fork HONDA CIVIC 1996 6.G Workshop Manual

Standards and Service Limits
Manual Transmission S40 - Section 13
MEASUREMENT
Capacity | (US qt, tmp qt)
End playDiameter of ball bearing contact area A(Transmission housing side)Diameter of 4th, 5th gear contact area BDiameter of 3rd gear contact area CDiameter of ball bearing contact area D(Clutch housing side)Bunout
STANDARD INEW}'1.9 (2.0, 1.7)for overhaul1.8 (1.9, 1.6) for oitchange
0.11 0.18 (0.004 _ 0.007)21.987 - 22.000 (0.8656 0.8661)
26.980 26.993 (1.0622 _ 1.0627)33.984 34.000 (1.3380 1.3386)25.917 - 25.99011.0227 1.0232)
0.02 (0.001) max.
SEBVICE LIMIT
ro
MainshaftAdjust21.930 (0.8634)
26.930 ('1.0602i33.930 (1.3358)
25.92011.0205)
0.05 (0.002)
39.07 ('r.538)
0.33 {0.013)0.31 (0.012)
30.15 (1.187)
30.05 (1.183)
37.07 {1.459)0.31 (0.0'12)
28.35 (1.116)
LrO
39.009 39.025 (1.5358 1.5364)0.06 0.21 (0.002 0.008)0.06 0.19 (0.002 0.007)30.22 30.21 (1.190 1.192)30.12 - 30.17 (1.186 1.188)
37.009 37.025 (1.4570 _ 1.4577)0.06 - 0.19 (0.002 - 0.007)28.42 - 2a.47 11.119,1.1211Countershaft Diameter of needle bearing contact area ADjameter of lst gear contact area gDiameter of ball bearing contact area CRunout
30.000- 30.015 {1.181 1 - 1.1817)35.984 - 36.000 (1.4167 1.4173)24.980 24.993 (0.9835 - 0.9840)0.02 (0.001)max.
29.950 (1.1791)3s.930 r.4146)24.930 (0.9815)0.0s (0.002)
End play (When tightened by the specified torque)Thickness
41.009 - 41.025 ('t.6145 1.6152)0.03 0.10 (0.001 _ 0.004)30.41 30.44 (1.197 - 1 198)
41 .01 11.617J0.22 (0.009)
30.36 (1.195)
gear End ptay (When tightened by the specified torque)44.009 - 44.025 (1.7326 1.7333)0.04 - 0.12 (0.002 - 0 005)31.91 31.96 (1.256 1.258)
44.01 11.t35)0.24 (0.009)
31.85 (1.2s4)
33.04 {1.301)38.93 (1.533)32.01 (1.260)
27.06 (1.065)
33.93 (1.336)
3r.93 {1.257)22.81 (0.898)
23.51 (0.926)
15.08 (0.594)
0.14 (0.006)
0.4 (0.016)
0.16 (0.006)
o.6210.0244112.78 (0.5031)
t.D.o. D.Length
33.000 - 33.010 (1.2992 1.2996)38.989 39.000 11.53s0_ 1.53s4)32.03 - 32.06 tl.261 - 1.2621Spacer collar(Mainshaft 4thand 5th gear)
Beverse rdler gear LD.Gear to reverse gear shaft cjearance
27.002 27.012 (1.0631 _ 1.0635)33.989 - 34.000 (1.3381 - 1.3386)3r.989 - 32.000 (1.2594 1.2598)22.83 - 22.86 (0.899 0.900)23.53 23.56 (0.926 - 0.928)
rs.016 15.043 (0.5912 _ 0.5922)0.032 0.077 (0.0013 _ 0.0030)Ring-to gear clearance {Ring pushed against gear)0.73 - 1.l8 (0 029 - 0.046)Fork finger thickness
Fork to-synchro sleeve clearance
lsv2nd/sth I 6.2 - 6.410.244 - O.ZS2)3rdl4th 7.4 i.6lO 2g1 O 2ggt0.35 - 0.65 (0.014 - 0.026)Beverse shitt fork Fork pawl groove widthFork to-reverse idler gear clearanceL groove widthFork'to-5th/reverse shift piece pin clearance
