Elect HONDA CIVIC 1996 6.G Workshop Manual

End Cover/lntermediate Housing
Removal
NOTE:
. Cleanall parts in solvent or carburetor cleansr, and drywith compressed air,. Blow out all passages.
. When removing the end cover/intermediate housing, replacs the following parts:- O-rings- End cover gasket- Transmission housing gasket- Sealing rings- Sealing washers
8 x 1 .25 mm BOLT
REVERSE BRAKE
{u
END PLATE
6 x 1.0 mm BOLT
Dtsc
PLATE
DISC SPRING
SNAP
THRUST
END COVERGASXETFeplac€.25x31 mmSelective part
RING GEAR
THRUST WASHER
THRUSI NEEDLEBEARING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
SUN GEAR
INPUT SHAFT
SNAP RING
CLUTCH ENDPLATE
sNAP /R|NG I
8 x 1.25 mm BOLT
TRANSMISSTONHOUSING GASKETReplace.
DOWEL PIN
INIERMEDIATEHOUSING ASSEMSLY
FORWARD CLUTCHASSEMBLY
SEALING RING (RUBBER}
Replace.
SNAP RING
o.BINGReplace.
SNAP RINGRETAINER
SPRING RETAINER/RETURN SPRINGS
14-318
HOUSING

14. Measure the clearance between the clutch end plate
and toD disc with a dial indicator, Zero th€ dial indica-
tor with the clutch end plate lowered, and lift it up to
the snap ring. The distance that the clutch end plate
moves is the clearance between the clutch end plate
and toD disc.
NOTE: Take measurements in at least three places,
and use the average as the actual clearance.
Clutch End Plate-to-Top Disc Clesranc€:
STANDARD: 0.6 - 0.8 mm 10.024 - 0.031 inl
15. It the clearance is out of tolerance, select a new ciutch
end plate from the following table, then recheck.
NOIE: lf ihe thickest clutch end plate is installed but
the clearance is still over the standard, replace the
clutch discs and clutch Plates.
FORWARD CLUTCH END PLATE
After replacing the clutch end plate, make sure thal
the clearance is within tolerance.
16.
PTATE I{UMBEN
Plate No.Part NumberThickn€ss
1or1522561 - P4V - 0033.5 mm (0.138 in)
2or1622562 - P4V -OO33.6 mm (0.142 in)
3or1722563-P4V-0033.7 mm (0.146 in)
4or1822564 - P4V - 0033.8 mm (0.150 in)
5or192256s-P4V-0033.9 mm (0.154 in)
6ot2022566-P4V-0034.0 mm (0.157 in)
7 ot 2122567 -P4V -0034.1 mm (0.161 in)
8ot2222568-P4V-0034.2 mm (0.165 in)
9ot2322569-P4V-0034.3 mm {0.169 in)
10 or 2422570-P4V -OO34.4 mm (0.173 in)
'll or 2522571,P4V-0034.5 mm (0.177 in)
12 ot 2622572-P4V-OO34.6 mm (0.181 in)
13 ot 2722573-P4V -OO34.7 mm {0.185 in)
14-327

Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection
1. Measure the distance between the flywheel housing
surface and the ball bearing as shown, then note
the measurement (Measurement A).
FLYWHEELHOUSING
>dt?'
BALL BEARING
EALL FLYWHEELBEARING HOUSTNG
Install the secondary gear shatt in the transmission
housing.
Measure the distance between the transmission
housing surface and the thrust washer mounting
surface of the secondary gear shaft as shown, then
note the measurement (Measurement B).
O
Measuring Distance A
BALL
14-328
Calculate 25 x 35 mm thrust shim thickness bv fol-
lowing formula.
FORMULA;
25 x 35 mm Thrust Shim Thicknoss
= Measurement A - Measurement B + Flywheel
Housing Gasket Thickness: 0.5 mm {0.020 in}
Example:
Measurement A: 32.7 mm (1.287 in)
Moasurem.nt B: 30.! mm {1.185 in}
25 x 35 mm Thrust Shim Thickness
= 32.7 mm (1.287 in) - 30.1 mm (1.185 in)
+ 0.5 mm {0.020 in)
= 3.1 mm (0.122 inl
Select 25 x 35 mm Thrust Shim D.
Select the 25 x 35 mm thrust shim from the follow-
ing the table.
THRUST SHIM, 25 x 35 mm
No.Part NumberThickne3s
90551 - P4V - 0002.8 mm (0.110 in)
B90552-P4V-0002.9 mm (0.114 in)
c90553-P4V-0003.0 mm (0.118 in)
D90554-P4V-0003.1 mm (0.122 in)
E90555-P4V-0003.2 mm (0.126 in)
90556-P4V-0003.3 mm (0.130 in)
G90557-P4V-0003.4 mm (0.134 in)
H90558-P4V-0003.5 mm (0.138 in)
90559-P4V-0003.6 mm {0.142 in)
90560-P4V-0003.7 mm (0.146 in)
K90561 - P4V - 0003.8 mm (0.'150 in)

