out HONDA CIVIC 1996 6.G Workshop Manual

MaintenanceBack-up Light Switch
Transmission Oil
NOTE: Check the transmission oil with the engine OFF
and the vehicle on level ground.
1. Remove the oil filler plug, then check the level and
condition of the oil.
OIL FILLER PLUG/14 N.m (4.5 kgl.m,33 lbl.ft)Proper Level
4.
WASHERReplace.
The oil level must be up to the filler hole. lf it is
below the hole, add oil until it runs out. then rein-
stall the oil filler plug with a new washer.
lf the transmission oil is dirty, remove the drain plug
and drain the oil.
Reinstall the drain plug with a new washer, and refill
the transmission with the recommended oil to the
proper lever.
NOTE: The drain plug washer should be replaced at
every oil change.
Reinstall the oil filler plug with a new washer.
OilCapacity
1.8 f (1.9 US qt. 1.6 lmp qtl at oil change
1.9 { (2.0 US $, 1.7 lmp qt) at overhaul
Always use Genuine Honda Manual Transmission
Fluid {MTF). Using motor oil can cause stiffer shift-
ing because it does not contain the proper addi-
t|ves.
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Replacement
NOTE: To test the back-up light switch, see section 23
1. Disconnect the connector, then remove the back-up
light swirch connector from the connector clamp.
2. Remove the back-up light switch.
25 N.m (2.5 kgf'm, 18lbf'ltl
Install the new washer and back-up light switch
Connect the back-up light switch connector.
ASHER
13-3

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

Mainshaft Assembly
I
lndex
Note the following during reassembly:
. The 3rd/4th and sth svnchro hubs are installed with a press
. Install the angular ball bearing with the thin-edge outer race facing the sth synchro hub
. Install the ball bearing with the ball cage facing up
prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces the 3rd/4th
and sth svnchro hubs.
Ballcage faces uP.
Thin edge of outerrace laces down.
3RD/4TH SYNCHRO SLEEVE
page 13'27
SYNCHRO SPRINGSYNCHRO RINGInspection,page 13-28
BALL BEARING {*1)ANGULAR BALL BEARING ('2)
Check for wear and operataon.Note the direction ot installation
5TH SYNCHROSLEEVElnspection, page 13-27
SYNCHRO HUB
SYNCHRO RINGInspection, pase 13 28
sTH GEARInspection, page 13-17
3RD GEARlnspection, page 1 3-1 6
34 x 39 x 27.5 mmNEEDLE BEARINGCheck for wearano opetaflon,
MAINSHAFTInspection, page 13-18
CHAMFEB
32 x 37 x 23.5 mmNEEDLE BEARINGCheck for wear andoperation.SPACER COLLABInspection, page 1316
34x39x23mmNEEDLE EEARINGCheck for wearand operation,
4TH GEARrnspeclron,
*1: D16Y7 engine*2: D16Y5, D16Y8 engines
page 13'16RINGInspectaon, page 13 28
SPRING
13-15

T
6. Measure the clearance between the spacer collar
and sth gear.
Standard: 0.06 - 0.19 mm 10.002 - 0.007 inl
Service Limit: 0.31 mm (0.012 inl
4TH GEAR
DIALINDICATOR
I
-<=q,
7.
5TH GEAR
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer coilar
Standard: 23.53 - 23.56 mm
10.926 - 0.928 in)
Sowice Limit 23.51 mm {0.926 in}
SPACERCOLLAR
sTH GEARSIDE
lf distance @ is less than the service limit, replace
the spacer collar with a new one,
lf distance @ is within the service limit, measure
thickness of 5th gear.
Siandatd:28.1:2 - 28.17 mm
11.119 - 1.121 in)
Servica Limit: 28.35 mm (1.116 inl
sTH GEAR
lf the thickness of 5th gear is less than the ser-
vice limit, replace sth Oear with a new one.
lf the thickness of sth gear is within the service
limit, replace the 5th synchro hub with a new
one.
Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEARING PULLER(Commercially
availablel
CAUTION: Remov€ ths synchro hubs using a press
and steel blocks as shown. Us€ of a iaw-type pullel
can caus€ damage lo the gear teeih.
Support 4th gear on steel blocks. and press the
mainshaft out of the sth svnchro hub as shown.
{cont'd)
13-17

Mainshaft Assembly
Disassembly (cont'd)
3. Support the 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th synchro hub as shown.
13-18
Inspection
'1. Inspect the gear surface and bearing surface for
wear and damage. then measure the mainshaft atpoints A, B, C, and D.
Siandard: A: 21.987 - 22.000 mm
10.8656 - 0.8661 inl
B: 26.980 - 26.993 mm
11.0622 - 1.0627 inl
C: 33.98,1- 34.000 mm(1.3380 - 1.3385 in)
D: 25.977 - 25.990 mm
|.1.0227 - 1.0232 inl
Service Limit: A: 21.930 mm 10.8634 inl
B: 26.930 mm {1.0602 in}
C: 33.930 mm (1.3358 in)
D: 25.920 mm (1.0205 in)
Check for wear and damage
lf any part of the mainshaft is less than the service
limit, replace it with a new one.
2. Inspect for runout.
Standardi 0.02 mm (o.(Xtl in) max.
S€rvice Limii: 0.05 mm (0.002 in)
NOTE: Support the mainshaft at both ends as
snown.
lf the runout is more than the service lirnit, reolace
the mainshaft with a new one.
Y