12.7 - 13.0 (0.50 _ 0.51)0.5 1. t (0.020 0.043)7 .05 - 7 .25 tO.21A - 0.28510.05 0.35 (0.002 0.014)Sh ift a rm A tnner diameter of sh ift arm C contact ffiShift arr14-go "L;L ".m C clearance13.05 13.13 (0.514 0.517)0.05 - 0.23 (0.002 _ 0.009)Inner diameter of shift arm B shaft contact pointShift arm 8-to shaft clearanceShift arm B to-shift piece clearanceDiameter of shift piece contact point
13.973 - 14.000 (0.5501 0.5512)0.013 0.070 (0.0005 _ 0.0028)0.2 - 0.5 {0.008 0.020)12.9 13.0 (0.508 - 0.512)MBS Shift prece Diameter of pin6.9 7 .1 \O.27 0 2A)
0.095 (0.004)
0.14 (0.006)
Adjust with shim
Differenlial carrier Pinion shaft bore diameterCarrier-to pinion shaft clearanceDriveshaft bore diameterCarrier to,driveshaft clearance
18.010 18.028 (0.7091 _ 0.7098)0.023 0.057 (0.0009 - 0.0022)26.025 26.04s {1.0246_ 1.0254)0.045 - 0.086 (0.0018 0.0034)BacklashPinion gear bore diameterPinion gear-to pinion shaft clearance
0.05 0.15 (0.002 0.006)18.042 - 18.066 (0.7103 _ 0.7113)0.055 - 0.095 {0.0021 _ o.oo37)
0 0.1 10 - 0.004)
3-8
LO

MEASUREMENTSTANDARD (NEW) SERVICE LIMITReverse idler geart.D.Gear-to reverse gear shaft clearance20.016 - 20.043 (0.7880 -0.7891)
0.036 - 0.084 {0.0014 - 0.0033)20.09 (0.7909)
0.16 (0.006)
Synchro ringRing to-gear clearance (Ring pushed against gear)0.73 - 1.18 (0.029 0.046)0.4 (0.016)Double coneClearance (Ring pushed against geadOuter synchro ring to gearIn ner synchro ring to-gearOuter synchro ring-to-synchro cone
0.9s - 1.68 10.037 - 0.066)0.5 - 1.0 (0.02 - 0.04)0.5 1.0 (0.02 - 0.04)
0.6 (0.024)
0.3 {0.01)0.3 (0.01)Shift forkFork {inger thicknessFork-to synchro sleeve clearance7.4 - 7.6 (0.291- 0.299i0.35 - 0.65 (0.015 0.026)1.0 (0.04)Beverse shift forkFork pawl groove widthFork-to-reverse idler gear clearanceL-groove width At 5th gear sideAt reverse sideFork'to-5th/reverse shift piece pin clearanceAt 5th gear sideAt reverse side
13.0 - 13.3 10.512 - 0.524)0.5 - 1.0 (0.02 - 0.04)7.4 t.1 10.29 -O.30)
7 .O5 - 7 .25 (0.21A - 0.2A5i'
0.4 0.9 (0.02 0.04)0.05 0.45 (0.002 - 0.018)
1€ {0.07)
Shift pieceShift piece-to-shift arm clearanceGroove width of shift arm contact areaShilt'piece-to-shift fork shaft clearanceWidth of shift lork contact area
0.1 - 0.3 (0.004 - 0.012)8.1-8.2 (0.319 - 0.323i0.2 - 0.5 (0.008 0.020)1 1.9 - 12.0 10.469 - 0.472)
0.6 (0.02)
0.8 (0.03)
Select armSelect arm-to-interlock clearanceSelect arm to-shim clearance0.05 - 0.20 (0.002 - 0.008)0.01 - 0.2 10.0004 - 0.008)0.45 (0.018)
InterlockWidth of select arm contact area9.9 - 10.0 (0.390 0.394)Change pieceChange piece-to-shilt arm holder clearanceGroove width ot shitt arm holder contact areaChange piece-to select arm clearanceGroove width of select arm contact area
0.05 - 0.35 (0.002 - 0.014)12.05 - 12.15 \0.474 -0.47a1
