differential HONDA CIVIC 1996 6.G Owner's Manual

OilSealRemoval
1. Remov€ the differential assembly.
2, Remove the oil seal from the transmission housing,
OIL SEALRoplace.
the oil seal from ths torque converterRemove
housing.
OIL SEALReplace.
TOROUE CONVERTEFHOUSING
Oil Seal Installation/Side Glearance
1. Install a 2.50 mm (0.098 in) set ring,80 mm in trans-
mission housing.
NOTE: Do not install the oil seal vet.
RING, 80 mm
TRAITISMISSlONHOUS|l{G
Install the differential assembly into the torque con-
verter housing using the specialtool as shown.
Install the transmission housing and tighten the
bolts {see page 14-178 and 14-179).
{cont'd)
14-169

Differential
Oil Seal Installation/Side Clearance (cont'd)
4. Tap on the transmission housing side of the differ-
ential assembly with the special tool to seat the dif-
ferential assembly in the torque converter housing.
DRIVER 40 mm l.D.
L
14-170
5. N4easure the clearance between the 80 mm set ring
and outer race of the ball bearino in the transmis-
sion housing.
STANDARD: 0 - 0.15 mm (0 - 0.006 inl
SET RING, 80 mm
BALL BEARING
lf the clearance is more than the standard, select a
new set ring from the table, and install:
SET RING, 80 mm
NOTE: lf the clearance measured in step 5 is stan-
dard, it is not necessary to perform steps 7 and 8.
Remove the transmission housing.
Replace the 2.50 mm (0.098 in) 80 mm set ring with
the one of the correct thickness selected in step 6.
7.
Part NumberThickness
90414-689-000
904r5-689-000
90416-689-000
90417-689-000
90418-689-000
904r9-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)

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

16. Install a new set ring on the end of each driveshaft'
17. Installthe right and left driveshafts (see ssction 16)
CAUTION: Whil6 installing the driveshafE in the
diffarential, be surs not lo allow du3t and othor for-
eign particl€s to enler into the transmission.
NOTE:
. Clean the areas where the driveshafts contact the
transmission (differential) thoroughly with sol-
vent or carburetor cleaner, and dry with com-
pressed air.
. Turn the right and left steering knuckle fully out-
ward, and slide each driveshaft into the differen-
tial until you feel its set ring clip engage the side
gear.
18. Install the damper fork, then install the rightand left
ball joints to the each lower arm with the castle nuts
and new cotter Plns.
DAMPER PINCH BOLT
10 x 1 .25 mma3 N.m l4.ia kgf.m,
32 tbl.ftl
4l
COTTERReplace.SELF.LOCKING NUT
12 x 1.25 mm
6il N.m t6.5 kgf'm, il7 lbf ftl
Replace.
19. Install the splash shield.
{5.0 - 6.0 kgf m, 36 - iB lbf'ft|
CASTLE NUT12 x 1,25 mm49 - 59 N.m
20. Connect the mainshaft speed sensor, the linear sole-
noid and the shift control solenoid connectors.
SHIFT CONTROL SOLENOIO LINEAR SOITNO|o
CONNECTOR CONNECTOR
6 r 1.0 mrn12 N.m (1.219f.m,
E.7 lbf.frl
CONNECTOR
21. Connect the countershaft speed sensor and the vehi-
cle speed sensor (VSS) connectors.
VEHICI..E SPEED
SENSOR CONNECTOR
COUNTERSHAFTSPEED SENSORCONNECTOR
(cont'dl
14-185

