light ACURA CSX 2006 Service Service Manual

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5-speed Manual Transmission
12-14 Clutch
Slave Cylinder Replacement
B
A
B C
A A
B
DC
(P/N 08798-9002)
(P/N 08C30-B0234M)
A
B (P/N 08798-9002)
C D
E
22 N·m
(2.2 kgf·m, 16 lbf·ft)
NOTE:
 Use fender covers to avoid damaging painted surfaces.
 Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid does contact the
paint or plastic, wash it off immediately with water.
 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.
1. Remove the clutch line bracket (A) and the slave cylinder (B).
2. Remove the roll pins (A). Disconnect the clutch line (B), and remove the O-ring (C). Plug or wrap the
end of the clutch line with a clean shop towel to
prevent brake fluid from coming out. 3. Install a new O-ring (A) on the clutch line (B), then
connect the clutch line to the slave cylinder (C).
4. Set in new roll pins (D) to the slave cylinder.
5. Pull back the boot (A), and apply s ilicone grease
(P/N 08C30-B0234M) to the boot and the slave
cylinder pushrod (B). Reinstall the boot.
6. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the pushrod of the slave
cylinder (C) and the release fork (D).
7. Install the slave cylinder and the clutch line bracket (E).
Replace.
Replace.
08/08/21 14:42:34 61SNR030_120_0016
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12-16 Clutch
Slave Cylinder Replacement (cont’d)
D
A
B
C
(P/N 08798-9002)
(P/N 08C30-B0234M)
A
B (P/N 08798-9002)
C D
E
22 N·m
(2.2 kgf·m, 16 lbf·ft)
3. Install a new O-ring (A) on the clutch line (B), then
connect the clutch line to the slave cylinder (C).
4. Set in new roll pins (D) to the slave cylinder.
5. Pull back the boot (A), and apply s ilicone grease
(P/N 08C30-B0234M) to the boot and the slave
cylinder pushrod (B). Reinstall the boot.
6. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the pushrod of the slave
cylinder (C) and the release fork (D).
7. Install the slave cylinder and the clutch line bracket (E). 8. Do the clutch hydraulic system bleeding (see page
12-7).
9. Check the clutch operation, and check for leaks.
10. Test-drive the vehicle.
Replace.
Replace.
08/08/21 14:42:35 61SNR030_120_0018
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Manual TransmissionM/T Differential
5-Speed Manual Transmission
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Special Tools . 13-2
Component Location Index . 13-3
Symptom Troubleshooting
Index . 13-4
Transmission Fluid Inspection and Replacement . 13-5
Back-up Light Switch Test . 13-6
Transmission Removal . 13-7
Transmission Installation . 13-14
Transmission Disassembly . 13-22
Reverse Shift Fork Clearance Inspection . 13-27
Change Lever Clearance Inspection . 13-27
Change Lever Assembly Disassembly/Reassembly . 13-28
Shift Fork Clearance Inspection . 13-29
Shift Fork Disassembly/Reassembly . 13-30
Mainshaft Assembly Clearance Inspection . 13-31
Mainshaft Disassembly . 13-33
Mainshaft Inspection . 13-34
Mainshaft Reassembly . 13-36
Countershaft Assembly Clearance Inspection . 13-41
Countershaft Disassembly . 13-42 .........
