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REVIEW - Clutch Install, Accord i-CTDI

F6HAD

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If you have a 7th gen Accord Diesel, chances are the clutch is going to need to be replaced at some point in its lifetime.

There's various debate about why the clutch seems to fail prematurely on the Accord diesel, and many are unnecessarily having their Dual Mass Flywheel changed (probably because unscrupulous dealers are telling them that their DMF is knackered).

There is definitely a known problem with the Cruise Control Clutch Pedal Switch on the range of Honda's fitted with the i-CTDI engine, where the switch is incorrectly adjusted from the factory and leaving some play in the clutch pedal. This ultimately has the effect of 'riding' the clutch and causes the self adjusting pressure plate to adjust itself down to it's lowest setting, effectively rendering it useless as it's no longer strong enough to apply the right pressure on the friction disc to mate with the flywheel face - thereby causing the slip.

Hopefully what you will see from the review below is the importance of having this job completed at a Honda dealership due to the specialist tools required to load the clutch correctly, but also the experience required to check the DMF for tolerance and generally just knowing their way around this engine.

It's really a very involved job, and requires almost complete removal of the lower subframe to remove the gearbox from the car.

I personally would not trust any other dealership with my car. Holdcroft Honda are an affiliated dealership with Typeaccord for a reason. Their service, experience and attitude is second to known. Their master Technician Gareth is the best in the business, and personally the only guy I let near my car for those jobs I can't do myself. He was the only choice to install the clutch on my car.

On my car, when we remove the gearbox, it was evident that both the DMF and clutch had been replaced already. Seeing as I got the car on 28k miles - then a complete clutch/DMF replacement must have taken place before 28k miles :D that certainly is worrying.

At the time of writing this review, Honda have agreed to replace clutches at their dealerships for a heavily subsidised price of £585 inc. Perhaps that's an admission of guilt, or just good customer relations. Either way, the price is unbeatable and you could try and save a few bob by buying the parts and letting your local garage try it... but personally I would say.. DON'T :D

Parts to be replaced:

  • Clutch Pressure Plate
  • Friction Disc
  • Release Bearing (this is extra and not part of the kit)
  • Transmission Fluid (extra)
  • Clutch Fluid (extra)
  • Split pins, greases, clips etc as the reassembly takes place

So... here we go..


Gareth starts by removing the ancilliaries from the top, battery, looms etc.


New release bearing


New Pressure Plate


New Friction Disc





Gaz starts on the drivetrain and hubs



His apprentice Mark knocking the ball joints to split them (looks violent but this is the best way on this car)

 

F6HAD

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The speed at which these guys work is amazing. Less than an hour in to the job and the drivetrain is basically off and they're working on the lower subframe.





Gearbox oil being drained whilst the box is in situ



Working away on the subframe, engine mounts etc






 

F6HAD

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Working from the top now to loosen the gearbox bolts etc



Subframe about to be split and lowered - they don't remove it totally as reinstall normally knocks the alignment out, the lower it enough at an angle to get the box in and out and keep the alignment in check.





How many Honda techs does it take to remove and lower a diesel gearbox - answers on a postcard :D



 

F6HAD

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Quick one of my strut and strut brace off the car :D




And here you can see the old pressure plate still on the car..




Time for it to come off



Old friction plate - notice how 'new' it still is. Clearly the friction disc wasn't the problem causing the clutch slip


Old friction plate vs new

 

F6HAD

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So THIS is the problem.

Notice Gaz pointing to the self adjusting mechanism on the pressure plate - it has adjusted to the lowest setting. The only real reason it would do this is if the clutch has been hammered all the time (I don't drive like that) or if the clutch pedal has been rested on all the time causing a 'riding' effect (I don't do that either). So when the job is complete, Gaz will check the cruise control pedal switch.





Next he installs the new release bearing, remembering to grease it up first

Bell housing being cleaned out and prepped



 

F6HAD

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Next we check the DMF for play. Some play is normal, and thankfully mine is well within tolerance. I'm a happy bunny (DMF's are expensive parts!)





THIS is the special tool I referred to earlier. This tool is designed and made by Honda for the dealerships to ensure the clutch is perfectly loaded on the i-CTDI Accord. If you do it without this tool, chances are you will drastically shorten the life of your clutch and possibly cause damage to the DMF face.




Checking the bolts for correct torque settings


Pressure plate being installed (friction plate is inside already)


Clutch being loaded correctly with special tool



 

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Reassembly continues - one nut had sheared off, so the guys hammer it out and create a new threaded section







Fresh Honda MTF3 Gearbox oil going in:


And finally, clutch fluid replaced


The total job took from 10am, right upto 5.30pm with Gaz only taking a 30 minute break for lunch. Consider that this is how long it took expert engineers who worked without manuals, and did not have to make guesses on the location of bolts etc for anything..

It's genuinely a big big job, and Honda can really justify their original circa £1000 charges.

At £585 - don't even think about it, if your clutch is slipping, just have it done.

Gaz did check my Cruise Control Pedal switch, and as suspected, it was way out and needed adjusting. No wonder the clutch was replaced before 28k miles!! Why the DMF was replaced... I have no idea - probably a dealer wanting to make more money.