Continuously Variable Transmission (CVTI
Special Tools ................ 14-194
Description .................... 14-195
Clutches/Reverse Brake/Planetary
Gear/Pulleys .......... 14-198
power Flow ..............,..... 14-200
Electronic Control SYstem(,96 - 98 Modets) ......14-203
Electronic Control System
('99 - oo Models) " 14-205
Hydraulic Control '....... 14-208
Hydraulic Flow .'..-.....'... '14-212
Park Mechanism .....-...'.' 14-222
Eleqtrical Systom
Component Locations'96 - 98 Models """"""' 14-224,99 - 00 Modets ............. 14-225
TCM Circuit Diagram ('96 - 98 Models) ............. 14-226
TCM Terminal Voltage/Measuring Condiiions ('96 - 98 Models) '.... 14-228
PcM Circuit Oiaqram{A/T Control System: '99 - 00 Models} ...--.... 14-230
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)
A/4 Control System .'.'...14-232
Troubleshooting Procedures ... . .... .....',........."' '14-234
Symptom-to-ComPonent Chart
Electrical System - '96 - 98 Models ......'..... '14-234
Electrical System -'99 - 00 Models ..'....-..-. '11-210
Electrical Troubleshooting
Troubleshooting Flowcharts('96 - 98 Models) """'11-242
Troubleshooting Flowchart
('99 - 0O Modets) ...... 14-265
Linear Solenoids/lnhibitor Solenoid
Test ......................... . ...... 14-29f
Drive Pulley/Driven Pulley/Secondary Gear
Shaft Speed Sensors
Replacement .........'...... .14-292
Start Clutch Control
Start Clutch Calibration Procedure ....... ....,. 14-293
Hydraulic SYstem
Symptom-to-ComPonent Chart
Hydraulic System '.'.......14-294
Road Test ............................ 14-296
Stall Speed
Test......................... ...... 14-294
Fluid Level
Checking/Changing ....... 14-299
Pressure Testing ................. 14-300
Lower Valve BodY AssemblY
Replacement ..........,... 14-302
ATF Filter
Removal/lnstallation ..... 14-303
Transmission
Transmission
Removal ........... . 14-304
lllustrated Index
Transmission/Lower Valve BodY
Assembly ................. 14-308
Transmission Housing/Flywheel Housing ... 14-310
End Cover/f ntermediate Housing ..........'.'.... 14-312
Transmission Housing/Lower Valve Body Assembly
Removal ..........'.... .. " 14-314
Transmission Housing/Flywhesl Housing
Removal ................. ........ 1+316
End Cover/lntermediate Housing
14-318Removal .........,...............
Manual Valve Body
Disassembly/lnspection/Reassemblv .'.'.'..... 1 4-320
Forward Clutch
lltustrated Index ........................................ 14-321
Disassemblv .................. 14-322
Reassemblv , ,, . ',','......14-324
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection ..'.'....-... 14-324
Differential
lllustrated lndex ...,.....................,.,...-.-.-...'... 14-329
Backlash Inspection .-....14-329
Bearing Replacement ......'........'....'... ....'... 14-330
Differential Carrier Replacement ........'........ 14-330
Oil Seal Removal ........... 14-331
Oil Seal Installation/Side Clearance ....... . . 14-331
Flywheel Housing Input Shaft Oil Seal
Replacement .....,.... ...'.'.. 14-333
Transmission Housing Bearings
Driven Pulley Shaft Bearing
Replacenient ...................'. . ...................'.. 14-334
Secondary Gear Shaft Bearing
Reolacbment ...................... . .......... . ........ 14-335
Flywheel Housing Beating
Secondary Gear Shaft BearingReo1acement..................,........................... 14-335
Ring Gear Bearing
Replacement......... ........ 14-336
Control Shaft Assembly
Removal/lnstallation ....................'........... 14-336
Transmission
Reassembly .................. 14-338
Flywheel/Drive Plate .. . ...... . ...... ... . ....-.....'.'...14-341
Transmission
lnstalation ..................... 14-348
Cooler Flushing .'......... 14-352
shift cable
Removal/lnstallation....'........." """ 14-354
Adjustment .......'........ 14-355
Shift Lever ........................,. 14'356
Shift Indicator Panel
Adjustment ................ 14-357
ATF Cooler/Hoses
lnsta llation ......,,...... .... 14-357

C O-RING Replace.
e) OIL SEAL RePlace.' FLYWHEEL HOUSING
O flVWneel }|OUSttttG GASKET Replace
6 DIFFERENTTALASSEMELY
@ lrr plsslce uruE ASSEMBLY
O O-RING Replace
@ DOWEL PIN
€) ATF PUMP ASSEMBLY(O DowEL PlN, 18 x 10 mm
O O-RING Replace.o DowEL PlN, 22 x 10 mm
lrr puup oRve cxltttt
iA SNAP RING
f3 fxaUst St|t|l, zz t 28 mm Selective part
Gt lrr punp ontve spaocxer
O PITOT FLANGE
ito nTF purrap ontve SPRoGKET HUB
(O THRUST WASHERS
@ PITOT PIPE BRACKET
O PITOT LUBRICATION PIPE
@ PITOT PIPEt3 OIL SEAL Replace.
Oa SEt AtitC, SO mm Selective Part
o3 lrr passlce ltnE HoLOER ASSEMBLY
6) o-RING Replace.
€) START CLUTCH ATF FEED PIPE
CO O-RING Replace.
€I FEEO PIPE FLANGE
@ SNAP RING
O' CONNECTOR BRACKET
@ BALL BEARING
6} SNAP RING64 COTTER RETAINER6D CoTTERS,25.5 mm selective Part6t stlnt cLutcH asseMsLv
@ secoruomv ontvE GEAR ASSEMBLY
@ o-RINGS Replace
6) DIFFERENTIAL COVER
rO ttaUSr SntU, zs t 35 mm Selective part
@ SECONDARY GEAR SHAFT
@ PARK PAWL SHAFT
@ PARK PAWL SPRING.1i PARK PAWL
@ TONGUED WASHER REPIACE,
@ PARK ROO HOLDER
@ BALL BEARING
@ o-RING Replace.
@ VEHICLE SPEED SENSOR
@ OIL SEAL Replace.
ft,
)
TOROUE SPECIFICATIONS
6x1.0mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.25 mm
12 N.m (1.2 kgnm,8.7 lbf'ft)
22 N.m (2.2 kgf'm. 16lbf'ft)
26 N.m (2.7 kgf'm, 20 lbf'ft)
29 N.m {3.0 kgf'm, 22 lbift)
14-311

