Transmission mount HONDA CIVIC 1996 6.G Owner's Manual

Transmission
_\,]ffil
Reassembly (cont'd)
TRANSMISSIONHANGER
MAINSHAFTSUB.ASSEMBLY
*''
Ufln
$*U ./
TRANSMISSION HOUSINGMOUNTING BOLTS10 x 1.25 mm4{ N.m {4.5 kg{.m,33 lbI.ft)
TRANSMISSION HOUSING
REVERSE GEARCOLLAR
REVERSE GEAR
LOCK WASHER
SHIFT FORK
MAINSHAFT SPEEDSENSOR WASHER(D16Y7 engine)
MAINSHAFT
COUNTERSHAFTSUB.ASSEMBLY
OIFFER€NTIALASSEMBLY
SPEED
TRANSMISSIONHOUSING GASKET
TOROUE CONVERTERHOUSING
14-178

17.
18.
19.
lnstall the reverse idler gear and the gear shaft
holder (see page 14-175).
lnstall the differential assembly in the torque con-
verter housing.
Assemble the mainshaft sub-assembly and the
countershaft sub-assembly, then install them
together in the torque converter houslng
MAINSHAFTSUB-ASSEMBLY
20,
COUNTERSHAFTSUB.ASSEMBLY
Turn the shift fork so the large chamfered hole is
tacing the fork bolt hole, then install the shift fork
with the reverse selector, and tighten the lock bolt'
Bend the lock tab against the bolt head
SHIFT FORK
LOCK WASHERReplace.
6 x 1.0 mm4 N.m('l.4 kgl'm, 1O lbt'ft)
Large chamtered hole
21.
22.
lnstall the needle bearing, countershaft reverse gear
and reverse gear collar on the countershaft.
Align the spring pin on the control shaft with the
transmission housing groove by turning the control
shaft.
CONTROL SHAFT
Install the two dowel pins and a new gasket on the
torque converter housing.
Place the transmission housing on the torque con-
verter housing.
CAUTION: Make sure that lhe mainshaft speed
sensor is not installed on the transmission housing
before installing the transmission housing on the
torque conv€rter housing.
lnstall the transmission housing mounting bolts
along with the transmission hanger, then tighten
the bolts in two or more steps in the sequence as
shown.
TOROUE: ,l,t N'm l{.5 kgf'm, 33 lbf'ft}
TRANSMISSIONHANGER
24.
o
(cont'di
SPRING PIN
14-179

Transmission
1.
lnstallation
Flush the ATF cooler as described on page l4-187
and 14-188.
Install the torque converter assembly securely with
a new O-ring on the mainshaft
STARTER MOTOR
14 mm DOWEL PIN
TOROUE O-RING
CONVERTER Replace
lnstall the starter motor on
housing, then install the two
the torque converter housing.
lil mm DOWEL PIN
the torque converter
14 mm dowsl pins in
MOUNTINGBRACKET
Place the transmission on a jack, and raise it to the
engine assembly level.
Attach the transmission to the engine, then install
two transmission housing mounting bolts and two
rear engine mounting bolts.REAR ENGINEMOUNNNG BOLTS1,1r15mm&| N.m 18.5 kgf m, 61 lbf'ft]
Replace.
64 N.m {6.547 tbf frlWASHER
ENGINE
TRANSMISSION HOUSINGMOUNTING BOLTS12 x 1.25 mm
45 N.m {4.5 kgf.m,
JACK
6. Install the transmission mount bracket.
12 x 1.25 mm6il N.m {6.5 kgf.m, a7 lbf'ft)
12 x 1.25 mm74 N.m (7.5 kgf.m,54 tbt.fr)
TRANSMISSION MOUNT
7.Install the remaining transmission housing mount-
ing bolts and remaining rear engine mounting bolt.
REAR ENGINEMOUNTING BOLT14 x 1.5 mmel N.m (8.5 kgt'm,61 tbl.ft)Replace.
HOUSING
MOUNTING BOLTS12 x 1.25 mmg N m (6.5 kgf m, 'l? lblftl
8. Remove the transmission jack.
(cont'd)
14-183

