Disclaimer***Acura TL AWD V6-3.7L Technical Service Bulletin # 11-004 Date: 130126
M/T - Clutch Pedal Pops, Squeaks Or Clicks When Operated
11-004
January 26, 2013
Applies To:
2004-08 TL - ALL with M/T
*2010-11 TL-AL with M/T
2012 TL with M/T - From VIN 19UUA9E..CA000001 thru 19UUA9E..CA000672*
Clutch Pedal Pops, Squeaks, or Clicks
(Supersedes 11-004, dated March 31, 2011, to revise the information marked by asterisks)
REVISION SUMMARY
*In Applies To, under PARTS INFORMATION, and under REPAIR PROCEDURE, 2010-12 model years were added.*
SYMPTOM
The clutch pedal pops, squeaks, or clicks when you press or release it.
PROBABLE CAUSE
The clutch master cylinder has insufficient clearance between the piston and the push rod.
CORRECTIVE ACTION
Replace the clutch master cylinder.
PARTS INFORMATION
Clutch Master Cylinder Assembly:
2004-08: P/N 46920-S7A-A04
(Includes clutch master cylinder, O-ring, seal, and snap pin)
*2010-12: P/N: 46925-TA0-A02
(Includes clutch master cylinder, O-ring, seal, except snap pin)
Snap Pin: P/N 46942-S5A-003*
REQUIRED MATERIALS
Honda Genuine DOT 3 Brake Fluid: P/N 08798-9008
(Each repair requires one bottle.)
Honda Genuine Silicone Grease: P/N 08C30-B0234M
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Operation Number: 211101
Flat Rate Time: 1.1 hours
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Failed Part: P/N 46920-57A-A03
Defect Code: 03214
Symptom Code: 04201
Skill Level: Repair Technician
Disclaimer
Repair Procedure - 2004-06 TL
1. Remove the left rear and the left side engine compartment covers.
2. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
3. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the client's audio presets.
Make sure the ignition switch is OFF.
4. Disconnect the negative cable from the battery first, then disconnect the positive cable.
5. Remove the battery.
6. Remove the air cleaner assembly.
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7. Remove the battery base.
8. Remove the under-hood fuse/relay box.
9. Remove the driver's dashboard undercover:
^ Gently pull down the rear edges of the undercover to detach the clips.
^ Pull the cover away to release the pins from the holders.
^ Disconnect the foot light illumination connector (if equipped).
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10. Pry out the lock pin, and pull the pedal clevis pin out of the yoke. Remove the master cylinder mounting nuts.
11. Remove the clutch fluid reservoir mounting bolt.
12. Disconnect the clutch line from the bracket.
13. Detach the clutch line from the clamp(s).
14. Remove the clutch master cylinder.
15. Disconnect the clutch fluid reservoir hose and the clutch line:
^ Remove the retaining clip.
^ Remove the clutch line from the clutch master cylinder.
^ Wrap the ends of the reservoir hose and the clutch line with shop towels to prevent brake fluid from coming out.
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^ Remove the 0-ring and the clutch master cylinder seal from the clutch master cylinder.
16. Apply brake assembly lube to the clutch line, and install a new 0-ring and clutch master cylinder seal.
17. Attach the clutch line to the clamps, install a new retaining clip, and connect the reservoir hose.
18. To prevent the retaining clip from coming off, pry apart the the tip of the retaining clip with a screwdriver.
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19. Install the clutch master cylinder.
20. Connect the clutch line to the bracket.
21. Install the reservoir mounting bolt.
22. Make sure the hose clamps are positioned on the master cylinder and reservoir as shown.
23. Torque the master cylinder mounting nuts to 13 N.m (9.4 lb-ft).
24. Apply grease to the pedal clevis pin, slide it into the yoke, then install a new lock pin.
25. Adjust the clutch pedal, the clutch pedal position switch, and the clutch interlock switch.
26. Bleed the clutch master hydraulic system.
^ Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
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^ Use only Acura DOT 3 Brake Fluid, from an unopened container.
