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View Full Version : DIY: Clutch/Flywheel/Rear Main



davisj3537
04-21-2008, 07:09 AM
Well I'm not a certified mechanic so take my advice with a grain of salt kids. I'm not liable for your stupid mistakes.
Tools:
High lift jack
Jack stands
1/2 and 3/8 inch rachets
10,12,14,17,19mm sockets
6mm allen wrench
14mm open end wrench
17,10mm 12 point sockets
Screw driver
High temperature grease
Crow bar
2qts of tranny fluid
Air tools help a ton...
Patience
Personal best time of 4 hours today by myself:mcool:
Ok make sure you have everything you need before starting this puppy. Your new clutch should come with a pilot bushing,throw out bearing,clutch alignment tool, pressure plate and clutch disc. First you drain the tranny fluid by taking out the bottom bolt(Drain bolt=blue and Fill bolt=Red 17mm) with just a 3/8 inch rachet.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601846.jpg
When it is done draining put the drain bolt back in and snug it up. Then move on to the sway bar. Here is one of the endlinks and it will require a 6mm allen wrench and a 14mm wrench.Remove them both
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601830.jpg
Then remove the four 14mm bolts that hold the sway bar bushings in place. You can now remove the sway bar.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602244.jpg
Then get to work on the subframe. 19mm bolts in blue and 17mm in red.There are four of each. 2x2 on each side.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602234.jpg
Here is the rear mount. You need to remove the 4 17mm bolts to get the rear mount off. You can't see the last bolt in this picture but it is above these three.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602047.jpg
The front mount is pictured here. Remove the 17mm bolts shown in red and there is one just on the other side of this mount that only needs to be loosened so the mount can swing out of the way to remove the 17mm bolt in blue. Any easy bolt to forget about is the 17mm bolt holding on the starter that has to come out to get the tranny off so remove it while you are over here working on the front mount. Now that pesky subframe should fall right on your face:mbanana:
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602035.jpg
Unbolt that slave cylinder pictured here. I think it is two 12mm but on this car they were 13mm?
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602196.jpg
There is alot going on in this picture! In green are two sensors that need to be disconnected(I have already disconnected them in this pic). In blue are the two shifter cables. There is a pin through each one that needs to be removed(already done) and then you can slide the shifter cables off. In red are two 17mm bolts that hold the tranny on...you can't see them but they are there. There is one of these bolts about 6 inches all the way around the tranny so remove them all.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602188.jpg
Don't forget this 10mm oil pan bolt.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602041.jpg
Remove the three 14mm bolts pictured here and pull the intermediate shaft out of the tranny...A screw driver works good on the intermediate shaft and a crowbar works great on the other axle. You can kinda push on the tire to give you more room to pull the axles out.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602037.jpg
Alright now before removing the tranny mount pictured below you will need to put your jack underneath the oil pan with a large flat piece of wood between the two(so the pan isnt damaged by your jack). Raise the jack to barely support the oil pan. Remove the four 17m bolts in red and you can very slowly start to lower the jack untill you get the clearance to get the silver piece of the way and set it aside.At this point the tranny is hanging by a thread. The tranny can now be pulled out slightly and brought down(hopefully not crushing your feeble body beneath it) to the ground. It is very heavy(100lbs or so) and hard to manuever. A second set of hands comes in handy here.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602356.jpg
Ok now you will be looking at this minus the alignment tool in the middle.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601805.jpg
There are 6 12 point 10mm bolts holding the pressure plate/clutch on the flywheel. When you remove them make sure to do them only a couple turns at a time rotating around the pressure plate as you go. If you were to unscrew one after another all the way out then it will cause damage to the pressure plate!(Not that is matters cuz this is the old one but the new one will be put on the same way)You will have to stick a wrench through the flywheel and onto one of the ridges in the tranny to keep it from spinning while you take out the next 14 bolts.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601812.jpg
Now take off the flywheel. There are 8 12 point 17mm bolts holding it on. Inspect the flywheel and if it is smooth with no heat spots then it is probably just fine to go back on without a resurfacing. However it is cheap and easy to get a flywheel resurfaced and it is cheap insurance so go ahead and get it resurfaced if you are questioning it.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601869.jpg
Here is the rear main seal in green and in the center hole is the pilot bushing. Pull it out any method you see fit and put another one in its place. Use some high temp grease all over it. Any spots that need to be greased will be in pink. Use a screw driver and pop out the rear main seal if you are replacing it which I did on this car cuz it was leaking a bit. Clean up where the old seal was really good and then press in the new seal(It is super hard to screw this up).
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602044.jpg
Put the flywheel back on and torque those flywheel bolts in good. I didn't get out the tq wrench but on something like this I use the patented "Super Damn Tight" method. Make sure not to get any oil on the flywheel or clutch disc since it will ruin the new clutch disc. When you are putting the new clutch/pressure plate on use your alignment tool and center it in the pilot bushing. Line up the three pins in red below and then get to tightening the pressure plate bolts in the same fashion that we loosened them. Make sure to keep the alignment tool centered while you tighten the pressure plate.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601812.jpg
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297601805.jpg
Now on to the throw out bearing. Grease only the spots shown in the picture. DO NOT GREASE THE FRONT!!! Greasing the front could cause grease to be slung onto the clutch disc and ruin it.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602347.jpg
Manuever the new throw out bearing onto the shift fork and grease the spindle as shown.
http://pic20.picturetrail.com/VOL1334/6243981/17786139/297602213.jpg
Now you can lift the tranny back into the car(DAMN hard to do by yourself but I always end up with noone to help me:mcry:)
You install everything in the reverse order that you removed it. It will take some swearing and sweet loving to get the subframe back in to place but you will get it with some patience. It helps if you put in the front two subframe bolts first very loosely and then you can start reattaching the lower control arms and then lastly put the back two subframe bolts back in. I found that the easiest way to get 'er done. If you guys notice anything out of place or something I'm missing then let me know and I'll update...or if you want some specific pics I'll be doing another clutch Saturday so I can snag a few more.