Transmission
Installation (cont'dl
9. Attach the torque converter to the drive plate witheight drive plate bolts and torque as follows:Rotate the crankshaft pulley as necessary to tightenthe bolts to 1/2 of the specified torque. then to thefinal torque, in a crisscross pattern.
After tightening the last bolt, check that the crank-shaft rotates freely.
TOROUE: 12 N.m {1.2 kgl.m, 8.7 tbt{r}
10 x 1.25 mm
6x1.0mm12 N.m (1.2 kgt m,8.7 rbt ft)
I 1.25 mm2/t N.m {2.4 kg{.m,17 tbt ftlCONVERTEB
10. Install the torque convener cover and the €nginestiffener.'11. Tighten the crsnkshaft pull€y bolt, if necessary (see
section 61.
12. Connect the ATF cooler hoses to the ATF cooler lines(see page 1,t192).
ATF COOIIRUNE
10 x 1.25 mma,l N.m {4.5 kgl.m,33 rbt.fttRIGHT FRONT 12 x 1.25 mmMOUNT/BRACKET 6.t N.m (6.5 kg{.m,47 tbt ftl
13. Install the right front mounvbracket.
4,r N.m 14.5 kgf.m,33 lbtft)
COVER
L,
14-1A4
SHIFT CABLE
SHIFT CAAE COVER
14. Install the control lever with a new lock washer tothe control shaft, then install the shift cable cover.
CAUION: Taks care not to bend the shift cable.
L(rcK WASHERReplace.
8 x 1,25 r'|m22N-m12.2 tgt m. 16lbnftl
x 1.0 mmtit N.m 11.4 kgt m,10 tbr,ft,
15. lnstall the exhaust pipe A.
NOTE: D16Y8 engine is shown; D16y/ engine is sim_ilar.
Replace.
GASKETReplace.
SELF.LOCKING NUTReplace.10 x 1.25 mm54 N.m (5.5 lgf.m,40 tbt ftl
NUTSELF.LOCKING NUTReplace.8 x 1.25 mm22 N.m {2.2 kgl.m, 16lbtfrl
Replace.8 x 1.25 mm16 N.m {1.6 kgI.m,12 tbf.ft)

Shift Indicator PanelATF Cooler Hoses
Adiustment
'1.Check that the index mark on the indicator alionswith the N mark on the shift indicator panel whenthe transmission is in NEUTRAL.
3 N.m {0.3 kgf.m, 2lbt.ftl
lf not aligned. remove the front console {see section20t.
Remove the shift indicator panel mounting screwsand adjust by moving the panel,
NOTE: Whenever the shift indicator panel is removed,reinstallthe panel as described above,
INDEX MARK
L
14-192
Connection
1. Connect the ATF cooler hoses to the ATF cooler linesand ATF cooler, and secure them with the clips asshown.
TRANSMISSION CLIP

Description
The Continuously Variable Transmission (CVT) is an electronically controlled automatic transmission with drive and driv
en Oullevs, and a steel belt. The CVT provides non stage speeds forward and one reverse. The entire unit is positioned in
line with the engine.
Transmission
Around the outside of the flywheel is a ring gear which meshes with the starter pinion when the engine is being staned.
The transmission has four parallel shafts: the input shaft, the drive pulley shaft. the driven pulley shaft, and the secondary
gear shaft. The input shaft is in line with the engine crankshaft. The drive pulley shaft and the driven pulley shaft consist of
movable and fixed face pulleys. Both pulleys are linked by the steel belt.
The input shaft includes the sun gear. The drive pulley shaft includes the forward clutch which mounts the carrier assem-
bly on the forward clutch drum. The carrier assembly includes the pinion gears which mesh with the sun gear and the ring
gear. The ring gear has a hub-mounted reverse brake disc.
The driven pulley shaft includes the start clutch and the secondary drive gear which is integral with the park gear' The sec-
ondary gear shaft is positioned between the secondary drive gear and the final driven gear. The secondary gear shaft
includes the secondary driven gear which serves to change the rotation direction. because the drive pulley shaft and the
driven oullev shaft rotate the same direction. When certain combinations of planetary gears in the transmission are
engaged by the clutches and the reverse brake, power is transmitted from the drive pulley shaft to the driven pulley shaft
to provide E, E, E, and El.
Electronic Control'96 - 98 Models:
The electronic control system consists of the Transmission Control Module (TCM), sensors, three linear solenoids, and a
inhibitor solenoid. Shifting is electronically controlled under all conditions'
The TCM is located below the dashboard, behind the kick panel on the driver's side.'99 - 00 Models:
The electronic control svstem consists of a Powertrain Control Module (PCM), sensors, three linear solenoids and an
inhibitor solenoid. Shifting is electronically controlled under all conditions. A Grade Logic Control System to control shift-
ing in E position while the vehicle is ascending or descending a slope.
The PCM is located below the dashboard, under the kick panel on the passenger's side.
Hydraulic Control
The lower valve body assembly includes the main valve body, the Pressure Low (PL) reguiator valve body, the shift valve
body, the start clutch control valve body, and the secondary valve body. They are positioned on the lower part of the
transmission housing.
The main valve body contains the Pressure High (PH) control valve, the lubrication valve, and the pitot regulator valve.
The secondary valve body contains the PH regulator valve, the clutch reducing valve, the start clutch valve accumulator,
and the shift inhibitor valve. The PL regulator valve body contains the PL regulator valve and the PH-PL control valve
which is ioined to the PH,PL control linear solenoid. The inhibitor solenoid valve is bolted on the PL regulator valve body.
The shift valve body contains the shift valve and the shift control valve. which is joined to the shift control linear solenoid.
The start clutch control valve body contains the start clutch control valve, which is joined to the start clutch control linear
solenoid. The linear solenoids and the inhibitor solenoid are controlled by the TCM or PCM. The manual valve body which
contains the manual valve and the reverse inhibitor valve, is bolted on the intermediate housing.
The ATF pump assembly is located on the transmission housing, and is linked with the input shaft by the sprockets and
the sprocket chain. The pulleys and the clutch receive fluid from their respective feed pipes, and the reverse brake receives
fluid from internal hydraulic circuit.
Shift Control Mechanism
Input from various sensors located throughout the vehicle determines which linear solenoid the TCM or PCM will activate.
Activating the shift control linear solenoid changes the shift control valve pressure, causing the shift valve to move. This
pressurizes the drive pulley pressure to the drive pulley and the driven pulley pressure to the driven pulley and changes
their effective pulley ratio. Activating the start clutch control linear solenoid moves the start clutch control valve. The start
clutch control valve uncovers the port, providing pressure to the start clutch to engage it(cont'd)
14-195
,!