^ Make sure there is an adequate supply of brake fluid in the clutch reservoir, then slowly pump the clutch pedal until no more bubbles appear
at the bleeder hose.
^ It may be necessary to limit the movement of the clutch release fork with a block of wood to remove all the air from the system.
^ Tighten the bleeder screw to 8 N.m (5.8 lb-ft) (do not overtighten).
^ Make sure the clutch works properly, and check for brake fluid leaks.
27. Install the driver's dashboard undercover:
^ Plug in the foot light illumination connector (if equipped).
^ Push in the undercover to connect the pins to the holders.
^ Gently push up the rear edges of the undercover to attach the clips.
28. Install the under-hood fuse/relay box, and torque the two bolts.
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29. Install the battery base.
30. Install the air cleaner assembly.
31. Install the battery.
^ Clean the battery posts and cable terminals.
^ Connect the positive cable to the battery first, then connect the negative cable.
^ Apply multipurpose grease to the posts and cable terminals to prevent corrosion.
32. Enter the anti-theft codes for the audio system and navigation system (if equipped).
^ Enter the client's audio presets.
^ Set the clock.
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33. Install the left rear and the left side engine compartment covers.
34. Refill the brake fluid in the clutch reservoir to the MAX (upper) level line.
Repair Procedure - 2007-08 TL
1. Remove the left rear and the left side engine compartment covers.
2. Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
3. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the client's audio presets.
Make sure the ignition switch is OFF.
4. Disconnect the negative cable from the battery first, then disconnect the positive cable.
5. Remove the battery.
6. Remove the air cleaner assembly.
7. Remove the battery base.
8. Remove the under-hood fuse/relay box.
9. Remove the driver's dashboard undercover:
^ Gently pull down the rear edges of the undercover to detach the clips.
^ Pull the cover away to release the pins from the holders.
^ Disconnect the foot light illumination connector (if equipped).
10. Pry out the lock pin, and pull the pedal clevis pin out of the yoke. Remove the master cylinder mounting nuts.
11. Remove the clutch fluid reservoir mounting bolt.
12. Disconnect the clutch line from the bracket.
13. Detach the clutch line from the clamp(s).
14. Remove the clutch master cylinder.
15. Disconnect the clutch fluid reservoir hose and the clutch line:
^ Remove the retaining clip.
^ Remove the clutch line from the clutch master cylinder.
^ Wrap the ends of the reservoir hose and the clutch line with shop towels to prevent brake fluid from coming out.
16. Remove the 0-ring and the clutch master cylinder seal from the clutch master cylinder.
17. Apply brake assembly lube to the clutch line, and install a new 0-ring and clutch master cylinder seal.
18. Attach the clutch line to the clamps, install a new retaining clip, and connect the reservoir hose.
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19. To prevent the retaining clip from coming off, pry apart the the tip of the retaining clip with a screwdriver.
20. Install the clutch master cylinder.
21. Connect the clutch line to the bracket.
22. Install the reservoir mounting bolt.
23. Make sure the hose clamps are positioned on the master cylinder and reservoir as shown.
24. Torque the master cylinder mounting nuts to
13 N~m (9.4 Ib4t).
25. Apply grease to the pedal clevis pin, slide it into the yoke, then install a new lock pin.
26. Adjust the clutch pedal, the clutch pedal position switch, and the clutch interlock switch.
27. Bleed the clutch master hydraulic system.
^ Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
^ Use only Acura DOT 3 Brake Fluid, from an unopened container.
^ Make sure there is an adequate supply of brake fluid in the clutch reservoir, then slowly pump the clutch pedal until no more bubbles appear at
the bleeder hose.
^ It may be necessary to limit the movement of the clutch release fork with a block of wood to remove all the air from the system.
^ Tighten the bleeder screw to 8 N~m (5.8 Ib4t) (do not overtighten).
