Kg max HONDA CIVIC 1996 6.G Owner's Manual

Pressure Plate
\Removal/lnsPection
1.Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard {New}: 0.6 mm (0.02 inl max.
Seruice Limit: 1.0 mm {0.04 in}
FEELER GAUGE
CLUTCH ALIGNMENT DISCOTJAF_PM7O1 1ACLUTCH ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-37tOtOO
lf the height exceeds the service limit, replace the
pressure Plate.
3. Installthe special tools
PRESSURE PLATE
MOUNTINGBOLT
ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-371010Oo7924-PD20003GEAR HOLDER
07LA8-PVOOIOOot
ENGINEBLOCKADJUSTER BOLT
BOLT
4. To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
f
12-7
lnspect the pressure plate surface for wear' cracks,
and burning.
Inspect for warpage using a straight edge and leeler
ga uge.
NOTEr Measure across the pressure plate at three
pornrs.
Standard (Newl: 0.03 mm (0.001 inl max.
Service Limit: 0.15 mm (0.006 inl
lf the warpage exceeds the service limit, replace the
pressure plate.
STBAIGHT EDGE

Flywheel
\Inspection
1.
2.
3.
Inspect the ring gear teeth for wear and damage
Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
Measure the flywheel runout using a dial indicator
through at least two full turns Push against the
flywheel each time you turn it to take up the
crankshaft thrust washer clearance.
NOTE: The runout can be measured with engine
installed.
Standard (New): 0.05 mm (0.002 inl max.
Service Limit: 0.15 mm {0.006 in)
FLYWHEEL
OIAL INOICATOR
FLYWHEEL
lf the runout exceeds the service limit. replace the
flywheel.
Turn the inner race o{ the ball bearing with your tin-
ger. The ball bearing should turn smoothly and qui
etly. lf the inner race does not turn smoothly and
quietly, replace the bearing. Check that the ball
bearing outer race fits tightly in the flywheel. lf it is
loose. replace the ball bearing
IJ
4.
BALL BEARING tO
Replacement
1. Installthe special tool.
MOUNTINGBOLTS
RITIG GEAR HOLDER
oTLAB-PV00100oto7924-PD20003
2.Remove the flywheel mounting bolts in a crisscross
pattern in several steps as shown, and remove the
flywheel,
Remove the ball bearing from the flywheel
(cont'dl
12-9
FLYWHEEL
t\
m\J

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

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.
\J

Mainshaft Thrust ShimI
I
Adjustment (cont'dl
b.Attach the mainshaft holder to the mainshaft asfollows:
NOTEI
. Back-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip istoward the transmission.
. Align the mainshaft holder's lip around thegroove at the inside of the mainshaft splines,then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
MAINSIIAFTHOLDER07GAJ-PG20110
d.
Seat the mainshaft fully by tapping on the end witha plastic hammer.
Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base.
u
e. Zero a dial gauge on the end ofthe mainshaft.
MAINSHAFT HOLDER07cAJ_PG20110
Turn the mainshaft holder bolt clockwise: stop turn,ing when the dial gange has reached its maximummovement. The reading on the dial gauge is theamount of mainshaft end olav.
CAUTION: Turning the mainshaft holder bolt morethan 60 degre€s after the needle ot the dial gauge
stops moving may damage the iransmission.
lf the reading is within the standard. the clearance iscorrecl.
lf the reading is not within the standard, recheck theshim thickness.
Standard: 0.11 - 0.18 mm {0.00it - 0.007 in}
t.
\,J

Mainshaft Assembly
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage. then measure the mainshaft
at points A, B, and C. lf any parts of the mainshaft
are less than the service limit, reDlace mainshaft
with a new one.
Standard:
A: 27.987 - 28.000 mm {1.1018 - 1.1024 in}
B: 37.98i1 - 38.fi)0 mm (1.,|!t5,0 - 1.4960 inl
Ci27.977 - 27.990 mm 11.1015 - 1.1020 inl
Service Limit:
A; 27.940 mm {1.1000 in}
B: 37.930 mm (1./{133 in)
C:27.930 mm (1.0996 inl
(
2. Inspect for runout. lf the runout is more than the
service limit, replace the mainshaft with a new one,
Standard: 0.02 mm 10.0008 inl max.
Ssrvice Limit: 0.05 mm 10.002 inl
NOTE: Suooort the mainshaft at both ends as
shown.
t
Inspect for wearano oamage.
Inspect oil passages tor clogging.
13-72