Description
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clulches/Reverse Brake
The CVT uses the hydraulically-actuated clutches and brake to engage or disengage the transmission gears. When
hydraulic pressure is introduced into the clutch drum and the reverse brake piston cavity, the clutch piston and the reverse
brake piston move. This presses the friction djscs and the steel plates together, locking them so they don't slip. Power is
then transmitted through the engaged clutch pack to its hub-mounted gear. and through engaged ring gear to pinion
gears.
Likewise, when the hydraulic pressure is bled from the clutch pack and the reverse brake piston cavity, the piston releases
the friction discs and the steel plates, and they are free to slide past each. This allows the gear to spin independently on its
shaft, transmitting no power.
Start Clutch
The start clutch, which is located at the end of the driven pulley shaft, engages/disengages the secondary drive gear.
The start clutch is supplied hydraulic pressure by its ATF feed pipes within the driven pulley shaft.
Forward Clutch
The forward clutch, which is located at the end of the drive pulley shaft, engages/disengages the sun gear.
The forward clutch is supplied hydraulic pressure by its ATF feed pipe within the drive pulley shaft.
Reverse Brake
The reverse brake, which is located inside the inte.mediate housing around the ring gear, locks the ring gear in E posi-
tion. The reverse brake discs are mounted to the ring gear and the reverse brake plates are mounted to the intermediate
housing. The reverse brake is supplied hydraulic pressure by a circuit connected to the internal hydraulic circuit.
Planetary Gear
The planetary gear consists of a sun gear, a carrier assembly, and a ring gear. The sun gear is connected to the input shaft
with splines. The pinion gears are mounted to the carrier which is mounted to the fo.ward clutch drum. The sun gear
inputs the engine power via the input shaft to the planetary gear, and the carrier outputs the engine power. The ring gear
is only used for switching the rotation direction of the pullev shafts,
In E. E, and E positions (forward range), the pinion gears don't rotate and revolve with the sun gear, so the carrier
rotates. In E] positjon {reverse range), the reverse brake locks the ring gear and the sun gear drives the pinion gears to
rotate. The pinion gears rotate and revolve in the opposite direction from the rotation direction of the sun gear, and the
carrier rotates with pinion gear revolution.
Pulleys
Each pulley consists of a movable face and a fixed face, and the effective pulley .atio changes with engine speed. The
drive pulley and the driven pulley are linked by the steel belt.
To achieve a low pulley ratio, high hydraulic pressure works on the movable face of the driven pulley and reduces the
effective diameter of the drive pulley. and a lower hydraulic pressure works on the movable face of the drive pulley to
eliminate the steel belt slippage. To achieve a high pulley ratio, high hydraulic pressure works on the movable face of the
drive pulley and reduces the eifective diameter of the driven pulley, and a lower hydraulic pressure works on the movable
face of the driven pulley to eliminate the steel belt slippage.
b
14-198