Countershaft Assembly
Index
I.r
NOTE:
-re
The 3rd, 4th, and sth gears are installed with a press.
Prior_to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the3rd, 4th, and 5th gears.
Snap ring groove faces up.
LOCKNUT Replace.108-O- 108 N.m
I 11.0-O-11.0 kst.ml
I 79.6-0- 79.6 lbt.ft I
SYNCHRO SPRING
SYNCHRO RINGInspectaon, page 13-28
FRICTION DAMPER
Thin edge ol outerrace faces down.
Check for wear andoperatron,
/ BALL EEAR|NG t*1)
t NEEDLE BEARTNG (.2)
Check for wearand operatron,
WASHERBEARING
GEAR
4TH GEAR
3RD GEAR2ND GEAR
FRICTION DAMPER
SYNCHRO SPRING
SYNCHRO RINGInspection, page 13-2836 x 41 x 25.5 mmNEEDLE BEARINGCheck for wear and operataon.
Inspection, page 13-23
1ST GEARlnspection, page 13 21, 28lnspection, page 13-21, 2839x44x27mmNEEDLE BEARIfI'GCheck for wear andoperation.
SPACER COLLARInspection, page 13-21
REVERSE GEARlnspection, page 13 27
1ST/2ND SYNCHRO HUB
*1: D'16Y7 engine*2: D16Y5, D16Y8 engines
13-20

Countershaft Assembly
Disassembly
CAUTION: Remove the gears using a press and steelblocks as shown. Use of a iaw-type puller can damagethe gear teeth.
1. Securely clamp the countershaft assembly in a
bench vise with wood blocks.
2. Raise the locknut tab from the groove of the coun-
tershaft, then remove the locknut and the springwasher.
3.Remove the bearings using a bearing puller as
shown.
EEARING PULLER
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4. Support 4th gear on steel blocks, and press the coun-tershaft out of 5th and 4th gears as shown.
Support 1st gear on steel blocks, and press the coun-
tershaft out of 3rd gear as shown.
5.
I./
3RD GEAR
1ST GEAR

Inspection
1.surfaces lor
countershaftInspect the gear surfaces and bearang
wear and damage, then measure tne
at points A, B, and C.
Standard: A: 30.000 - 30.015 mm
(1.1811- 1.1817 inl
B: 35.984 - 36.000 mm
(1.i1167 - 1.4173 inl
C: 24.980 - 2i1.993 mm
{0.9835 - 0.9840 in)
Seryice Limit: A: 29.950 mm (1.1791 inl
B: 35.930 mm (1 '1146 in)
C: 24.930 mm 10.9815 in)
Check oil passages
for cloggrng-
ICheck for wearano oamage.
. lf any part of the countershaft is less than
service limit, replace it with a new one.
Inspect for runout.
Standard: 0.02 mm (0.001 inl max.
Seryice Limit: 0.05 mm {0'002 in)
. lf the runout is more than the service limit. replace
the countershaft with a new one.
the
2.
t,3. Install the parts on the countershait
Reassembly
CAUTION:
. Press the 3rd,4th, and sth gears on the countershaft
without lubrication.
. When installing the 3rd. 4th, and 5th geals, support
the shaft on steel blocks and installthe gears using a
pless.
NOTE: Reler to page 13-20 for reassembly sequence'
1. lnstall the needle bearing on the countershaft'
, 36x41 x 25.5mmNEEDLE BEARING
COUNTERSHAFT
2. Assemble the pans below as shown.
NOTE: Check that the fingers of the friction damper
are securely set in the grooves of the 1sv2nd syn-
chro hub.
2ND GEAR
39x/+4x27mmNEEDLE BEARING
SPACER COLLAR
FRICTION DAMPER
SYNCHRO RING
SYNCHRO SPRING
REVERSE GEAR
lST/2NOSYNCHRO HUB
SYNCHRO SPRING
SYNCHRO RING
FRICTION DAMPER
1ST GEAR
(cont'd)
13-23

Countershaft Assembly
Reassembly (cont'd)
4. Suppon the countershaft on a steel block as shownand install 3rd gear using the special tools and apress.
PRESS
35 mm l.o.07746-0030400
5. Install 4th gear using the special tools and a press.
DRlvER. 40 mm
DRIVER, 40 mm LO.07746 -0030100
ATTACHMENT,
07746- 0030100
ATTACHMENT,
DRIVER, 40 mm l.D.07746-0030100
ATTACHMENT,30 mm l.D.
35 mm LO.07746-0030400
6. Install 5th gear using the special tools and a Dress.
07746-00303005TI{ GEAR
.g
7. Install the bearings in the direction shown using thesDecialtools and a oress.
CAUTION: Install ths bearings with a maximumpressure ot 7.8 kN {800 kgt, 5,786 lbfl.
ATTACHMENT,30 mm l.D.07745 - q'303tl)
*1: 016Y7 engine*2: D16Y5, D16Y8 enginesThin edge of outerrace faces down,
8. Securely clamp the countershaft assemblv in
bench vise with wood blocks.
LOCKNUT
108+0r108N.m(11.0 * 0 - 11.0 kgt m. 79.6 - 0 * 79.6 tbf.ft)
Install the spring washer, tighten the locknut, thenstake the locknut tab into groove.
/rt-\
srySnap ring
lacss up.
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Differential
Thrust Shim Adjustment
1. Install the differential assembly, making sure it bot-toms in the clutch housing, using the special tool asshown.
DRIVER, 40 mm LD.07746 0030100
Install the thrust shim.
NOTE: Install the same size thrust shim that wasremoved.
Y
Install the transmission housing (see page l3-41).
NOTE: Do not apply liquid gasket to the mating sur-face of the clutch housing.
Tighten the transmission housing attaching bolts(see page 13-42).
I x 1,25 mm
27 N.m (2.8 kgt'm, 20 lbf'ft}
Use the special tool to bottom the differential assem-
bly in the clutch housing.
tJ
6. Measure clearance between thrust shim
ing outer race in transmission housing.
and bear-
13-32