0.05 - 0.25 (0.002 - 0.010)12.05 - 12. t5 (0.474 - 0.478)
0.8 {0.03)
0.5 (0.02)
Final driven gearBacklash0.090 - 0.149 (0.0035 - 0.0059)0.200 (0.008)DifferentialcarrierPinion shatt bore diameterCarrier to-pinion shaft clearanceDriveshaft bore diameterCarrier-to driveshaft clearanceCarrier-to-int6rmediate shatt clearance
18.000 - 18.016 10.7087 - 0.7093)0.013 - 0.045 {0.001 0.002)24.000 - 28.021 11.1024 1.1032)0.020,0.062 (0.0008 - 0.0024)0.05 - 0.087 {0.0020 - 0.0034)
0.10 {0.004)
0.12 (0.005)
0.14 (0.006)
Differential piniongearBacklashPinion gear bore diameterPinion gear-to-pinion shaft clearance
0.05 -0.15 (0.002 - 0.006)18.042 18.066 (0.710 - 0.711)0.055 - 0.095 (0.002 - 0.004)0.15 (0.006)
Set ring to bearing outer race0 - 0.10 (0 - 0.004)Adjust with shim
Standards and
Manual Transmission
Service
S4C (cont'd)
Limits
- Section 13
ua
.'1'
3-10
L,O

Automatic TnsmtsstonSection 14Un;t of length: mm {in)
r
MEASUREMENT
a
STANDARD INEW)SEBVICE LIMIT
TransmissionMainshaft 2nd gear thrust washer thickness
Thrust washer thicknessMainshaft ball bearing left sideMainshaft lst gear
Countershaft 3rd gear splined washer '96 97 models'98 - 00 models
One-way clutch contact area
Countershaft 1st gear LD.
Park gear O.D.Mainshaft feed pipe A, O.D. (at 15 mm (0.59 inlfrom
Mainshaft feed pipe B, O.D. (at 30 mm {1.2 in) from end)
Countershaft feed pipe O.D. lat 15 mm (0 59 in) from
eno)Mainshaft sealing ring thickness
129 mm 11.1 iniand 35 mm {1.4 in))
Mainshaft bushing l.D.
Mainshaft bushing LD.
Countershaft bushing LD.Mainshaft sealing ring goove width
3.97 4.00 10.156 - 0.157)4.02 - 4.05 (0.158 0.159)
4.07 - 4.10 (0.160 - 0.161)4.12 - 4.15 (0.162 0.163)
4.17 - 4.20 10.164 - 0.165)4.22 - 4.25 (0.166 - 0.167)4.27 - 4.30 (0.168-0.169)
4.32 - 4.35 (0.170 0.171)
4.37 - 4.40 10.172 - 0.173)
4.42 - 4.45 10.114 - 0.175l
1
I
+Wear or damage
2.95 - 3.05 {0.116 - 0.120)2.43 2.50 (0.096 - 0.098)4.45 - 4.50 (0.175 - 0.177i4.95 - 5.00 (0.195 0.197)
Wear or damage
+I
83.339 - 83.365 (3.2810 3.2821)
66.685 - 66.698 (2.6254 - 2.6259)
8.97 - 8.98 (0.353 - 0.354)
5.97 5.9810.2350 - 0.2354i7.97 - 7.98 (0.3138 - 0.3142)
1.87 - 1.97 {0.074 0.078)
6.0 r8 - 6.030 {0.2369 - 0.2374)
9.000 - 9.01s 10.3543-0.3549)8.000-8.022 (0.3150 - 0.3158)
2.025 - 2.015 l0.0197 -0.0417)
Wear or damageWear or darn age
8.95 (0.352J
5.95 (0.234)
7.95 (0.313)
1.80 (0.071)
6.045 (0.2380)
9.03 (0.356)
8.03 {0.316)2.08 (0.082)
Regulatorvalve body
Seating ring conlact area l.D.35.000 35.02511.3780 1.3782)35.050 (1.3799)
Shifting device andpark brake controlReverse shift fork Iinger thicknessPark brake pawl
Park gear
5.90 - 6.00 (0.232 - 0.236)5.40 (0.213)
lWear or other defect
Servo bodyShift fork shaft bore LD.