Differential
Oil Seal Installation/Side Clearance (cont'dl
3. Installthe flywheel housing, and tighten the bolts.
DOWEL PIN
1 .25 mmN m (3.0 kgt m,22 lbf.ttl8x29
uigE
14-332
4. Measure the clea.ance between the 80 mm set ring
and outer race of the ball bearing in the transmis-
sion housing.
STANDARD: 0 - 0.15 mm (0 - 0.006 in)
lf the clearance is more than the standard, select a
new set ring from the table, and install it.
SET RING, 80 mm
NOTE: lf the clearance measured in steD 4 is stan-
dard, it is not necessary to perform steps 7 and 8.
Remove the flywheel housing.
Replace ttle 2.50 mm (0.098 in) set ring, 80 mm with
the one ot the correct thickness selected in steD 5.
6.
7.
Part NumberThickness
904'r4-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
2.50 mm (0.098 in)
2.60 mm (0.102 in)
2.70 mm (0.106 in)
2.80 mm (0.110 in)
2.90 mm (0.114 in)
3.00 mm (0.118 in)

Transmission
Reassembly
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat all parts with CVT Fluid.
. Replace the following parts:- O-rings- Sealing rings- Sealing washers- Gaskets- Start clutch assembly and secondary drive gear assembly8 x 1.25 mm37 N.m {3.8 kgf.m,27 lbtftl
MANUAL VALVE
6x1.0mm12 N m 11.2 kgf.m,8.7 lbl.ft)
LINESREVERSE BRAKEEND PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
END COVEB
DOWELPIN
END COVER GASKET
6x1.0mm12 N.m 11.2 kgtm,8.7 lbtft)THRUST SHIM,25 x 31 mmSelective part
RING GEAR
THRUST WASHER
THRUSTBEARING
8 x 1.25 mm29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATEHOUSING ASSEMBLY
ROLI.IR
SNAPRINGeBH^cMANUALVALVEBOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGSTRANSMISSIONHOUSING GASKETSNAP RING
FORWARD CLUTCH
SNAP RING
SHAFTASSEMALY
DOWEL PtN
SPRING RETAINER/RETURN SPRINGASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14-338
SNAP RING RETAINERTRANSMISSION HOUSING

Transmission
16.
Reassembly (cont'dl
21.
17.
lf the clearance is not within the standard, remove thereverse brake end plate and measure its thickness.Select and install a new reverse brake end Dlate.then recheck.
NOTE: lf the thickest reverse brake end olate isinstalled, but the clearance is still over the standard,replace the reverse brake discs and plates.
REVERSE BRAKE END PLATE
After replacing the reverse brake end plate, makesure that the clearance is within the standard.Remove the snap ring, reverse brake end plate,
discs, plates. and disc spring.
Install the snap ring retainer on the drive pulley
shaft.
Wrap the drive pulley shaft splines with tape to pre-
vent damage to the O-rings, then install new O-n ngs.
Install the forward clutch assembly on the drive pul-
ley shaft, then installthe snap ring.
SITAP
O-RINGS
18.
19.
20.
SI{AP RIM;BETA EB
DRIVE PUI.IEYSHAFT
Plat6 No.Part NumberThickness
122551 - P4V - 0033.6 mm (0.142 in)
22552-P4V-0033.8 mm (0.150 in)
22553-P4V-0034.0 mm (0.157 in)
422554-P4V-0034.2 mm (0.165 in)
522555-P4V-0034.4 mm (0.173 in)
622556-P4V-0034.6 mm (0.181 in)
722557 -P4V -OO34.8 mm (0.189 in)
822558-P4V-0035.0 mm (0.200 in)
14-340
25. Installthe carrier assembly on the forward clutch.
22. Verity that the outside diameter ol the snap ring iscorrect.
SI{AP RIiIG
Install the input shaft and the sun gear as a subassemDry.
Install the th.ust needle bearing and the thrustwasher on the sun gear.
CARRIER ASSEMBLY
THFUST I'IEEDI!EEARIT{G
Msximum 41.4 mm 11.63 in)
IHruST