davisj3537
04-21-2008, 08:04 AM
http://pic20.picturetrail.com/VOL1334/6243981/17786139/298130453.jpg
http://pic20.picturetrail.com/VOL1334/6243981/17786139/298130459.jpg
Thats right motha fucka:rockon:

03Si757
04-21-2008, 10:21 AM
Hey man, what grease did you use, im at this part on an engine swap, and I cant seem to find any. Checked honda and they looked at me like i was stupid.

davisj3537
04-21-2008, 11:14 AM
Hey man, what grease did you use, im at this part on an engine swap, and I cant seem to find any. Checked honda and they looked at me like i was stupid.

You can just get any high temp grease. I found a tube of it at oreilly's but anywhere should have it. Just ask for any high temp grease. I'd grab a pic of my tube of grease but I'm not at home.

03Si757
04-21-2008, 12:29 PM
You can just get any high temp grease. I found a tube of it at oreilly's but anywhere should have it. Just ask for any high temp grease. I'd grab a pic of my tube of grease but I'm not at home.

I just snagged some Valvoline SynPower greas, temp protection of like -60F - 425F So I guess it should work. Plus its a multi purpose grease so itll help on a few other things.

davisj3537
04-21-2008, 12:32 PM
I just snagged some Valvoline SynPower greas, temp protection of like -60F - 425F So I guess it should work. Plus its a multi purpose grease so itll help on a few other things.

Should work just fine buddy:llama::plane:

Jpax
04-21-2008, 12:33 PM
GREAT DIY! and I need to get bonged myself.

davisj3537
04-21-2008, 12:36 PM
GREAT DIY! and I need to get bonged myself.

Thanks Jpax. I think we all need to get bonged from time to time.:mangel:

civictype_r04
04-21-2008, 01:35 PM
I could've used this when I installed my clutch and flywheel.

STP03BlueSI
04-22-2008, 12:44 PM
I am pretty sure there is some ephatchers that would help me do this when the time comes:mbiggrin:

davisj3537
04-22-2008, 01:16 PM
I just realized I was missing the first half of the DIY...added and now its complete.

03Si757
04-23-2008, 11:16 AM
HELP! Im not sure if the Pressure plate is supposed to rest against the flywheel. There is a good amount of space between the pressure plate and flywheel when mounted.

03Si757
04-23-2008, 12:19 PM
NVM, I got it.

davisj3537
04-23-2008, 12:26 PM
Well when you bolt down the clutch to it there is no space. That is what holds the clutch in place buddy:mwink:

03Si757
04-25-2008, 10:10 AM
Hey davis, get a DIY for bleeding the clutch! Im having trouble doing it.

