M/T - Clutch Pedal Squeak/Twang or Notchy Feel

02-002

January 11, 2005

Applies To:
See VEHICLES AFFECTED

Squeak at the Clutch Pedal
(Supersedes 02-002, dated September 21, 2004)

SYMPTOM
A squeak, a twang, or a notchy feel when the clutch pedal is pressed.

PROBABLE CAUSE

The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving.








VEHICLES AFFECTED

CORRECTIVE ACTION

Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting.

REQUIRED MATERIALS

Silicone Grease: P/N 08C30-B0234M, H/C 6110928

Brake Fluid: P/N 08798-9008, H/C 4423802

PARTS INFORMATION

Civic/Civic Hybrid Master Cylinder:
P/N 46920-S5A-G04, H/C 7569452

Accord/Civic Si/CR-V/Element Master Cylinder:
P/N 46920-57A-A02, H/C 7604507

WARRANTY CLAIM INFORMATION

In warranty:
The normal warranty applies.

Operation Number: 211101

Flat Rate Time: 0.6 hour (All Civics)
0.8 hour (Accord/CR-V/Element)

Failed Part:
Civic/Civic Hybrid:
P/N 46920-55A-G01
H/C 6571103

Accord/Civic Si/CR-V/Element:
P/N 46920-S7A-A01
H/C 6729031

Defect Code: 03214

Symptom Code: 04201

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.

DIAGNOSIS

Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes.

REPAIR PROCEDURE

NOTICE
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.

1. Remove the clutch master cylinder.

Refer to the appropriate service manual:

2003-04 Accord (L4): page 12-6

2003-04 Accord (V6): page 12-8

2001-04 Civic: page 12-5

2002-04 Civic Si: page 12-5

2003-04 Civic Hybrid: page 13-5

2002-04 CR-V: page 12-5

2003-04 Element: page 12-6

Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list.

2. Install the new clutch master cylinder, but do not attach the clutch line fitting.





3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring.

4. Connect the clutch line fitting to the clutch master cylinder.

5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid.

6. Check to see if the noise is gone when pressing the clutch pedal.

^ If the noise is gone, the repair is complete.

^ If the noise is still present, look for other causes.

7. Test-drive the vehicle to check for proper clutch operation.





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