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Countershaft Inspection . 13-43
Countershaft Reassembly . 13-44
Synchro Sleeve and Hub
Inspection and
Reassembly . 13-50
Synchro Ring and Gear Inspection . 13-50
Mainshaft Bearing and Oil Seal Replacement . 13-52
Countershaft Bearing Replacement . 13-53
Mainshaft Thrust Clearance Adjustment . 13-54
Transmission Reassembly . 13-56
Gearshift Mechanism Replacement . 13-61
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Component Location Index . 13-62
Backlash Inspection . 13-63
Differential Carrier,
Final Driven Gear
Replacement . 13-63
Carrier Bearing Replacement . 13-64
Oil Seal Replacement . 13-65
Differential Thrust Clearance Adjustment . 13-66
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13-3
Component Location Index
GEARSHIFT MECHANISM
TRANSMISSION FLUID BACK-UP LIGHT SWITCH
TRANSMISSION
CHANGE LEVER ASSEMBLY COUNTERSHAFT ASSEMBLY
MAINSHAFT ASSEMBLY
SYNCHRO RING and GEAR SHIFT FORK
COUNTERSHAFT
CHANGE LEVER
SYNCHRO SLEEVE and HUB
REVERSE SHIFT FORK
DIFFERENTIAL
REVERSE IDLER GEAR
MAINSHAFT
REVERSE LOCK CAM Replacement, page 13-61
Inspection and Replacement, page 13-5 Test, page 13-6
Removal, page 13-7
Installation, page 13-14
Disassembly, page 13-22
Reassembly, page 13-56
Disassembly/Reassembly, page 13-28 Clearance Inspection, page 13-41
Clearance Inspection, page 13-31
Inspection, page 13-50 Clearance Inspection, page 13-29
Disassembly/Reassembly, page 13-30
Disassembly, page 13-42
Inspection, page 13-43
Reassembly, page 13-44
Bearing Replacement,page 13-53
Clearance Inspection,
page 13-27
Inspection and Reassembly,page 13-50
Clearance Inspection,
page 13-27
Disassembly, page 13-33
Inspection, page 13-34
Reassembly, page 13-36
Bearing and Oil Seal Replacement, page 13-52
Thrust Clearance Adjustment, page 13-54
08/08/21 14:44:17 61SNR030_130_0005
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13-6 Manual Transmission
Back-up Light Switch Test
A
BACK-UP LIGHT SWITCH 2P CONNECTOR A
29 N·m
(3.0 kgf·m,
22 lbf·ft)
B
BACK-UP LIGHT SWITCH 2P CONNECTOR
1. Disconnect the back-up light switch 2P connector(A).
2. Check for continuity between back-up light switch 2P connector terminals No. 1 and No. 2. There
should be continuity only when the shift l ever is in
reverse.
 If the test result is OK, go to step 5.
 If the test result is faulty, go to step 3. 3. Remove the back-up light switch (A). Check for
continuity between back-up light switch 2P
connector terminals No. 1 and No. 2. There should
be continuity when the actuator (B) is pressed, and
no continuity when the actuator is released.
 If the test result is OK, check the reverse shift mechanism in the transmission.
 If the test result is faulty, replace the back-up light switch.
4. Apply liquid gasket (08C70-K0230M, 08C70- K0334M, or 08C70-X0331S) to the threads of the
back-up light switch, and install it on the
transmission housing.
5. Connect the back-up light switch 2P connector.
Terminal side of male terminals Terminal side of male terminals
08/08/21 14:44:18 61SNR030_130_0008
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Special Tools Required
13-7
Transmission Removal
A
B C
D
A A
B
A
B C
 Engine hanger adapter
VSB02C000015
 2006 Civic engine hanger VSB02C000025
 Engine support hanger, A and Reds AAR-T 1256
 Front subframe adapter VSB02C000016
These special tools are available through the Acura
Canada Technical Tools Department; FAX
866-398-8665/e-mail: ch_technicaltools ch.honda.com
NOTE: Use fender covers to avoid damaging painted
surfaces.
1. Do the battery removal procedure (see page 22-69).
2. Remove the cowl cover and the under-cowl panel (see page 20-163).
3. Remove the air cleaner assembly (see page 11-345).
4. Remove the harness clips (A) and the intake air duct (B), then remove the battery base (C) with the
coolant reservoir (D). 5. Remove the clutch line bracket (A), then carefully
move the slave cylinder (B) out of the way to avoid
bending the clutch line.
NOTE: Do not press the clutch pedal after the slave
cylinder has been moved.
6. Disconnect the back-up light switch connector (A), the output shaft (countershaft) speed sensor
connector (B), and the harness clips (C).
