Idler HONDA CIVIC 1996 6.G User Guide

Torque Value
A - 15 N.m (1.5 kgf.m, 1'1 lbf.ft)
B - 27 N.m (2.8 kgf.m. 20 lbift)
C - 31 N.m {3.2 kgnm, 23 lbift)
\
O BALL BEARING (*T)
ANGULAR
BALL BEARING {*2I
O 5TH SYNCHRO HUB
O 5TH SYNCHRO SLEEVE
€) SYNCHRO SPRING
o SYNCHRO B|NG
@ 5TH GEAR
@ gz xgt x 23.5 mm
NEEDLE BEARING
@ SPACER COLLAR
@34x39x23mm
NEEDLE BEARING
(D 4TH GEAR
O SYNCHRO RING
C) SYNCHRO SPRING
CO 3RD/4TH SYNCHRO SLEEVE
@ 3RD/4TH SYNCHRO HUB
(} 3RD GEAR
@34x39x27.5mmNEEDLE BEARING
G) MAINSHAFT
G) WASHER
@ SPRING WASHER
@ BALL BEARING
Check for wear and
operation.(E 26x42x7 mm OIL SEAL
Replace.
@ 28 mm PLUG BOLT
5,1 N.m {5.5 kgf'm, /t0 lbt'ft)
@ lsT/zND SELECT SPRING
L. 36.26 mm (1./P8 in)
@ SHIFT ARM SHAFT
@ CLUTCH HOUSING
@ INTEELOCK GUIDE BOLT
39 N.m (4.0 kgf.m, 29 lbf.ftl
@ REVERSE SHIFT HOLDER
@ REVERSE IDLER GEAR
@ REVERSE IDLER GEAR SHAFT
@ 5 x 22 mm SPRING PIN
Replace.
@ 3RD/4TH SHIFT PIECE
@ 5TH/REVERSE SHIFT PIECE
@ MBS SHIFT PIECE
@ 1ST/2ND SHIFI FORK
*1:D16Y7 engine*2: D16Y5, D16Y8 engines
@ 3RD//|TH SHIFT FORK
@ 5TH/REVERSE SHIFT FORK
@ 52 mm SNAP RING
@ 65 mm THRUST SHIM (*11
70 mm THRUST SHIM (*21
Selection, page 13-36
@ OIL GUIDE PLATE
@ wASHER Replace.
@ BACK.UP LIGHT SWITCH
25 N.m (2.5 kgf'm, 18 lbf'ft)
@ sET SCREW
22 N.m {2.2 kgf.m, 16 lbl.ft}
@ WASHER Replace.
@D SPRING 1.31.6 mm (1.2,1inl
@ STEEL BALL 15/16 in)
@ BACK-UP LIGHT
SWITCH HARNESS BRACKET
@ TRANSMISSION HANGER
@ 32 MM SEALING BOLT
25 N.m (2.5 kgf.m, 18 lbt'ft)
@ OIL SEAL
Replace.
@ OIL DRAIN PLUG
39 N.m (4.0 kgf.m, 29 lbf.ft)
@ WASHER Replace.
@} OIL FILLER PLUG
44 N.m (4.5 kgf.m, 33 lbf'ftl
@ WASHER Replace.
@) TRANSMISSION HOUSING
€) CLUTCH LINE BRACKET
@ OIL GUTTER PLATE
@ REVERSE LOCK CAM
@ REVEBSE SELECT SPRING
L. 63.4 mm {2.,196 in)
@ REVERSE SELECT RETAINER
@ SHIFT ARM C
@ SHIFT ARM B
@ INTERLoCK
@ COLLAR
@ SHIFT ARM A
@ SPRING WASHER
@ MAGNET
@ sET BALL SPRING BOLT
22 N.m (2.2 kgf.m, 16 lbf.ftl
@ 14 x 20 mm DOWEL PIN
@ 72 mm THRUST SHIM l*11
80 mm THRUST SHIM (*21
Selection, page '13-33
@ DIFFERENTIAL ASSEMBLY
See page 13-30
@ 14 x 25 x 17.5 mm OIL SEAL
Replace.
@ 35 x 56 x 8 mm OIL SEAL
Replace.
@ SHIFT ROD
@ BOOr
@ OIL GUIDE PLATE
@30x47x21 mm
NEEDLE BEARING (* 1}
30x55x21 mm
NEEDLE BEARING {'2)
@ COUNTERSHAFT
@36x41 x 25.5 mm
NEEDLE BEARING
Check for wear and
operatron.
@ lsT GEAR
@ FRICTION DAMPER
@ SYNCHRO RING
@ SYNCHRO SPRTNG
@ lST/2ND SYNCHRO HUB
@ REVERSE GEAR
@ SYNCHRO SPRING
@ SYNCHRO RING
@ FRICTION DAMPER
@ SPACER
@39x4lx27mm
NEEDLE BEARING
@ 2ND GEAR
@ 3RD GEAR
@ 4TH GEAR
@ sTH GEAR
@) BALL BEARING {* 1}
NEEDLE BEARING (*2}
@ BALL BEARING
@) SPRING WASHER
@ LoCKNUT Replace.
108 - 0- 108 N.m
ftt.o* o- 1r.o kst.m,l
179.6- 0- 79.6 rbtft I