26. Install the thrust washer, the thrust needle bearing'
and the thrust washer on the carrier assembly'
SNAP RING
THRUST SHIM,
25x31 mm
Selective Pan
21.
24.
RING GEAR
THRUST NEEDLETHRUST WASHERS
EEARING
CARRIERASSEMBLY
lnstallthe ring gear and the 25 x 31 mm thrust shim,
then installthe snaP rrng.
Verify that the outside diameter of the snap ring is
correct,
Maximum 30.7 mm (1.21 in)
SNAP RING
Measure the clearance between the 25 x 31 mm
thrust shim and the snaP rlng.
STANDARD: O.O5 - 0.11 mm (0.0020 - 0.00'8 in)
NOTE: Take measurements in at least three places'
and use the average as the actual clearance
29.
,**r#*,".
'- t )
RING GEAR
14-341
30.
31.
lf the clearance is out of tolerance, remove the 25 x
31 mm thrust shim and measure its thickness'
Select and install a new 25 x 31 mm thrust shim.
then recheck.
THRUST SHIM, 25 x 31 mm
snap nng.RING
After replacing the 25 x 31 mm thrust shim, make
sure that the clearance is within tolerance and the
snap ring outside diameter is correct'
Install the disc spring in the direction shown'
Starting with a reverse brake plate, alternately
install the reverse brake plates and discs lnstall
selected reverse brake end plate, then install the
32.
33.
34.
REVERSEEND PLATE
BRAKE
Dtscs
SPRINGlnstall in this direction.
(cont'd)
REVERSEPI-ATES
No.Part Numb.lThickne*3
90451 - P4V - 0001.05 mm (0.041 in)
B90452-P4V-0001.12 mm (0.044 in)
c90453-P4V-000'1.19 mm (0.047 in)
D90454 - P4V - 000'l.26 mm (0.050 in)
90455-P4V-0001.33 mm (0.052 in)
F90456-P4V-0001.40 mm (0.055 in)
904s7-P4V-0001.47 mm (0.058 in)
90458-P4V-0001.54 mm (0.06'l in)
90459-P4V-000'1.61 mm (0.063 in)
J90460-P4V-0001.68 mm (0.066 inl
K90461-P4V-0001.75 mm (0.069 in)
90462-P4V-0001.82 mm (0.072 in)
M904a0-P4V-0001.085 mm (0.0427 in)
N90481-P4V-0001.155 mm (0.0454 in)
o901a2-P4V-0001.225 mm (0.0482 in)
90483-P4V-0001.295 mm (0.0510 in)
o90484-P4V-0001.365 mm (0.0537 in)
R904a5-P4V-0001.435 mm (0.0565 in)
90486-P4V-0001.5O5 mm (0,0593 in)
T90487-P4V-0001.575 mm (0.0620 in)
90488-P4V-00{)1.645 mm {0.0648 in)
90489-P4V-0001.715 mm (0.0675 in)
90490-P4V-0001.785 mm (0.0703 in)

Transmission
Reassembly (cont'd)
35. Verify that the snap ring end gap is correct.
Minimum 18 mm (0.71 in)
,/\,
."or**ol!/'
Install the manual valve body lines A and B wkhnew O-rings on the manual valve body and the inter-mediate housing.
6x1.0mm12 N..n (1.2 kgt m,8.7 rbtft)
8 x 1.25 mm37 N.m 13.8 kgf.m,27 lbf.ftl
flgENDCOVER
37.
ENDCOVER GASKET
DOWEL PINSO-RINGS
MANUAL VALVEBODY LINE A
uaNYuAL VALVE
Install the two dowel pins and new end cover gas_ket on the intermediate housing, then install new O_rings on the ATF feed pipes.
Install the end cover (three 6 mm bolts, eleven g
mm bolts).
NOTE: Install the nine 8 mm bolts in the end cover(two 8 mm bolts remain in the end cover) thentighten the eleven 8 mm bolts.
14-342
39. Install the park pawl, spring, and shaft on the trans-mission housing, then move the control lever to anvgear other than E position.
THBUST SHIM,25x35mm
SNAP RINGCOTTERRETAINER
COTTERS,25.5 mmSelective pan
START CI.UTCHASSEMBLY
O.RINGS
PARKPAWL SPRING
PARK PAWL
,10, Install the secondary gear shaft with setected 25 x35 mm thrust shim (see page ,14-328).
41. Wrap the driven pulley shaft splines with taDe toprevent damage to the O-rings, then install new O_rings.
42, Assemble ths secondary drive goar assembly in thestart clutch assembly, then installthem on the drivenpulley shaft,
43. Pull the handle of the special tool up, then installthe tip of it into the driven pulley shaft hole, and setthe special tool on the stan clutch.
CAUTION: Whib in3trling thc st rt ctutch and rh.3ocondlry driye g.!r a3sombly using lh€ specialtool, bo 3urc nol to sllow du3t or olher foraign par_ticlos to ontq into tho iransmbsion.
I c,rr r,unar".
SECONDARYGEAR SHAFT
START CLUTCHINSTALLER07TAE - P4V0r30
SECONDARYORIVE GEAFASSEMBLY