Shift fork shaft valve bore l.D.
14.000 - 14.010 (0.5512 - 0.5516)
37.000 - 37.039 (1.4567 - 1.4582)37.045 (1.4585)
ATF pumpATF pump gear side clearanceATF pump gear-to-body clearance DriveDaiven
ATF pump driven gear LD.ATF pump driven gear shaft O.D
0.03 -0.05 {0.001 - 0.002)0.1050 - 0.1325 (0.0041 - 0.0052)
0.0350 - 0.0625 (0.0014 - 0.0025)14.0'|6 - 14.034 {0.5518 - 0.5525i13.980 13.990 (0.5504 0.5508)
0.07 (0.003)
Differentialcarrier
Pinion shaft contact area LD.
Carrier to'pinion clearanceDriveshaft contact are LD.
Carrier to-driveshaft clearance
18.010 18.028 {0.7091 0.7098)
0.023 - 0.057 (0.0009 -0.0022)
26.025 * 26.045 11.0246 1.0254)
0.045 - 0.086 (0.0018 - 0.0034)
0.1 {0.004)
0.12 {0.005)
Differentialprnron gearBacklasht.D.Pinion gear to-pinion shaft clearance
0.05 - 0.15 {0.002 - 0.006)18.042 - 18.066 (0.7103 - 0.7113i0.055 - 0.095 (0.0022 - 0.0037)ffi.oour
Set ring-to bearing outer race clearance0 - 0.15 (0 0.006)Adjust
(cont'd)
3-13

ILubrication Points
For the details of lubrication points and types of lubricants to be applied, refer to the lllustrated Index and various workprocedures (such as Assembly/Reassembly, Replacement, Overhaul. Installation, etc.) contained in each section.
No.LUBRICATION POINTS
Engine
LUBRICANT
"Energy Conserving" grade oil,The oil container may also display the Apl Certification markshown below. Make sure it says ,,For Gasoline Engines.,,SAE Viscosity: See chart below,
I
TransmissionManualGenuine Honda MTF*1
Genuine Honda Premium FormulaAutomatic Transmission Fluid (ATF)*,
Genuine Honda CVT Fluid*3
Genuine Honda DOT3 Brake Fluid*a
Automatic
CVT
3Brake Line
ClL,tci t""e4
I
Genuine Honda DOT3 Brake Fluid*aPower steering gearboxSteering grease P/N 08733 - BO70EShift lever pivots (manual transmission)Grease with molybdenum disulfide7-:ti
9
10'l'l
l3
14
't7
18
19
20
2122
Release fork (manual trancmi<si^nl
Steering bootsTailgate hinges and latches (2-door HatchbacklSteering ball joints
Shift lever (automatic transmission)Pedal linkageBrake master cylinder pushrod
Super High Temp Urea crease (p/N 08798 - 9OO2)
i Multi-purpose grease
I
I
Honda White Lithium Grease
Multi-purpose grease
Silicone grease
@
Trunk hinges and latch (4-door Sedan and 2-doorCoupe)Door hinges upper and lowerDoor opening detentsHood hinge and hood latch-FUet T ter ttd
Clutch master cylinder pushrodThrottle cable end and throttle linkageRear brake shoe linkagesSteering wheel (back side)
23
E-
Caliper piston seal, dust seal,caliper pin. pistonThrottle cable end (dashboard lower panel)
Power steering system (for cars with p/S)
Air conditioning compressorComDressor oil:SANDEN: SPlo P/N 38897 - p13 -A01AH or 38899 - p13_ A01{For Refrigerant: HFC-134a (R-134a))
CERTIFICATION SEAL
ffi
NorE: The items m arked * 1, *2, +3, *4 and +5 on above chan are described as folows:*1: Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because itdoes not contain the proper additives.*2: Always use Genuine Honda premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affectshift quality.+3: Use Genuine Honda cVTfluid only usingotherfluid can affect tra nsmission operation and may reduce transmission life.*4: Always use Genuine Honda DoT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and dec.ease the lifeof the svstem.*5: Always use Genuine Honda Power steering Fluid. using any other type of power steering fluid or automatrc transmissionfluid can cause increased wear and poor steering in cold weather.
