I changed out the clutch on a 92 Accord EX about 2 weeks ago.

The repair went fine. It was the first time I did a clutch. We put the transmission back together, bled the clutch line, took it for a test drive and all was good. The car then sat for about 10 days as I went on vacation.

When I got back, I took it to emission testing where they ran it on the dyno to simulate an uphill acceleration, putting a lot of stress on the car. All was well, I passed with flying colors.

Immediately after that, I drove it home and was going down a hill, took the engine up to 4,000 rpm to shift from 2nd into 3rd and I hear this clunking, rattling sound. At first, I though I may have blown the engine, as if a piston had broken. I blew the engine on a Isuzu Rodeo before, so this was a familiar sound. The clanking sound got louder. I was still able to shift gears, and at certain instances, the noise went away, and then would come back.

I managed to make it home (only a few miles drive). As I was coming to a stop, I put the car in neutral and the car was fighting to say alive. I came to a complete stop and shut the engine off. Then I restarted the car, the clunking sound immediately started again. I tried to shift gears while the car was still parked, and was unable to, even with the clutch pushed all the way down.

The following morning, I got in the car (engine off) and was able to shift gears again. But as soon as I turned the engine back on, I was NOT able to shift gears. Next, I restarted the car while already in 1st gear and drove it down the block. I seems that the clutch is engaging, but did not disengage when I pushed the clutch pedal down.

My only thought is that the throw-out bearing may have gotten out of position (I don't know how). We had to continually reposition the throw-out bearing while attempting to mount the transmission back onto the engine, so I was concerned that it may come loose. Is this even possible?

My other thought is that the installation of the clutch was done wrong, but I followed all instructions to the "T", straight from the Honda service manual.

I looks like I am going to have to take another weekend and tear this thing apart to find the source of the problem...something I am not looking forward to.

Have anyone experienced something like this after doing a clutch replacement? Any insight would be helpful.

 

I had a friend drop by who is a Honda mechanic to help me diagnose this problem. He's thinking either I installed the clutch plate incorrectly or I have a defective clutch.

I bought the clutch replacement package from Checker's for about $110. The same Honda parts go for about $450, so there is a good chance my clutch may have already failed or is defective. He told me even Honda parts sometimes have defects and they have to redo the work at the dealership.

The clunking sound I hear is either caused by the flywheel (which appears to not be spinning straight) banging against the engine or not making the proper contact with the clutch plate.

Or possibly the throw out bearing came loose and is clanging around the transmission housing.

Well...I won't know for sure unless I take this thing apart (AGAIN), hopefully the 2nd time will be the charm.

 

The throw-out bearing slides along the tranny input shaft, so it's hard to imagine it coming LOOSE from it's proper position. Maybe part of it actually broke apart? I would hope that's a fairly rare thing.

Check the throw-out LEVER which goes from the slave cylinder, in through the tranny bellhousing. I do remember one post here, where that thing broke.

Unfortunately, you're gonna be taking the tranny out again to figure it out.