manual transmission HONDA CIVIC 2003 7.G User Guide

Manual Transmission
Transmission Installation (cont'dl
'10. Installthe three rear mounting bolls for the
transmission rear mount.
59 N.m (6.0 kgf.m,43 tbf.ft)
Loosely tighten the front engine mount bracket
mounting bolt.
11.
12.
t5.
14.
Install the intermediate shaft (see page 16-24).
Installthe drivershafts (see page 16-17).
lnstall the three way catalytic converter (TWC)
assembly (see step 17 on page 5-12).
10 x 1.25 mm
13-10
6x1.0mm12Nm
15.Install the transmission mount bracket (A) and the
transmission mounting bolt {B).
12 x 1.25 mm54 N.m {5.5 ksf.m, 40lbf.ft)
12x 1.25 nn54 N.m(5.5 kgf.m,40 tbt.ft)
16.
17.
/t':::= 12 x 1.25 mm-) 54 N.m(5.5 kgf.m,40 tbf.ftl
Install the air cleaner bracket (C).
Install the two upper transmission mounting bolts.
12 x 1.25 mrn64 N.m (6.5 kgt.m,47 lbf.ftl
18. Remove the engine hanger and special tool from
engrne.

Manual Transmission
Transmission Installation (cont'dl
Apply super high temp urea grease (P/N 08798-
9002) to the end of the slave cylinder rod. Install the
slave cylinder and the clutch line bracket. Take care
not to bend the clutch line.
8 x 1.25 mm22 N.m (2.2 kgf.m, 16 lbf ft)6x1.0mm9.8 N.m(1.0 kgf.m,7.2 tbt.ftla^_#._gEEa9En(P/N 08798-9002)
24. Installthe harness clip.
13-12
25. Installthe cable bracket (A) and cables (B).
BWZ[i:i'u'T!'*n'-'
lPlN 08798-9002)
Apply a light coat of super high temp urea grease(P/N 08798 - 9002)to the cable ends.
Connect the back-up light switch connector (A) and
the vehicle speed sensor {VSS)connector (B).
26.
t1

Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
,.Y
-'- R
,ot/u
,t- v -1A' i6 t3l
\?
q'/V^
.!) DIFFERENTTAL ASSEMBLY
r2l SHIFT FORK ASSEMBLY
a9l 6 mm FLANGE BOLT12 N.m (1.2 kgf m,9lbf ftl
..4] BEARING sET PLATE
G, COUNTERSHAFT ASSEMBLY
O NEEDLE BEARING
3 OIL GUIDE PLATE C
e 14 x 20 mm DOWEL PIN
.9-i MAGNETi.!! MAINSHAFT ASSEMBLY
U 28 mm WASHER
t€4
i[, 28 mm SPRING WASHERiO BALL BEARING(l 28 x 43 x 7 mm OIL SEALReplace.
.D REVERSE GEAR SHAFT
1' REVERSE IDLER GEARf lr 6 mm SPECIAL BOLT15 N.m (1.5 kgt.m, 11 lbf.ft)
(!I REVERSE SHIFT FORK
.4' REVERSE LOCK CAMQ-t 35 x 58 x 8 mm OIL SEALReplace.
n""
?]] BACK-UP LIGHT SWITCH29 N m (3.0 kgf.m,22 lbf ftl.?1 O.RINGReplace.
1!) VEHICLE SPEEo sENsoR (Vss).O 8 mm FLANGE BOLT22 N.m (2.2 kgf m, 16lbf.ftl
.' CLUTCH HOUSINGiI6) TRANSMISSION HANGER
tl 10 mm FLANGE BOLT44 N.m {4.5 kgt.m,33 lbf.ft}
:
r'<__J'.@t / ,, tl
' j=-X ri ,1.-6
'-==-Yh,_-9
13-14

Manual Transmission
Transmission Disassembly (cont'd)
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the detent bolts (A), springs, steel balls,
and back-up light switch (B).
Remove the vehicle speed sensor (VSS) (A) and
O-ring (B).
13-16
3, Remove the interlock bolt (A), the change lever
assembly (B), 8 x 14 mm dowel pins (C), andthe
clutch line clip bracket {D).
€
Remove the drain plug (A), filler plug (B), and
10 mm flange bolt (C).