(cont’d)
08/08/21 14:44:19 61SNR030_130_0009
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’06 model ’07-09 models
13-20Manual Transmission
Transmission Installation (cont’d)
A
B
C
A
D 8x1.25mm
27 N·m
(2.8 kgf·m,
20 lbf·ft)
BC
C
B
A
(P/N 08C30-B0234M) 8x1.25mm
27 N·m
(2.8 kgf·m,
20 lbf·ft)
BC
C
A (P/N 08C30-B0234M) E
36. Install the harness clips (A) on the shift cable
bracket (B) and the harness bracket (C).
37. Apply a light coat of silicone grease (P/N 08C30- B0234M) to the shift cable ends (A).
NOTE: 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. 38. Install the shift cable bracket (B) and the shift cables
(C), then install new cotter pins (D) or lock pins (E).
Replace.
08/08/21 14:44:54 61SNR030_130_0022
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13-21
A
B C
B
A 8x1.25mm
22 N·m (2.2 kgf·m, 16 lbf·ft)
6x1.0mm
9.8 N·m
(1.0 kgf·m,
7.2 lbf·ft)
(P/N 08798-9002) C
D B
C A
6x1.0mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft)
6x1.0mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft)
6x1.0mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft)
39. Connect the back-up light switch connector (A) and the output shaft (countershaft) speed sensor
connector (B). Install the harness clips (C).
40. Apply super high temp urea grease (P/N 08798-9002) to the end of the slave cylinder
pushrod. Install the slave cylinder (A), then install
the clutch line bracket (B). Be careful not to bend
the clutch line. 41. Install the battery base (A) with the coolant
reservoir (B).
42. Install the harness clips (C) and the intake air duct (D).
43. Install the air cleaner assembly (see page 11-345).
44. Do the battery installation procedure (see page 22-69).
45. Install the under-cowl panel and the cowl cover (see page 20-163).
46. Check the shift lever and the clutch operation.
47. Check the wheel alignment (see page 18-5).
48. Test-drive the vehicle.
08/08/21 14:44:55 61SNR030_130_0023
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DYNOMITE -2009-

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Exploded View - Clutch Housing
13-22Manual Transmission
Transmission Disassembly
MAINSHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY
REVERSE IDLER GEAR
REVERSE LOCK CAM BALL BEARING
REVERSE IDLER GEAR SHAFT
14x20mmDOWELPIN
MAGNET DIFFERENTIAL ASSEMBLY
OIL GUIDE PLATE C BEARING SET PLATE
NEEDLE BEARING
28 mm WASHER 28 mm SPRING WASHER
REVERSE SHIFT FORK
SHIFT FORK ASSEMBLY
CLUTCH HOUSING
72 mm SNAP RING
6 mm FLANGE BOLT
13 N·m (1.3 kgf·m, 9 lbf·ft)
35x58x8mmOILSEAL 28x43x7mmOILSEAL20 mm WASHER BACK-UP LIGHT SWITCH
29 N·m (3.0 kgf·m, 22 lbf·ft)
20 mm BOLT
44 N·m (4.5 kgf·m, 33 lbf·ft)
6mmSPECIALBOLT
15 N·m (1.5 kgf·m, 11 lbf·ft)
Replace. Replace. Replace.
08/08/21 14:44:56 61SNR030_130_0024
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13-24 Manual Transmission
Transmission Disassembly (cont’d)
C
A
A
D E
B C
F
D
B
AB B
C
D
A
D
AB
D
C D
D
E
G
F
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the release fork and the replace bearing (see page 12-24).
2. Remove the detent bolts (A), the 12 mm sealing washers (B), the springs (C), the steel balls (D), and
the back-up light switch (E). Then remove the
transmission hanger (F).
3. Remove the 20 mm bolt (A) and the 20 mm sealing washer (B). 4. Remove the interlock bolt (B), the change lever
assembly(C),the8x14mmdowelpins(D),and
harness bracket A.
5. Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), and the sealing washers (D).
6. Remove the output shaft (countershaft) speed sensor (E) with the O-ring (F) and the plain washer
(G).
08/08/21 14:44:58 61SNR030_130_0026
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