Tnhatch03
04-25-2008, 06:22 PM
great Davis!

davisj3537
04-25-2008, 07:39 PM
Hey davis, get a DIY for bleeding the clutch! Im having trouble doing it.

I'll see if I can't do it this Sunday. I've got a customer coming over for some camshafts...i'll get some pics and see if I can't muster up a Bleeding DIY.:laser:

03Si757
04-25-2008, 08:55 PM
I'll see if I can't do it this Sunday. I've got a customer coming over for some camshafts...i'll get some pics and see if I can't muster up a Bleeding DIY.:laser:

Good deal man. Best insider on this site :horn:

02Si&07Si
04-29-2008, 06:27 PM
Hey man, what grease did you use, im at this part on an engine swap, and I cant seem to find any. Checked honda and they looked at me like i was stupid.

Because thats what they think lol. So lets just think that back since they give us stupid reasons for not fixing problems that began with them.

Great write up. Go Sharks. And yea beg someone to help you with this, The Subframe itself is a heavy biotch and took friends to help me do this. P.S. Without a lift... whew goodluck.

Laz's EP
04-29-2008, 06:48 PM
Great write up, How hard is this job to do. I need to replace some syncros in my tranny and I have someone that will do the job but doesn't have time to remove the tranny. You said that it was a 4 hour job, is that to remove and re install the tranny?

I was thinking of doing this, I can do it in my garage. :mfrown:

What do you think, anyone with some type of mechanical experience can do this?
Thanks

Guardian
04-30-2008, 06:18 PM
HELP! Im not sure if the Pressure plate is supposed to rest against the flywheel. There is a good amount of space between the pressure plate and flywheel when mounted.

the disc was on backwards

Fico
05-01-2008, 04:45 AM
so basicly, once the engine is just chilling there gellin, you take the intermidiate shaft off by slipping it out, are you able to take the drivers side axel out as easy? or do i need the socket for the hub?

davisj3537
05-01-2008, 06:35 AM
Great write up, How hard is this job to do. I need to replace some syncros in my tranny and I have someone that will do the job but doesn't have time to remove the tranny. You said that it was a 4 hour job, is that to remove and re install the tranny?

I was thinking of doing this, I can do it in my garage. :mfrown:

What do you think, anyone with some type of mechanical experience can do this?
Thanks

I can get the tranny out in 1 hour flat:cheer2:you can do it buddy. I have done a good number of them but still I say you can do it man. Just follow this is you get lost or stuck.

davisj3537
05-01-2008, 06:36 AM
so basicly, once the engine is just chilling there gellin, you take the intermidiate shaft off by slipping it out, are you able to take the drivers side axel out as easy? or do i need the socket for the hub?

I only took the axles out of the tranny and then let them rest on the ground still attached to the hub.

Fico
05-01-2008, 06:46 AM
I only took the axles out of the tranny and then let them rest on the ground still attached to the hub.

thats what i figured, but there is really enough play to get them out? it seemed like there wouldnt be

davisj3537
05-01-2008, 11:31 AM
thats what i figured, but there is really enough play to get them out? it seemed like there wouldnt be

There is if you remove the lower control arms:mwink: You have to remove those anyway if you are removing the subframe(atleast the way I do it).

Fico
05-01-2008, 12:54 PM
There is if you remove the lower control arms:mwink: You have to remove those anyway if you are removing the subframe(atleast the way I do it).

Ohhh yeah. i completely forgot about that shit, lol those axels will come out easy peesey that way lol

davisj3537
05-01-2008, 12:57 PM
Ohhh yeah. i completely forgot about that shit, lol those axels will come out easy peesey that way lol

Easy peesey is right sir:croc:

02_epdriver
05-01-2008, 01:13 PM
Thats awesome great job man. I need to do this really soon here

locoep3
05-03-2008, 10:01 PM
nice rite up

sleepy_ep
05-04-2008, 10:06 PM
awesome thanks for the write-up, I will be doing tranny work in the near future.

