out HONDA CIVIC 1996 6.G Workshop Manual

Driveshafts
Reassembly (cont'dl
8. Fit the inboard joint onto the driveshaft, and note
these items:
. Reinstall the inboard joint onto the driveshaft by
aligning the marks on the inboard joint with the
marks on the rollers.
. Hold the driveshaft so that the inboard joint
points up to prevent it from falling off.
Adjust the length of the driveshafts to the figure
below, then adjust the boots to halfway between
full comDression and full extension. The ends of the
boots seat in the groove of the driveshaft and joint.
Right driveshaft, 1600 OOHC VTEC model:475 - 480 mm (18.7 - 18.9 in)Left driveshaft, all othei models:774-779 mm (30.5 - 30.7 in)Right driveshaft, all other models:501 - 506 mm 119.7 -'19.9 inl
Left driveshaft. 1600 DOHC WEC model:475 - 480 mm 118.7 - 18,9 inl
16-12
OYNAMIC DAMPEROUTBOARD JOINT
10. lf necessary position the dynamic damper as shown
Detow.
. Install a new dynamic damper band. and bend
down both sets of locking tabs.
. Lightly tap on the doubled-over ponjon of the
band to reduce its height.
Loft:
1600 DOHC VTEC model: 26 i 2 mm (1.0 t 0.1 inl
All other models: 9,1t 2 mm (3.7 10.1 inl
With "SR1" mark: 7512 mm 12.9 ! 0.1 inl
Right:
16dl DOHC VTEC models: 2612 mm 11.0 t 0.1 inl
All other modelii
DYNAMIC DAMPER
-SR1" MARK
U.S. and Canada-Produced ITPE BOOTI
Left 53612 mm {21.1 10.1 in}
Right: 2txt 12 mm {10.it 1 0.1 in}
5512 mm (2.2 t 0.1 inl
INBOARO JOINT
DYNAMIC DAMPER BAND

Driveshafts
17.
Reassembly (cont'dl
Unwind the boot band tool, and cut off the excess 5- 10 mm (0.2 - 0.4 in) from the clip.
5-10mm10.2 - 0.a inl
Secure the end of the boot band by tapping it downwith a hammer,
19. Installthe new set ring,
18.
Note these items after reassembly:. Make sure the band and clip does notanything and the band does not move.a Remove any grease remaining on thesurfaces.
interfere with
su rrou nding
16-14
Outboard Joint Sid.:
1. Wrap the splines with vinyl tape to prevent damageto the boot.
TPE tvDe:-. OUTBOARO BOOT ITPE)
BOOT BANDReplac€,
Rubber typ.:
Install the boot band and outboard boot, thenremove the vinyl tape. Take care not to damage theboot,
Install the stop ring into the driv€shaft groove.
DRIVESHAFT
>VINYL TAPE
VINYL TAPE

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4. lnsert the driveshaft into the outboard joint until the
stop ring is close on the ioint.
DRIVESHAFT
To completely seat the outboard joint, pick up the
driveshaft and joint, and drop them from about 10
cm (4 to 5 inches) onto a hard surface. Do not use a
hammer as excessive force may damage the drive-
shaft.
16-15
J
6. Check the alignment of the paint mark with the out-
board joint end.
Pack the outboard joint with the joint grease includsd
in th€ new ioint boot set.
Gleaso quanlity
U.S., canada, and Brazil'Ploducod:
115 - 135 g {4.0 - 4.8 oz}
Japan-Producod:
161X, DOHC VTEC angino:
Rubbor boot: 90 - 100 g 13.2 - 3.5 oz)
TPE boot: 1tl6 - 115 I {3'7 - tl'l oz}
Excapt 1000 DOHC VTEC engine:
Rubbel boot: 70 - 80 g l.2.5 - 2.8 ozl
TPE boot: 95 - 105 g {3.4- 3.7 oz}
7.
DRIVESHAFT
(cont'd)

Driveshafts
Reassembly lcont'd)
Installthe outboard boot and the boot bands.. lf the boot is the rubber type. go to step 13.. lf the boot is the TPE type, go to step 9.
Fit the boot ends onto the driveshaft and outboard
ioint.
10, Set the ear clamp band by threading the tab into theholes of the band.
EAR CLAMP BANDReolace.
8.
16-16
11. Close the ear portion of the band with a commer-cially available boot band Dincerc.
BOOT BAND PINCERSKENT-MOORE J,35910or eouivalent
Chsck the clearanca between the closed ear oonionof the band. lf the clesrance is not within the stan-
dard, close the ear portion of ths band further.
6.0 mm (0.24 in) MAX
3.0 mm 10.t2 inl MAX
EAR FOFNON

I
13. Fit the boot ends onto the driveshaft and the
outboard joint
Fit the double loop boot bands onto the boot ends'
Pull up the slack in the band by hand'
Mark a position on the band 10 - 14 mm {0 4 - 0 6
in,) from the cliP.
14.
16.
CLIP
lrz
17. Thread the free end of the band through the nose
section of a commercially avaiiable boot band tool
KD-3191 or equivalent and into the slot on the wind-
ing mandrel.
BOOT BAND TOOL
lCommerciallY available)
KD-3191 or equivalent
MANDREL
Place a wrench on the winding mandrel of the boot
band tool, and tighten the band until the marked
spot on the band meets the edge of the clip'
Lift uo the boot band tool to bend the free end of
the band 90" to the clip Center punch the clip, then
fold over the remaining tail onto the clip
Mark spot.
18.
1q
(cont'd)
16-17