Reassembly
CAUTION:
. Press the 3rd/4th and the 5th synchro hubs on the
mainshaft without lubrication.
o When installing the 3rd/,lth and the sth synchro
hubs, support the mainshaft on steel blocks, and
installthe synchro hubs using a prsss.
. Install the 3rd/4th and the sth synchro hubs with a
maximum plessur€ of 19.6 kN (2,000 kg, 14,466 lbl.
NOTE: Refer to page 13-67 for reassembly sequence.
1, Support 2nd gear on steel blocks, then install the
3rd/4th synchro hub using the special tools and a
press, as snown.
NOTE:
. After installing. check the operation of the
3rd/4th synchro sleeve and hub.
. Assemble the 3rd/4th synchro hub and sleeve
together betore installing them on the mainshaft.
Closed end
3RD/4THSYNCHRO HU3DBIVER, 10 mm l.O.07746 - 00301U)
/ lrrlcHlileNr. ss .- t.o.07746 - 0030,100
l.
3RD/{THSYNCHROSLEEVE
2ND GEAR
2. Install the sth synchro hub using the special tools
and a press as snown.
DRIVER, {0 mm l.O.07746 - 0030100
ATTACHMENT,35 mm LD.
sTH SYNCHRO HUB
07716 - 0030,100
3. Install the angular ball bearing using the special
tools and a press as shown.
PRESS
+
DRIVER, 40 mm LD.0?7a6 - It030100

t
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage, then measure the counter-
shaft at points A, B, and C. lf any parts of the coun-
tershaft are less than the service limit. reDlace coun-
torshaft with a new one.
Standard:
A: 2/t.980 - 2{.993 mm (0.9835 - 0.9&O in}
B: 35.984 - 37.000 mm {1.4561 - 1.4567 in)
G: 33.fiD - 33.015 mm {1.2992 - 1.2998 in)
Sorvicc Limit:
Ar 2/t.9't0 mm 10.9819 inl
B: 36.930 mm {1.'l5qt in}
C: 32.950 mm {1.2972 in}
Insp€ct for wear
Inspect oil passage for clogging.
13-77
2. Insoect for runout. lf the runout is more than the
service limit, reolace the countershaft with a new
one.
Strndard: 0.02 mm {0.(x)08 in) max.
Servic. Limit 0.05 mm (0.002 in)
NOTE: SuoDort th€ countershaft at both ends as
shown.
Rotate lwo complelerevotutons.

Gountershaft Assembly
Reassembly
CAUTION:
. Pross 4th and sth gears on the countershaft without
lubrication.
. When installing ilth and sth geafs, support the shaft
on steel blocks, and install the gears using a press.
. Install ilth and sth gear with a maximum pressure of
25.5 kN (2,600 ksf, 18,806lbf).
NOTE; Refer to page 13-74 for reassembly sequence.
'1. Install the distance collar and the needle bearinos
on the countershaft.
COUNTERSHAFT
Install the friction damper, the synchro ring, and the
synchro spring on 1st gear.
Install the 1sv2nd synchro hub by aligning the fin-
gers on the friction damper and the grooves in the
1sv2nd synchro hub, as shown.
lST/2NO
13-78
lSI GEAR
insteps2-6onthe
{
4.lnstall the reverse gear.
Install the synchro spring. and the double cone
synchro as shown.
Assemble the friction damper, the needle bearing,
and 2nd gear, then install them by aligning the fin-gers on the friction damper and the grooves in the
1sv2nd synchro hub with the fingers of the double
cone synchro and the grooves on 2nd gear, as
snown.
Installthe spacer.
FRICTION DAMPER
Install the parts assembled
countershaft.
;
2ND GEAR