)
1.Remove the ATF passage line holder assembly'
Remove the flywheel housing (twenty bolts)'
Remove the ATF passage line assembly (one bolt)
Remove the ATF pump drive sprocket (three bolts),
then remove the ATF pump drive chaan.
Move the pitot flange toward its cutout, then remove
the pitot flange.
PITOT PIPE
Remove the snap ring securing the ATF pump drlve
sprocket hub. then remove the 22 x 28 mm thrust
shim, the ATF pump drive sprocket hub and the thrust
wasners,
Remove the differential assemblY.
Remove the park pawl shaft, the park pawl spring,
and the park Pawl'
Remove the snap ring securing the start clutch, then
remove the cotter retainer and the cotters.
7.
9.
J
14-317
10. Set the special tool on the start clutch' and attach the
oawl of the special tool to the park gear securely as
shown.
CAUTION:
. Do not place tho pawl of the spocial tool on the
start clutch guidc. ll the pawl ot the spocial tool
contacts the 3tart clutch guid€, the start clutch
guido may be damaged.
. Be sure not to allow dust and other foreign par-
ticles to enter into the drivon pull6y shaft'
START CLUTCHREMOVER07TAE - P4V0120
11.Remove the start clutch and the secondary drive
gear assembly using the special tool, then remove
the secondary gear shaft.
START CLUTCHREMOVER07TAE - P4V0120
START CLUTCHASSEMBLYReplace.
START CLUTCHASSEMBLY
PAWL

Differential
l.lllustrated Index
BOLTS10 x 1.0 mm98 N.m 110.0 kgf.m,72 tbl.ltlLeft-hand threads
FII{AL ORIVEN GEAR
BAIT EEANIM;
SET RING. 8() tnmSoloctivo pan
Bacl(lash Inspection
1. Place the differential assembly on V-blocks, and install
both axles.
2. Check the backlash of both pinion gears.
Standard (Newl: 0.05 - 0.15 mm 10.002 - 0.006 in)
PINION GEARS
lf the backlash is out of tolerance, replace the differ-
ential carrier.
14-329

Differential
Bearing Replacement
NOTE: Check the bearings for wear and rough rotation.
lf the bearings are OK, removal is not necessary.
'1. Remove the ball bearings using a bearing puller.
Install the new ball bearings
with a press as shown.
BAI-L BEARING
using the special tool
ORIVER 10 mm l.O.
07746 - 0030100
14-330
BALL BEARING
Differential Carrier Replacement
1. Remove the final driven gear from the differential
carner.
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS10 x 1,0 mm98 N'm 110,0 kgf.m,72 tbl.ttlLeft-hand threads
DIFFERENTIALCARRIER
Install the final driven gear with its chamfered side
on the inner bore facing the differential carrier.
Tighten the bolts to the specified torque in a crisscross
Paftern.
TOROUE: 98 N.m (10.0 kgt.m, 72 lbf.ft)

l.
Oil Seal Removal
Remove the differential assembly.
Remove the oil seal from the transmission housing.
1.
2.
TRANSMISSONHOUSING
OIL SEALR€placa.
3. Remove the oil seal from the flywheel housing.
Oil Seal Installation/Side Clearance
1. lnstall a 2.50 mm (0.098 in) thick 80 mm wide set
ring in the transmission housing.
NOTE: Do not installthe oil seal yet.
TRANSMISSIONHOUStl{G
lnstall the differential assembly into the transmrs-
sion housing using the specialtool as shown
DIFFEREI{NALASSEMBLY(cont'd)
14-331