13-1 1

Reverse Shift Holder
)
Glearance Inspection
1.Measure the clearance between the reverse shift
fork and sth/reverse shift piece pin.
Standard: 0.05 - 0.35 mm 10.002 - 0.01,1 inl
Service Limit 0.5 mm (0.02 in)
lf the clearances are more than the service limit.
measure the widths of the groove in the reverse
shifi fork.
Standard: 7.05 - 7.25 mm (0.278 - 0.285 inl
lf the widths of the grooves are not within the
standard, replace the reverse shift holder with a
new one.
lf the width of the grooves are within the stan-
dard, replace the sth/reverse shift piece with a
new one,
\
t
REVERSE
REVERSE SHIFT HOLDER
3. Measure the clearance between the reverse idler
gear and the reverse shift fork.
Standard: 0.5- 1.1 mm {0.02 - 0.0,1in)
Service Limii: 1.8 mm 10.07 inl
REVERSE IDLER GEAR
lf the clgarances is more than thg service limit, mea-
sure the width of the reverse shift fork.
Standlrd: 12.7 - 13.0 mm {0.5110 - 0.512 in}
lf the width is not within the standard, replace
the reverse shift holder with a new one.
lf the width is within the standard, replace the
revsrse idler gear with a new one.
REV€RSE SHIFT FORK
REVERSE SHIFT FORK
REVERSE SHIFT HOLOER
13-13

Reverse ldler Gear
Mainshaft, Cou ntershaft,
Shift Fork
Removal
1. Remove the reverse shift holder.
REVERSE SHIFTHOLOER
Remove the reverse id ler
idler gear.
gear shaft and reverse
REVERSE IDLERGEAR SHAFT
13-14
Disassembly
1. Remove the interlock guide bolt from under the
clutch housing.
SHIFT ARM 8ATTACHING BOLT
CLUTCHHOUSING
INTERLOCK GUIDE BOLT
Remove the shift arm B attaching bolt.
Remove the mainshaft and countershaft assemblies
with the shift fork from the clutch housinq.
NOTE: Before removing the mainshaft and counter-
shaft assemblies, tape the mainshaft splines to pro-
tect the seal.
Tape the mainshaftsplines.
WASHER
SPRINGWASHER

Transmission
Reassembly lcont'dl
11. Position the 36 mm spring washer and washer onto
the mainshaft bearing.
MAINSHAFT/COUNTERSHAFTSHIFT FORK ASSEMELIES
Tape the mainshaftsplines.
12.
13.
Install the mainshaft, countershaft, and shift fork
assemblies.
NOTE; Align the finger of the interlock with thegroove in the shift fork shaft,
lnstall the spring washer and shift arm B attaching
bolt.I x 1.0 mm31 N.m (3.2 kgl.m, 23 lbt.ft)
IST/2ND SELECT SPRINGL. 36.26 mm 11.428 in)
54 N.m 15.5 kgf.m,40 tbt.ftl
SPf,INGWASHER
GUIDE BOLT
14.
39 N.m 14.0 kgf.m, 29 lbf.frl
Install the 1sv2nd select spring, 28 mm plug bolt.
and interlock guide bolt,
NOTE: Apply Iiquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads of the 28 mm plug bolt
and interlock guide bolt.
13-40
15. Install the reverse idler gear and reverse idler gear
shaft.
REVERSE IDLERGEAR SHAFT
LJ16. Install the reverse shift holder.
REVERSE SHIFT
l5 N.m (1.5 kgf.m,11 lbt.trl
GEAR
6 x 1.0 mm