Driveshafts
Reassembly (cont'dl
20. Unwind the boot band tool, and cut off the excessfree end of the band to leave a 5 - 10 mm (0.2 - 0.4in.) tail protruding from the clip.
21. Bend the band by tapping it down with a hammer.
NOTE: Maks sure the band and the clip does notinterfere with anything, and the band does notmov6. Remove any grease remaining in the sur-
rounding surtaces.
AANO END
16-18
INBOARD JOiIT
SET RII{G GR(X)VE
Installation
1, Install the new set ring onto the driveshaft groove.
Always use a new set ring whenever the driveshaftis being installed.
2. Install the outboard joint into the knuckte.
OUTBOARD JOINT
KNUCKI.E

Intermediate Shaft
Removal
Drain the transmission oil or fluid {see section 13 or
r 4).
Remove the left driveshaft (see page 16-3).
Remove the three dowel bolts.
OOWEL BOLTS'10 x 1.25 mm
Remove the intermediate shaft from the differential.
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
'1.
2.
3.
INTERMEDIATE SHAFT
16-20
Disassembly
NOTE: Be careful not to damage the metal rings on theintermediate shaft during disassembly.
1. Remove the set ring.
2. Remove the intermediate shaft outer seal from theDeaflng suppon.
3. Remove the external circlip,

Disassembly
Press the intermediate shaft out of the shaft bearing
using the special tools and a press as shown.
Remove the internal circliP
Press
I
SUPPORT BASEATTACHMENT07JAF - SH20400INTERNAL CIBCLIP
BEARING SUPPORT RING
Check for damage or distortion
6. Press the intermediate shaft bearing out ot the bear-
ing support using the special tools and a press as
shown.
HANOLE DRIVER
0?749 - 00'10000
Press
I
DRIVER ATTACHMENT,12x47 mm07746 - 0010300FLOATING RUBBEB
DAMPERCheck for deterioration
and oamage.SUPPORT BASE
ATTACHMENT07JAF _ SH20it00
BEARING SUPPORT
Check for damage
I sErR'NG
A4 Reolace
VUOUTER SEALReplace.(cont'd)
ReassemblY
NOTE:
. clean the disassembted parts with solvent, and dry them thoroughly with compressed air' Do not wash the rubber
parts with solvent.
. Becareful not to da mage the metal ringson the intermediate shaftduring reassembly'
BEARING SUPPORT RINGDOWEL BOLTS10 x 1.25 mm39 N.m 14.0 kgf.m,29 lbIftl
EXTERNAL CIRCLIP
Pack the interiorof the outer seal.2.0-35s10.07-012oz)
INTERNAL CIRCLIP
INTERMEDTATE SHAFT BEARING
Replace,
INTERMEDIATE SHAFT RING
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16-21

lntermediate Shaft
Reassembly (cont'd)
1. Press the intermediate shaft bearing into the bear-ing support using the special tools and a press asshown.
Prass
I
DRIVER ATTACHMENT,52x55mm07746 - 001 0(X)
Seat the internal circlip in the groove of the bearingsuppon.
Press the intermediate shaft into the shaft bearingusing the special tools and a press.
Praa.r
I
@---
LJ
INTERMEDIATE SHAFT
DRIVER ATTACHMENT,35 mm LD.
16-22
Seat the external circlip in the groove of the inter-mediate shaft.
Install the outer seal into the bearing support usingthe special tools as shown.
NOTE: Install the seal ftush with the bearing sup-port.
Pre$
t HANDr.r DRTVER- 0011r(x)0
Pack the Interiorof the ouler seal.2.0- 3.5 g {0.07 -0.12 ozl
OUTEN SEAL
Install the new set ringgroove.
ORIVER ATTACHMENT,52x55mm077i16 - 0010/O0
in the intermediate shaft

Inspection and Adjustment
Steering Operation
Steering Wheel Rotational Play
Place the front wheels in a straight ahead position andmeasure the distance the steering wheel can be turnedwithout moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm (0 - 0.4 in)
lf the play exceeds the service limit, perform rack guide
adjustment (see page lT-5).
lf the play is still excessive after rack guide adjustment,inspect the steering linkage and gearbox as descrjbed
Detow.
Steering Linkage and Gearbox
TIE.ROO LOCKNUTCheck for loose locknut.
BOOTInspect for damage and deterioration.
STEERING JOINTSCheck for loose joint
END BALL JOINTInspect for faulty movementano oamage.
GEABBOX MOUNTINGInspect f or deterioration.GEABBOX ASSEMBLY
Ste€ring Effort Check
Raise the front wheels off the ground.
Turn the steering wheel with a spring scale and check itsreaorng,
Standard: 15 N (1.5 kgf, 3.3 lbll maximum
lf it reads more. perform rack guide adjustment (see
page 17-5).
COLUMNInspect for loose columnmounting bolts and nuts.
PINION SHAFT GROMMETfor damage and deterioration.
BALL JOINT BOOTInspect for damage and deterioration.See pago 17-68 tor replacement.
ao-\---------U
17-4
Inspect for loose mounting bolts.