4-2
Recommended Engine Oil
Engine oil viscosity forambrent temperature ranges
API SERVICE LABEL

81642 engine:
8 x 1.25 mm
22N,n 12 2 kdl'rn,
Replace.
,&16 rbt.ftl
Replace.
SELF.LOCKING8 x 1.25 mm16 N.m t1.6 kg{ m, 12 lbl'ft)
Replace.
GASKETSReplace.
10 x 1 .25 mm
s4 N.m {5.5 kgf m, 40 lbf'ftl
32.
PIPE A
RePlace'
Remove the damper forks (see section 18).
Disconnect the suspension lower arm ball joints
(see section 18).
Remove the driveshafts.
CAUTION:
o Do not pull on th€ drivoshaft. the CV ioint may
com9 apart.
o Use care whgn prying out the assombly.
Pull it straight to avoid damaging the differential
oil seal or intermediate shaft dust seal.
NoTE: Coat all precision-finished surfaces with
clean engine oil. Tie plastic bags over the driveshaft
enos.
34.
HO2S CONNECTOR
!^.
35.
36.
Lower the hoist.
Remove the upper and lower radiator hoses and
heater hoses,
37. Removs the ATF cooler hoses, then plug the ATF
cooler hoses and PiPes (A,/T)
UPPERRADIATOR HOSE
HOSES
(cont'd)

Release Bearing
)
4. Torque the mounting bolts in a crisscross pattern as
shown. Tighten them in several steps to prevent
warping the diaPhragm sPring.
19 rbf.ft)
\
RING GEAR HOLDERoTLAB-PV00100ot07924-PD20003
CLUTCH ALIGNMENT SHAFT
OTJAF_PM7O12AHANOLE07936-3710100
MOUNTING BOLTS
8 x 1.25 mm
25 N.m (2.6 kgl'm.
Removal/lnspection
1. Remove the release fork boot from the clutch hous-
Ing.
2. Remove the release fork from the clutch housing by
squeezing the release fork set spring with pliers
Remove the release bearing.
Check the release bearing for play by spinning it by
hand.
CAUTION: The releass bearing is packed with
grease. Do not wash it in solvent.
lf there is excessive play, replace the release bear-
ing with a new one.
RELEASE FORK
12-11

Release Bearing
Installation
NOTE: Use only Super High Temp Urea Grease(P/N 08798 - 9002).
1. With the release fork slid between the release bear-
ing pawls, install the release bearing on the main-
shaft while inserting the release fork through the
hole in the clutch housing.
RELEASE FORK BOLT12 x 'l .25 mm
tP/N 0a79a-90021O.3-0.9 s 10.01 -O.03 ozl
Align the detent of the release fork with the release
fork bolt, then press the release fork over the
release fork bolt sequarely.
-Gr08798-9002)
2.
12-12
IJ
3. Move the release fork right and left to make surethat it fits properly against the release bearing, and
that the release bearing slides smoothly.