Lower Valve Body Assembly
Replacement
@ Make sure lifts, iacks, and saf€ty stands
are placsd prop€rly {sea section 1).
CAUTION: While removing and installing th6 lower
valve body asssmbly, b€ sule not to allow dust and
other for€ign particles to entsr inio the transmksion.
1. Raise the front of the vehicle, and support it with
safetv stands (see section 1).
2. Set the parking brake, and block both rear wheels
securetv.
4.
6.
Remove the drain plug, and drain the CVT fluid.
Reinstall the drain plug with a new sealing washer(see page 1+299).
CAUTION: Keop all of other toreign parliclos out of
the transmission.
Disconnect the 8P connector from the solenoid har-
ness connector.
Remove the ATF cooler hoses at the ATF cooler
lines. Turn the ends of the ATF cooler hoses up to
prevent ATF from flowing out, then plug the ATF
cooler noses.
CAUTION: Keep all of other foroign particlo3 out of
tho transmission.
Remove the right front mounvbracket.
10 x 1.25 mmila N.m (,1.5 kgf.m, 33 lbtft)
RIGHT FRONTMOUNT/BRACKET
ATF COOLER LINE
10 x 1.25 mmsil N.m 15.5 kgf.m,40 rbr.ft)
ATF COOLER HOSE
14-302
14.
7. Remove the ATF cooler outlet line.
8. Remove the ATF cooler line bracket bolt.
9. Remove the ATF pan (fourteen bolts).
10. Remove the ATF strainer (two bolts).
1 l. Remove the one bolt securing the solenoid harness
connector,
12. Remove the
bolts).
lower valve body assembly (eight
LINE BOLT28 N.m (2.9 kgtm,21 lbtft)SEALINGReplace.
ATF COOI.-EROUTLET
OOWEL PIN
O.RINGFeplace.
SOLENOIO HARNESSCONNECTOR
5x1.0mm12 N.m 11.2 kgt.m,8.7 tbt.ftlO.RINGReplace.ATFSTNAINER
6x1.0mm12 N.m 11.2 kgt m,E.7 tbt'ft)
OOWEL NN
BODY ASSEMBLY
6x1.0mm12 N.m 11.2 kgf.m,8.7 rbf.ft)
ATF PAN GASKETReplace.
VALVE
ATF COOLER INLETUNE BRACKET BOLT8 x 1,25 mm26 N.m {2.7 kgf.m,20 tbf.frl
13.
ATF PANx 1.0 mm12 N.m 11.2 kgf.m, E.7 lbf.ftl
Install the new lower valve bodv in the reverse
ordgr of the removal orocedure.
CAUTION: Koep all ot other fo.oign particles out of
ths transmission.
NOTE:
. Replace the following parts:
- O-rings on the solenoid harness connector
and the ATF strainer- ATF pan gasket- Sealing washers
. lf the ATF cooler inlet line bracket is bent or
warped, put it back to the original position.
Perform the start clutch calibration orocedure on
page 14-293.

I
6. Disconnect the vehicle speed sensor (VSS) connec-
tor, the driven pulley speed sensor connector, and
the secondary gear shaft speed sensor connector.
SECONDARY GEARSHAFT SPEEDORIVEN PULLEY
SPEED SENSORCONNECTORSENSOR
7. Remove the transmission housing mounting bolts.
14-305
8. Remove the drain plug, and drain th€ CVT fluid
Reinstall the drain plug with a new sealing washer.
CAUTION: While installing the drain plug' bo 3ur.
nol io allow du3l 8nd other toreign particles to
enter into th€ trsnsmi$ion.
DRAIN PLUG18 x 1.5 rnm(, N.m (5.0 kgfm, 36 lbf'ft|
9. Remove the splash shield.
SEALING WASHERReplaco.

Remove the distributor'
Atach a hoisting bracket to the engine, then lift the
engine slightly.
Place a iack under the transmission. and raise the
transmission just enough to take weight off of the
mounts, then remove the transmission mount bracket
TRANSMISSION MOUNT
22.
TRANSMISSION MOUNT
14-307
23. Remove the transmission housing mounting bolt
and rear engine mounting bolts
REAR ENGINE MOUNTING
TRANSMISSION HOUSING
MOUNTING BOLT
Pull the transmission away from the engine until it
clears the l4 mm dowel pins, then lower it on the
transmission jack
WASI{ER