Manual Transmission
Transmission Disassembly (cont'd)
12. Remove the reverse shift fork.
Apply vinyl tape to the mainshaft splines to protect
the seal, then remove the mainshaft assembly (A)
and countershaft assembly (B) with the shift forks
{C)from the clutch housing (D).
14. Remove the 28 mm spring washer (E) and28mm
washer (F).
t7t1I
13-18
15. Remove the differential assembly (A) and magnet(B ).
Remove the oil gutter plate (A), 72mm shim (B),
and oil guide plate M.
16.

Manual Transmission
Change Lever Assembly Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
BREATHER CAPTurn the arrow toward the {ronto{ the vehicle, and install it.
SELECT LEVERBe careful not to damage the dust sealwhen installing it.@).1 IlLrl
rrl
I
DUST COVEB
a^^
7 Fr"irr6-rooa
(P/N 08798-9002)
ROLLER
6x1.0mm12 N.m(1.2 kgl.m,8.7 lbf.ft)
'^ E-='-Fl !-d 1sr/2Noq )-=^l sELEcr
i €2 sPntruc
,.* (A)tace. ix#,,l
H\
lV srxSELECT-z:-=:l-': SPRING
r\
tr7
,/u
/
\op
(g)'
' -, OIL SEAL,/ ReDlace./-r,s
\__/
INTERLOCK
SHIFT ARM
SELECT STOPPLATE
REVERSE LOCK CAMSTRIKER
SHIFT ARM COVER
WASHER
9.8Nm{1.0 kgf.m, 7.2 lbf.ft)
13-20

Manual Transmission
Shift Forks Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
sTH SHIFT FORK
13-22
PIN DRIVER, 5 mm

Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
6. Measure the thlckness of 4th gear.
. lf thethickness of 4th gear is lessthantheservice
limit, replace 4th gear with a new one.. lf thethicknessof 4th geariswithin the service
limit. replace the 3rd/4th synchro hub with a new
one.
Standard: 23.92 23.97 mm
(0.941 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
7. l\4easure the clearance between the distance collar
(A) and sth gear (B) with a dial indicator (C). lfthe
clearance is more than the service limit. go to step
8. lf the clearance is with in the service limit, go to
steD 10.
Standard: 0.06 0.16 mm(0.002-0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
13-24
Standard:
Standard:
Service Limit:
8. Measure distance O on the distance collar.
. lf distance O is notwithinthestandard, replace
the distance collar with a new one.' lf distanceO iswithinthe standard, gotostep9.
24.03 24.08 mm
(0.946 0.947 in.)
9. Measure the thickness of 5th gear.
. lf thethicknessof 5th gearis lessthantheservice
limit, replace 5th gear with a new one.. lf the thickness of sth gear iswithin the service
limit. replace the 5th synchro hub with a new one.
23-92 23.97 mm
10.941 0.944 in.l
23.80 mm (0.937 in.l

Manual Transmission
Mainshaft Disassembly (cont'dl
3. Supportthe 3rd gear (A) on steel blocks, and press
the mainshaft out of the 3rd/4th synchro hub (B).
Use of a jaw-type puller can damage the gear teeth.
13-26
Mainshaft Inspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, C, D, and E. lf any part of the mainshaft
is less than the service limit, reDlace it with a new
o ne.
Standard:
A Ball bearing surface (transmission housing side):
27.987 28.000 mm (1.1019 1.1024in.)
B Distance collar surtace:
31.984 32.000 mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000 mm (1.53/t8 1.5354 in.)
D Ball bearing surface (clutch housing side):
27 .977 -27 .990 mm (1.1015 1.1020in.)
E Bushing surface:
20.80 20.85 mm (0.819 0.821 in.)
Service Limit;
A: 27.93 mm 11.100 in.l
B: 31.93 mm |.1.257 in.l
C: 38.93 mm 11.533 in.l
Di 27.92 mm {1.099 in.l
E: 20.75 mm 10.817 in.l
{

Manual Transmission
Mainshaft Reassembly
Exploded View
A
QJ'
frfl
Y7
ANGULAB BALL BEARINGCheck for wear and operation.Note the direction ofinstallation.3RD/4THSYNCHROSLEEVE
3RD/4THSYNCHRO HUB
SYNCHROSPRING
SYNCHRO RING
TAPEBED CONE RING
MBS DISTANCE COLLAR
SYNCHRO SLEEVE
NEEDLE BEARINGCheck for wear and operation.
GEAR
SYNCHRO RING
SYNCHRO SPRING
NEEDLE BEARINGCheck for wear and operation.
MAINSHAFT
4TH/5TH GEAB DISTANCE COLLAR
\(
a
13-28