DIY Clutch Replacement on Your Honda S2000
Introduction:
The Honda S2000 is renowned for its exhilarating driving experience, thanks in no small part to its precise manual transmission. However, over time and with spirited driving, the clutch assembly may wear out, leading to slippage, difficulty shifting, or even complete failure. In this comprehensive guide, we'll take you through the step-by-step process of replacing the clutch on your Honda S2000, empowering you to maintain peak performance and keep the thrill of the road alive.
Assessing the Situation:
Before diving into the DIY clutch replacement, it's essential to diagnose the symptoms of a failing clutch in your Honda S2000.
Common signs include:
Slipping: Revving the engine without a corresponding increase in vehicle speed.
Difficulty Shifting: Grinding or resistance when shifting gears.
Soft or Spongy Pedal: A lack of resistance or inconsistent pedal feel.
If you're experiencing any of these issues, it may be time to replace the clutch assembly.
Gathering Your Tools and Parts:
To tackle this project successfully, you'll need the following tools and parts:
Tools:
Socket wrench set
Torque wrench
Jack stands
Low profile jack
Transmission jack (optional)
Parts (arguably the best combo for the S2000):
OEM Flywheel
Pressure Plate ACT HO21
OEM Clutch Disc
OEM Throw Out Bearing
OEM Pilot Bearing
DIY Clutch Replacement Process:
Now, let's walk through the step-by-step process of replacing the clutch on your Honda S2000:
Preparation:
Park your S2000 on a level surface and engage the parking brake.
Ensure the vehicle is securely supported on jack stands or ramps.
Remove Transmission:
Top:
Begin by removing the OEM air box. The airbox is secured by three (3) 10mm bolts.
Remove the serpintine belt, the tensionor pulley is moved with a 14mm socket or wrench.
Remove at least the top alternator bolt so that the alternator can be repositioned enough to locate and remove
the starter bolt.
Using a long extension, remove the top starter bolt. This is a 14mm bolt.
Remove the OEM heat shield that is attached to the vehicle. This is secured with four (4) 10mm bolts.
Remove the exhaust manifold heat shield four (4) 12mm bolts.
Remove the seven (7) exhaust manifold nuts. These are 12mm.
Inside:
Remove the shift knob and center console.
With a flat head screwdriver there are 4 arrows on the plastic piece, insert screwdriver and push towards the outside of the ring.
Remove the shifter. Three (3) 10mm bolts. Take care reinstalling these!
TIP: Wrap the driver side seatbelt through the steering wheel and clip it into the buckle. This will prevent the steering wheel
from moving later on.
Under:
Remove the exhaust support. These are two (2) 14mm bolts.
Remove the bolts holding the catalytic converter to the manifold. Two (2) 12mm bolts.
Remove the motor mount bolts. Four (4) 17mm bolts.
Lift the passenger side of the engine and remove the exhaust manifold.
Remove the A/C condensor bolts. Four (4) 12mm
Remove the 10mm bolt on the steering shaft and remove the shaft.
Remove driveshaft bolts. Eight (8) 8mm allen.
Remove the lower tension bar. Six (6) 14mm bolts
Lower the subframe about 3" Note: DO NOT TOTALLY REMOVE ALL OF THE BOLTS
Remove the slave cylinder. Two (2) 12mm bolts
Support the transmission and remove the transmission bolts.
Disengage the clutch for from the throw out bearing by pulling it.
Lower the transmission.
Replace Clutch Assembly:
With the transmission removed, access the clutch assembly.
Remove the pressure plate and clutch disc from the flywheel.
Inspect the flywheel for wear or damage and resurface or replace as needed.
Install the new clutch disc, pressure plate, and release bearing using the clutch alignment tool.
Torque the bolts to the manufacturer's specifications in a crisscross pattern.
19 lb/ft for the Pressure Plate and 94 lb/ft for the flywheel.
Reinstall Transmission:
Carefully guide the transmission back into position, aligning it with the engine.
Reinstall the transmission bolts and torque them to the specified value.
Reassemble all components previously removed.
Test Drive and Adjustment:
Reconnect the car battery.
Start the engine and test the clutch engagement and pedal feel.
Adjust the clutch pedal if necessary to achieve the desired engagement point.
Take the vehicle for a test drive to ensure smooth shifting and proper clutch operation.
Conclusion:
Congratulations! You've successfully completed the DIY clutch replacement on your Honda S2000, restoring its crisp shifting and performance to like-new condition. By following these steps and utilizing the right tools and parts, you've not only saved money on labor costs but also gained valuable insight into the inner workings of your beloved sports car. Now, hit the road with confidence, knowing that you've mastered the art of the shift and can enjoy the thrill of driving your Honda S2000 for miles to come.