This review is testament to Holdcroft Honda's expertise, seriously. Stoke is a 200 mile round trip for me, but I made the trip without hesitation, and would do every time.

Gaz is a gent, and Steve Mitchell (Head of Service) is a real supporter of our club, so make sure you look them up when you next need anything doing on your Honda.

Holdcroft Honda
Sneyd Street
Cobridge
Stoke on Trent
Staffordshire
ST6 2PB

tel: 01782 261593
fax: 01782 271564
 

kingnesh

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Great write up Faddy and I can vouch for Holdcrofts work. They did my clutch and did a great job and great service.
 

vile

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Yep great right up mate i can agree with HH i also drove a 300 mile round trip to get mine done as well
 
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phb10186

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none of the images are working mate... There is clearly a cruise control problem, which is news to me.
 

Tyler Durden

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I know this is an old thread, but...

If the adjustment to the cruise control pedal switch had been done first would this have stopped the clutch slip problem? From what I have read, there didn't seem to be much wrong with the old clutch, accept the adjusters.
 

F6HAD

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Hi Barry, I think the cruise control switch exacerbates the problem but is not the ultimate cause. The ultimate cause is a poor pressure plate spring design.
 

Tyler Durden

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So the damage had been done?

Once the self adjusting mechanism on the pressure plate has adjusted to the lowest setting, is that it?

Would it go back to another setting if the pedal was adjusted?
 

teo_359

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Hi I know this an old thread but as Tyler said "...Once the self adjusting mechanism on the pressure plate has adjusted to the lowest setting, is that it?

Would it go back to another setting if the pedal was adjusted? ..." or if the clutch was dismantled could it be possible to reverse adjust the self adjusting mechanism
and reuse it with a new clutch plate only if DMF is good for reuse?
 

F6HAD

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Nope not as far as I'm aware as the spring is inside the cover plate, which is riveted on. Why would you even want to do that? A new one is maybe £75
 

TheHole

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nebitomi.

we dont need to use caps in everything dude.

he stated in the write up.. (if you read it) that the play with the DMF was within tolerance and did not need replacing.
 

F6HAD

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My flywheel was fine at the time and the engineer commented that it looked like it had already been replaced at some point. As long as it's within 3-36mm of play, Honda say it's ok.
 

JimJonesSIc

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My flywheel was fine at the time and the engineer commented that it looked like it had already been replaced at some point. As long as it's within 3-36mm of play, Honda say it's ok.

Alright

Do you know if they are still doing the replacement at the same price?
 

shab_the_man

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Alright

Do you know if they are still doing the replacement at the same price?
Hello

I believe the price may of gone up slightly but hopefully still in the same ball park. Why not give them a call and just ask for a price. Do mention your a member of this club
 

SpeeLaT

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teo said:
Hi I know this an old thread but as Tyler said "...Once the self adjusting mechanism on the pressure plate has adjusted to the lowest setting, is that it?

Would it go back to another setting if the pedal was adjusted? ..." or if the clutch was dismantled could it be possible to reverse adjust the self adjusting mechanism
and reuse it with a new clutch plate only if DMF is good for reuse?
Yes you can reset the pressure plate but you will need a tool to compress the fingers inorder to reset it. You can find lots of info on the LUK site with regards SAC clutches.

Mine has started slipping today, I have already stumpped the £1000 to Honda once before and when they showed me the clutch they said it didn't need replacing but once you have the car in peices its the only route replace. Now its gone again and after looking at many resources online including the mannufacturers site LUK they can be reset. I have also replaced SACs on BMWs they come pretensioned from LUK the Honda clutch is also listed as being preset so there is no need for special tools once the pressure plate is mounted you remove the pretension plate and the rest is like a normal clutch. I will attempt a DIY guide when I start mine with pictures if you guys are interested. I am sure there is no need to fully remove the gearbox from the car to get to theclutch but whe will see.

Reset the pressure plate http://forum.e46fanatics.com/showthread.php?t=629140
 

Draga

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would any one know a ball park for a 2.4 cl9 petrol accord with exedy stage 1 clutch and fly wheel :p
 

Accord127

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I am given an estimate of 1355 € in France for parts only
844€ for DMF
253€ clutch
32€ Engine oil sealn
 

fasgen

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As of 2021

I am given an estimate of 1355 € in France for parts only
844€ for DMF
253€
if someone need good condition used Kit, I'm currently about to to break my own L9VE..R.I.P
2008 Honda Accord 2.2 i-cdti, 6 spd, A nearly new full kit was fitted myself (clutch+dmf + pressure plate + release bearing) Will take the engine out then can confirm it condition. It done 10-15k miles about since.

Drop me a text who is after good set, guys
 

Witherkay

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You fitted it yourself? Was it particularly difficult? I want to upgrade to the 6-speed box but don't think I can justify Honda fees
 

Accord127

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You fitted it yourself? Was it particularly difficult? I want to upgrade to the 6-speed box but don't think I can justify Honda fees
What all you need to change for six speed box ( other than the box ) cables? Lever ? Etc
 
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