44. Push the handle of the special tool, then tighten the
nut to seal the secondary drive gear assembly on
the driven pulleY shaft securelY.
STAAT CLUTCH Ii'ISTALIIR07TAE - PaV0130
OF
46.
SHAFTHA'{DI,-E
Pull the handle of the special tool up, and remove
the special tool.
lnstallthe cotters, then measure the clearance Delween
the cotters and the start clutch guide
STANDARD: 0 - 0.13 mm (0 - 0.005 inl
NOTE: Take measurements in at least three places,
and use the average as the actual clearance
GAUGE
lil(il
COTTERS, 25.5 mm
START 1
GAUGCSTART CLUTCH
14-343
47.
48.
lf the clearance is not within the standard, remove
the cotters and measure their thickness
Select and install new cotters, then recheck.
COTTERS, 25.5 mm
After replacing the 25.5 mm cotters, make sure that
the clearance is the standard
lnstall the cotter retainer and the snap rlng
Verify that the outside diameter of the snap ring is
correct.
Minimum 33.9 mm (1.33 in)
SNAP RII{G
lnstall the thrust washers. the ATF pump drrve
sprocket hub and the 22 x 28 mm thrust shim on the
inDUt shaft, then install the snap ring.
49.
50.
52.
THRUST WASXERS
INPUT SHAFT
(cont'd)
No.Part NumberThickness
90429-P4V-0002.9mm(0.114 in)
B90430-P4V-0003.0mm(0.118 in)
c90431 -P4V-0003.1 mm (0.122 ln)
D90432-P4V-0003.2 mm (0.126 in)
SNAPRING\
ATF PUMP DRIVESPROCKET HUB
THFUST SHIM, 22 x 2a mm
Selective pan

Transmission
Reassembly (cont'd)
53. Verify that the outside diameter of the snap ring iscorrect.
Maximum 26.3 mm (1.04 in)
54.
SNAP RING
Measure the clearance between the 22 x 28 mmthrust shim and the snap ring.
STANDARD: 0.37 - 0.65 mm (0.015 - 0.026 inl
NOTE: Take measurements in at least three places,
and use the average as the actual clearance.
lf the clearance is out of tolerance, remove the 22 x
28 mm thrust shim and measure its thickness.
Select and install a new 22 x 28 mm thrust shim,then recheck.
THRUST SHIM, 22 x 28 mm
55.
co.
No.Part Numb€rThicknsss
c90573-P4V-0001.15 mm (0.0,{5 in)
D90574-P4V-0001.40 mm {0.055 in)
E90575-P4V-0001.65 mm (0.065 in)
F90576-P4V-0001.90 mm (0.075 in)
90577-P4V-0002.15 mm (0.085 in)
90578-P4V-0002.40 mm (0.095 in)
14-344
INPUT SXAFT
After replacing the 22 x 28 mm thrust shim. makesure that the clearance is within tolerance and thesnap ring outside diameter is correcr.
Install the pitot flange using its cutout as shown toclear the pitot pipes.
Install the ATF pump drive sprocket. and put theATF pump drive chain on the ATF pump drive anddriven sprockets, then install 8nd tighten the bolts(three bolts).
TF PUMP DRIVE CHAIN
58.
59.
6x1.0mm12 N.m
11.2 kg{.m,8.7 lbf.ftl
ATF PUMP ORIVESPROCKET
PITOT FLANGE
ATF PUMP