).
Install the new pilot bearing (A) into the flywheel using the special tools. Apply a light coat of oil to the bearing outer surface.
Install the flywheel and mounting bolts, finger-tight.
Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.

Clutch Disc and Pressure Plate Installation

Note. The clutch disc and pressure plate are a matched set and must be replaced together.

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Scheme 39: Clutch Disc and Pressure Plate Installation

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Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
Install the ring gear holder.
Apply super high temp area grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools.
Align a point mark (A) across the pressure plate (B) and flywheel (C).
Install the pressure plate and the mounting bolts (D), finger-tight.
Install the special tools.
Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.
Be careful not to damage the pressure plate (A). Tighten (180 degrees apart) the pressure plate mounting bolts (B) in the pattern as shown in several steps. Pressure Plate Mounting Bolt Torque: 25 N.m (2.6 kgf.m, 19 lbf.ft)
Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure, then remove the special tools.
Make sure the diaphragm spring fingers are all the same height.

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Scheme 43: Release Bearing Replacement

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Scheme 45

Remove the release fork boot (A) from the clutch housing (B).
Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D). Remove the release bearing (E).
Check the play of the release bearing by spinning it with your hand. If there is excessive play, replace the release bearing. NOTE: The release bearing is packed with grease. Do not wash it in solvent.
Apply super high temp area grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), and the release bearing (C), in the shaded areas.
With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.
Align the detent of the release fork with the release fork bolt, then squarely press the release fork over the release fork bolt.
Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.
Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly. Wipe off any excess grease.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If manual transmission maintenance is required)

The Acura TL SRS includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt retractors, side curtain airbags in the sides of the roof, and side airbags in the front seat-backs. Information necessary to safely service the SRS is included in this article. Items marked with an asterisk ( * ) include or are located near SRS components. Servicing, disassembling, or replacing these items require special precautions and tools, and should be done only by an authorized Acura dealer.

To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work must be performed by an authorized Acura dealer.
Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags and/or side airbags.
Do not bump or impact the SRS unit, front impact sensors, or side impact sensors when the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF; otherwise, the system may fail in a collision, or the airbags may deploy.
SRS electrical connectors are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, in the roof side, and around the floor. Do not use electrical test equipment on these circuits.

Clutch System Acura TL III