M/T - Clutch Pedal Noise
98-084July 16, 2004
Applies To:
1998-99 Accord With M/T - ALL
Updated information is indicated by asterisks and black bars.
Clutch Pedal Noise
(Supersedes 98-084, dated October 7, 2003)
SYMPTOM
A squeak or groan when you press the clutch pedal. The pedal may also feel notchy as it travels. This noise usually happens in warm weather.
PROBABLE CAUSE
The walls of the nylon clutch master cylinder are rough, causing excessive friction on the piston.
CORRECTIVE ACTION
Replace the clutch hydraulic system (clutch master cylinder, slave cylinder, damper tube, and related parts).
PARTS INFORMATION
When this service bulletin was first issued, the parts were available as a kit. The kit had an aluminum-bodied clutch master cylinder, a slave cylinder, a damper tube, and related parts. Later, these kits were discontinued and the kit parts made separately available. The replacement parts currently in stock are for the aluminum-bodied system only and are not compatible with the original system. To complete this repair, you must order and install all of these parts:
REQUIRED MATERIALS
Super High Temp Urea Grease:
P/N 08798-9002, H/C 3720984
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 211104
Flat Rate Time: 1.4 hours
Failed Part: P/N 46920-S84-A01
H/C 5438098
*Defect Code: 03214
Symptom Code: 04213*
Template ID: 98-084A
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Remove the intake air duct.
* NOTICE
Do not spill brake fluid on the vehicle; it could damage the paint. If brake fluid contacts the paint, wash it off immediately with water.
2. Use a syringe to remove the brake fluid from the clutch master cylinder reservoir.
3. Disconnect the reservoir hose from the clutch master cylinder. Use a shop towel to plug the end of the hose to keep brake fluid from coming out.
4. Remove the lock pin and the pedal pin from the clutch master cylinder pushrod. Remove the two clutch master cylinder mounting nuts.
5. Release the clutch line from the engine compartment bulkhead (two clips).
6. Remove the two slave cylinder mounting bolts and the two clutch line mounting bolts.
7. Remove the clutch line, the master cylinder, and the slave cylinder from the vehicle as a unit.
8. Lay the new clutch line on the work bench. Install the new clutch master cylinder onto the end of the line with a new 0-ring. Secure the line to the clutch master cylinder with the new retaining clip.
9. Install the new slave cylinder onto the other end of the clutch line with another new 0-ring. Tap in the new roll pin. Apply super high temp urea grease to the end of the pushrod.
10. Position the assembled pieces in the vehicle. Torque the slave cylinder mounting bolts to 23 N.m (17 lb-ft). Torque the clutch master cylinder mounting nuts to 13 N.m (9.4 lb-ft). Clip the clutch line to the bulkhead, and install the mounting bolts.
11. Apply multipurpose grease to the pedal pin, then attach the clutch pedal to the clutch master cylinder pushrod with the pin. Secure the pedal pin with the lock pin.
12. Attach the reservoir hose to the clutch master cylinder. Open a container of Honda DOT 3 brake fluid, and fill the clutch master cylinder reservoir.
13. Remove the cap from the bleeder screw on the slave cylinder, and loosen the screw. Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
14. Make sure the reservoir has enough brake fluid, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose.
NOTICE
Do not overtighten the bleeder screw; you could damage the slave cylinder.
15. Torque the bleeder screw to 8 N.m (6 lb-ft), and reinstall the cap.
16. Refill the reservoir.
17. Reinstall the intake air duct.
18. Test-drive the vehicle to make sure the clutch pedal is properly adjusted and works without making noise.*
Disclaimer