Laz's EP
05-07-2008, 09:11 AM
Well after looking and not having luck finding a 5 speed, I decided to take the tranny off myself and with the money that I would have used to buy the new tranny and labor,I'll use it towards having my tranny rebuild. Also I've been thinking, since I'm boosted and hopefully soon will be over 400 whp, I know that I'll be repairing again the tranny in the future.
I will be using this DYI.
Any words of advise, will be appreciated. :der:

goldEp
04-09-2010, 02:15 PM
nice write up.. im doing this now i cant find torque specs..!! i need torque specs for the flywheel and if on hand for the presure plate.. thanks.???

groovezog
04-10-2010, 11:03 AM
nice write up.. im doing this now i cant find torque specs..!! i need torque specs for the flywheel and if on hand for the presure plate.. thanks.???
76 ft lbs for the flywheel, and 19 ft lbs for the pressure plate.

SUSHI_NE1
05-30-2010, 09:42 PM
Wow... this is an awsome write-up. I'm totally gonna do this soon.

EP3 Dream
10-17-2010, 06:38 PM
i think ill have a shop do it for me O.o its not too much to ask for a shop to install an aftermarket clutch that i provide right?

02ES1
10-21-2010, 10:37 PM
Most shops should be more than happy to install any clutch you give them as long as it's the right one :mbiggrin: Out here i was quoted $700-$800 though which makes me want to get a jack that can lift higher than the one i own and do it myself!

epSleepy
11-01-2010, 08:07 PM
I think anyone with the tools can and should do it. You get to know so muuuuch about your car while tearing it down that the experience is invaluable. The feeling of accomplishment is a high in and of itself. DOOOO ITTTT... take the extra money to buy some new tools.... and the extra 400 u'll have left over even after buying tools can be used for a night out on the town or a deposit into a "power maker" fund....

02ES1
02-23-2011, 08:33 PM
I've been in the process of doing this (and other things) and what I've learned is, our engine bay is way too fucking cramped! :mconfused: And huge props to the OP for being able to do this in 4 hours. I still can't wrap my head around that one.

EP3 Dream
02-25-2011, 07:20 AM
i had to stick my thin arm through the engine bay to get a screw, thing is, wasnt even the ep3! it was the honda fit! i guess all compact hatches are like that? -shrugs- they still come out nice lol

dyeownsme
05-04-2011, 08:52 PM
Awesome, I'll have the balls to try this when the time comes...

I'm also looking to swap in a 6th gear...

summoner12
06-04-2012, 01:03 AM
Started the work on this job today. I got as far as the trans on the floor and called it quits. I need new engine mounts and since the AC compressor is on it's way, I'm gonna wait for it before I finish up. I figure it'll be a lot easier to do mounts and AC while the sub frame is leaned up against the wall.

Any thoughts on the Innovative motor mounts? I see all four for $370.... not trusting the eBay 'stock' look-a-likes. Rather go with something a bit 'sporty' since the clutch and flywheel aren't stock (lighter flywheel and exedy clutch). I don't have any power mods... but who knows. No more car payment on my Sti.... might start putting money into the cars, instead of the bank.

Some points I'd like to make about the install. This guide kinda misses on some points along the way. Things that might go better if done in a certain order, or things not mentions. Most noted in my mind were some covers and subframe. I'd recommend removing the LCA bolts forst (19mm in blue) and having them held out of the way.... then remove the actual frame bolts, which are 17mm. Oh.... silly but remember that when you pop off that drain plug to have your pan situated out from under the drain hole. LOL It isn't 'gear' oil in there, it's motor oil, so it sorta 'shoots' out of the hole with a nice arc to it. I missed the pan by like 4".:mredface: Also removing the tires from the wheel hubs is a good idea, keeps things easier to move around.

los
06-04-2012, 05:53 AM
great diy im about to do this in the next week doesnt look too hard but its a lot better when you have a lil guide like this thanks

los
06-05-2012, 06:32 AM
how do you go about bleeding the clutch pedal is it a needed if you are just changing clutch? and also how do you adjust it, in cable trannys you adjust at the cable so how would you adjust the tranny on an ep ?

fdnyjon
06-21-2012, 04:22 PM
http://pic20.picturetrail.com/VOL1334/6243981/17786139/298130453.jpg
http://pic20.picturetrail.com/VOL1334/6243981/17786139/298130459.jpg
Thats right motha fucka:rockon:

lol