After installin new clutch pressure plate and.

JAMIEKUYKENDOLL

MEMBER
1994 HONDA PASSPORT
246,000 MILES

After installin new clutch pressure plate and release bearing per instructions in Haynes Manual, I put everything back together only to notice the clutch to the floor. The obvious first solution was to bleed the system. While doing so I realized there was no resistance. After futher searching I noticed that the release bearing is not putting clutch fork in to place so the hydrolic system can do its job. Hydrolics work great. The release bearing had to be seated into the flywheel and seemed to have done so. The new cclutch and pressure plate had already in place the wire retainer and was supposed to snap in place. Just doesnt go far enough. What do I need to do to correct this problem, or did I miss a step? I saw on internet where there was missed step in Haynes manual, but the new clutch from NAPA already had it in place. I am little stumped, please advise

1 Reply

HMAC300

MECHANIC
48,601 POSTS

Removal� (2WD)

1. Remove� hood.� Disconnect� negative� battery� cable.� Remove� fan.� Place� shift� lever� in� Neutral� position.� Remove� shift� lever
insulation.� Remove� shift� lever� grommet� and� dust� cover.� Remove� shift� lever� cover� bolts� and� shift� lever.� Cover� hole� to� prev
support� vehicle.
2. Remove� suspension� crossmember� bolts.� Remove� starter.� Remove� clutch� release� cylinder� bolts.� Mark� drive� shaft� for� instal
Disconnect� drive� shaft� flange� at� rear� axle.� Remove� center� bearing� retainer� bolts.� Remove� drive� shaft� and� center� bearing�
3. Remove� exhaust� pipe� bracket� bolt� from� side� of� transmission.� Disconnect� front� exhaust� pipe� from� exhaust� manifold� and� cat
electrical� connector� from� transmission.� Disconnect� speedometer� cable.� Remove� clutch� housing� dust� cover.
4. Attach� engine� hoist� and� lifting� sling.� Remove� rear� engine� mount� bolts.� Remove� center� crossmember� and� exhaust� pipe.� Raise
slightly.� Support� transmission� with� transmission� jack.� Separate� engine� and� transmission.
5. Mark� pressure� plate� and� flywheel� for� installation� reference.� Support� clutch� assembly� with� clutch� aligner.� Remove� pressure
evenly� in� a� diagonal� pattern.� Remove� clutch� assembly.
Installation

1. Lubricate� ball� stud� and� install� release� fork.� Lubricate� shift� collar.� Assemble� release� bearing, � shift� collar, � release� fork, � an
clutch� aligner, � install� clutch� assembly� into� original� position.
2. Tighten� bolts� evenly� in� diagonal� pattern� to� specification.� See TORQUE� SPECIFICATIONS�.� Lubricate� input� shaft� spl
contact� surfaces� with� molybdenum� grease.

3. Operate� transmission� jack� to� position� transmission� at� same� level� as� engine.� Mate� transmission� to� engine� and� install� engin
3.2L, � pull� firmly� on� clutch� release� fork� to� engage� release� bearing� to� pressure� plate.� A� click� should� be� heard� indicating� re
all� models, � reverse� removal� procedure.
Make sure that the relase arm is fully positioned into release bearing