Bolt SizeTorque Value
cn
E
F
6x1.0mm
6x1.0mm
8 x 1.0 mm
8 x '1.25 mm
8 x 1.25 mm
8 x 1,0 mm
12 N.m (1.2 kgnm, 8 lbf'ft)
15 N.m (1.5 kgf'm, 11 lbf ft)
15 N.m (l.5 kgf.m, 11 lbift)
24 N'm (2.4 kgim, 17 lbift)
27 N.m (2.8 kgf.m,20 lbf'ft)
30 N.m (3.1 ksf m. 22 lbift)
5i WASHER Replace.6 TRANSMrssioN HouslNG!9 80 mm SHIM@ SHIFT PIECE SHAFT(6' INTERLOCK@ sHrFr PECE6} SHIFT ARM HOLDER@ seucr nnrvtI9 SELECT RETURN SPRING
@ 10 mm SHIM6, 10 mm WASHER@ LOCK COLLARi6sl 3 x l5 mm SPRING PIN Replace.t0 8 mm SPRING WASHERA) CHANGE PIECEll SPRING L.25.6 mm (1.01 in)'' MAGNET?4) CLUTCH HOUSINGta. 14 x 25 x 16 mm OIL SEAL Replace.A sHrFT BooO D|FFERENT|aL ASSEMBLYSee section 15iIO SHIFT ROD BOOT6 OIL GUIDE PLATE@ 33 x 60 x 20 mm NEEDLE BEASINGO BEARING RETAINER PLATElD LocK WASHER Replace..0 couNTERSHAFIA DISTANCE COLLAR6 & x 4I x 22 mm NEEDLE BEARING6. 1sr GEAR@ FRICTION DAMPERO SYNCHRO RING.d SYNCHRO SPRING@ 1ST/2ND SYNCHRO HUB..9i. REVERSE GEARC) DOUBLE CONE SYNCHROO FRICTION DAMPERS SPACER6 T2 x TI x 24 mm NEEDLE BEARING(!' 2ND GEAR61 3RD GEARiD 4TH GEAR@ 5TH GEAR(O NEEDLE BEARING(10 BALL BEARING@ SPRING WASHERf,o LoCKNUT Replace.108 - 0- 108 N'm111.0- 0* 11.0 kgf m,80* 0- 80lbI.ft)IO CLUTCH LINE BRACKET.d BACK.UP LTGHT SWITCH HARNESS BRACKET
:!, ANGULAR BALL BEABING:2, STOP RING:3] TAPER RING..-I NEEOLE BEARINGl!-- SPACERO SYNCHRO RING? SYNCHRO SPRINGE 5TH/REVERSE SYNCHRO SLEEVE...] sTH/REVERSE SYNCHRO HUB
O SYNCHBO EING.11-r sTH GEAR1A 38 x 43 x 26 mm NEEDLE BEARINGI13) SPACER COLLAR[!] /ITH GEAR.T5) SYNCHRO RING
O SYNCHRO SPRING17 3RD/4TH SYNCHRO HUB
O 3RD/4TH sYNcHRo SLEEVE
ii9 38D GEAR8I MAINSHAFT2i WASHERA SPRING WASH€R?I BALL BEARING.a4, 28 x 41 x 7 mm OIL SEAL Replace..2i 35 x 56 x 8 mm OIL SEAL Replace.t-t 14 x 20 mm DowEL PIN
.'] OIL CHAMBER PLATE
O REVERSE IDLER GEAR SHAFT.iI.., REVERSE IDLER GEAR'd REVERSE SHIFI HOLDERait srH/REVERSE sHIFT PIECE'34 5 x 22 mm SPRING PIN Replace.3' 1ST/2ND SHIFT FORK,34' 3RD/4TH SHIFT FORKi9t) srH/nevense sstrr ronx33 OIL GUTTER PLATE!' SNAP RING3d 72 mm THRUST SHIM
@ OIL GUIDE PLATE4t 10 mm WASHER Replaceti REVERSE TDLER GEAR SHAFT BoLT54 N.m {5.5 kgf m, 40lbIft)4N TBANSMISSION HANGER B43] BREATHER CAPA,J TRANSMISSION HANGER AIT' BACK-UP LIGHT SWITCH
I
25 N.m {2.5 kgl.m, 18lblftl14 mm WASHER RePlaceaO 14 mmtt 16 mm16 mm SEALING BOLT29 N.m (3.0 kgf m,22 lbf ft):4s) 32 mm SEALING BoLT25 N m 12.5 kgl m, 18 lbl'ft)40 x 62 x I mm OIL SEAL ReplaceSTEEL BALL D.5/15 iNSPRING L. 30 mm {1.2 in)12 mm WASHER Replace.SET SCREW22 N.m {2.2 kg{ m, 16 lbl ftlOIL DRAIN PLUG39 N.m {4.0 kgf m, 29lbtftlWASHER Replace.OIL FILLER PLUG4,t N.m {4.5 kgl m, 33 lblftl
.!rl00
@l
13-55