4. Install the release fork boot; make sure the bootseals around the release fork and clutch housino.

\
S40 Model (All except'99 - 00 2-door Si' SiR)
Manual Transmission
Special Tools ..'.......... 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Troubleshooting '....... 13-4
Transmission AssemblY
Removal ................. 13-5
lnstallation ............. 13-8
lllustrated Index ...............'........."........ 13-10
Transmission Housing
I Removaf .."""""""' 13-12
J R"rr"r"" Shift Holder
Clearance lnspection ....................... 13-13
Reverse ldler Gear
Removal ....'.........." 13-14
Mainshaft, Countershaft, Shift Fork
Disassembly ......'... 13-14
Mainshaft AcsemblY
Index ............... ....... 13-15
Clearance Inspection ..'.................... 13-16
Disassembly .......... 13-17
Inspection ....'......... 13-18
Reassembly ........... 13-19
Countershaft AssemblY
lndex ................ ...... 13-20
Clearance lnspection ."..........'......." 13-21
Disassembly ..."""' 13-22
Inspection .............. 13-23
Reassembly ..'.""... 13-23
Shift Fork AssemblY
lndex ............... ."'... 13-25
Clearance lnspection ."......."........'.. 13'26
MBS Shift Piece Inspection ....-.....'.. 13'27
Synchro Sleeve, Synchro Hub
f nspection/lnstallation .......'...... ".... 13'27
Synchro Ring, Gear
Inspection '....'..".... 13'28
Shift Rod
Removal .'......".""" 13'29
Differential
lndex ......."'...... .'."' 13-30
Backlash Inspection ..........."......."... 13-30
Bearing Beplacement'.............'.".... 13'31
Final Driven Gear Replacement '..... 13-31
Thrust Shim Adiustment ..."........... 13-32
Clutch Housing Bearing
Replacement .......'. 13-34
Mainshaft Thrust Shim
Adiustment '....'..".. 13-36
Transmission
Reassembly ........... 13-39
Oil Seals
Replacement ......... 13-43
Gearshift Mechanism
Overhaul ................ 13-44
\

Troubleshooting
Reverse Gear Noise Reduction System
Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia.
The resulting speed difference between mainshaft and reverse idler gear produces gear noise.
The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shifting
into reverse, the sth/reverse shjft piece, connected to the shift lever, rotates the cam plate. This causes the sth synchro set
to stop the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be less
gear norse.
NOTE: This system is not a fully-synchronized gear noise reduction system.
Therefore, you may hear gear noise when
O you shift into reverse with the vehicle not yet completely stopped.
@ you shift quickly into reverse during fast idling.
-
Gear noise is oresent when shift-ing into reverce after the engineis started.
Test-drive the vehicle.
ls the gear noise present whenshifting into 5th gear?Beplace the 5th synchro hub and3leeve e3 a set,
Measure the clearance between5th shift fork and 5th synchrosleeve {see page 13'26).
ls the clearance 1.0 mm (0.04
in) or less?
Measure the MBS shift piece pin(see page 13-27).
ls ( 6.8 mm (0.27 in) or more?Replace the MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4

Transmission Assembly
Removal(cont'd)
17. Remove the three upper transmission mounting
bolts and the lower starter mounting bolt,
STARTERMOUNTINGBOLT10 x 1.25 mm44 N.m (4.5 kgf.m,33 rbnftl
TRANSMISSIONMOUI{TING EOLTS12 x 1.25 mm& N.m (6.5 kgt'm,47 lbl.ftl
18. Remove the rear mount bracket bolts and transmis-
sion mounting bolts.
12 x 1.25 mm64 N.ft 16.5 kgl.m,47 lbl.ftl
SPECIAL BOLTReplace.'ll x 1.5 mm84 N.m (8.5 kgf.m, 61 lbf.ftl
SPECIAL BOLTReplace.14 x 1,5 mln84 N.m (8.5 kgl.m, 61
WASI{ERREARMOUNTBRACKET
rbl.ftt
Pull the transmission away from the engine until it
clears the mainshaft. then lower it on the transmis-
sion jack.
CAUTION: Take caro not to b6nd tho clutch lin€.
1(|
Installation
Install the transmission assembly in the reverse order of
removal.
Before installing, check that the two dowel pins are
installed in the clutch housing.
When installing the starter cable, make sure that the
crimped side of the ring terminal is facing out (see
section 23).
Apply grease to the parts as shown, then install the
release fork and release bearing,
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
RELEASE FORK BOLT12 x 1.25 mm29 N'm 13.0 kgt,m,(P/N 08798-90021
22 tbl.ttlR€LEASEBEARING
J
RELEASEFORK8()07
ra
{PiN 08798-9002)
tP/N 08798-900210.3-0.9 g
10.01-0.03 ozl