^ Make sure the clutch works properly, and check for brake fluid leaks.
28. Install the driver's dashboard under cover:
^ Plug in the foot light illumination connector (if equipped).
^ Push in the undercover to connect the pins to the holders.
^ Gently push up the rear edges of the under cover to attach the clips.
29. Install the under-hood fuse/relay box, and torque the two bolts.
30. Install the battery base.
31. Install the air cleaner assembly.
32. Install the battery.
^ Clean the battery posts and cable terminals.
^ Connect the positive cable to the battery first, then connect the negative cable.
^ Apply multipurpose grease to the posts and cable terminals to prevent corrosion.
33. Install the left rear and the left side engine compartment covers.
34. Enter the anti-theft codes for the audio system and navigation system (if equipped).
^ Set the clock
^ Enter the client's audio presets
35. Refill the brake fluid in the clutch reservoir to the MAX (upper) level line.
Repair Procedure - 2010-12 TL
NOTE:
The repair procedures are in an outline form that you can use as a checklist for the repair. If you need more details on the procedures listed
below, view them online.
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^ Clutch Master Cylinder Replacement
^ Clutch Hydraulic System Bleeding
^ Clutch Pedal, Clutch Pedal Position Switch A and Clutch Pedal Position Switch B Adjustment
1. Remove the brake fluid from the master cylinder reservoir with a syringe.
2. Remove the clutch reservoir.
3. Disconnect the clutch line from the clutch master cylinder. To prevent spills, cover the joint with rags or clean shop towels.
NOTE:
Use a flare nut wrench to loosen the flare nut while holding the clutch line connector with another wrench.
4. Remove the driver's dashboard undercover.
5. Pry out the lock pin, and pull the pedal clevis pin out of the yoke. Remove the master cylinder mounting nuts.
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6. Remove the clutch master cylinder and the clutch master cylinder seal.
7. Disconnect the reservoir hose.
NOTE:
Inspect the hose. If the hose has damage, leaks, interference, or twisting, replace it.
8. Remove the retaining clip, then remove the clutch line connector and the 0-ring from the master cylinder.
9. Install the clutch line connector with a new 0-ring to the new clutch master cylinder, then set in a new retaining clip to the master cylinder.
^ Apply silicone grease on the 0-ring and the joint part of the clutch line connector.
^ Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your
hands or gloves.
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10. To prevent the retaining clip from coming off, pry apart the tip of the clip with a screwdriver.
11. Connect the reservoir hose, and adjust the hose clamp position and direction.
NOTE:
When attaching the reservoir hose, align the yellow mark on the hose to the rib on reservoir connection area, and the blue mark on the hose
to the rib on the clutch master cylinder connection area.
12. Install a new clutch master cylinder with a new seal.
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13. Install the master cylinder mounting nuts. Torque the mounting nuts to 13 N~m (9.4 lb-ft).
14. Apply multipurpose grease to the clevis pin, and the mating surfaces of the clevis and the pedal. Slide the clevis pin into the clevis, then install
the lock pin.
15. Connect the clutch line to the clutch master cylinder.
NOTE:
Use a flare nut wrench to tighten the flare nut while holding the clutch line connector using another wrench.
16. Install the clutch reservoir.
17. Bleed the hydraulic system.
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^ Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
^ Use only Acura DOT 3 Brake Fluid, from an unopened container.
^ Make sure there is an adequate supply of brake fluid in the clutch reservoir, then slowly pump the clutch pedal until no more bubbles appear
at the bleeder hose.
^ It may be necessary to limit the movement of the clutch release fork with a block of wood to remove all the air from the system.
^ Tighten the bleeder screw to 8 N~m (5.8 lb-ft) (do not overtighten).
^ Make sure the clutch works properly, and check for brake fluid leaks.
18. Adjust the clutch pedal, clutch pedal position switch B and clutch pedal position switch A.
19. Check the clutch operation and check for leaks.