Transmission Housing
Removal
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting theworkbench.
'1. Remove the back-up light switch.
2. Remove transmission hanger B.
3. Remove the set screws, the springs, and the steelballs.
BACK.UP UGHTswrTcH
SET SCREW
4. Remove the reverse idler gear shaft bolt.
WASHERReplace.
REVEBSE
13-56
5. Loosen the transmission housing attaching bolts ina crisscross pattern in several steps, then removethem.
TRANSMISSIONHANGER A
R€move the 32 mm sealing bolt.
Expand the snap ring on the countershaft ball bear-ing, and remove it from the groove using a pair ofsnap ring pliers,
32 mm SEALING BOLT
o.
1.
I{
ATTACHING BOLT
SNAP RING

Reverse Shift Holder, Reverse ldler Gear
Clearance Inspection (cont'dl
3. Measure the clearance between the reverse
gear and the reverse shift holder.
Standard: 0.5 - 1.0 mm 10.02 - 0.04 inl
Service Limit: 1.8 mm (0.07 inl
id ler
lf the clearance is more than the service limit. mea,
sure the width of the reverse shift holder.
Standard: 13.0 - 13.3 mm (0.512 - 0.524 in)
lf the width is not within the standard, replace
the reverse shift holder with a new one.
lf the width is within the standard, replace the
reverse idler gear with a new one.
REVERSE SHIFT HOLDER
13-58
Removal
1. Remove the reverse shift holder.
Remove the reverse idler gear and the reverse idlergear shaft.
REVERSE SHIFT HOLDEB
REVERSEIDLER

Transmission
Reassembly (cont'd)
11. Installthe change holder assembly.
6x1.0mm15 N.m {1.5 kgf.m,
12 N.m {1.2 kgf.m,9lbtftlCHANGE HOLDERASSEMBLY
Install the shift piece and the interlock. then installthe shift piece shaft.
12.
13-92
(
13. Measure the distance @ after mounting the shiftpiece shaft. lf it's incorrect. check the installation.
Distance @: 11.9 - 12.3 mm {0./t7 - 0.48 inl
14. Install the .everse idler gear and the reverse idlergear shaft.
REVERSE IDLER GEAR
REVERSEIDLE

25. Install the 32 mm sealing bolt
NOTE: Apply liquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads.
26. Tighten the reverse idler gear shaft bolt'
REVERSE IDLER G€AR
SHAFT BOLT10 x 1.25 mm5a N.rn t5.5 kgl m, {0 lbtftl
32 mm SEALING BOLT
25 N.m {2.5 kgl'm,
lnstall the steel balls, the springs, and the set
screws.
Install the back-up light switch and the transmission
hanger B.
BACK.UP LIGHT SWITCH
25 N.m 12.5 kgt m, 18 lblttl
TRANSMISSIONHANGER B
8x2117
1.25 mmN.m (2.4 kgf m,lbf.ftt
II
I
I
EALL
\\
\
\
SET SCREW'12 x 1.0 mm
22 N.m (2.2 kgf'm,16 tbt.trl
13-95

Description
Power Flow (cont'd)
El Po3ition
1, Hydraulic pressure is switched by the manual valve to the servo valve, which moves the reverse shift fork to thereverse position. The reverse shift fork engages with the reverse selector, reverse selector hub, and the countershaftreverse gear.
Hydraulic pressure is also applied to the 4th clutch. Power is transmitt€d from the mainshaft reverse gear via thereverse idler gear to the countershaft reverse gear.
The rotation direction of the countershaft reverse gear is changed via the reverse idler gear,
Power is transmitted to the final drive gear, which drives the final driven gear.
TOROUE
MAINSHAFT
COU TERSHAFT
REVERSE SELECTORHUBREVERSE SETICTOR
REVERSE SHIFTFORK
REVERSE IDLER
14-12
FINAL ON|VEN GEAR