Elect HONDA CIVIC 1996 6.G Manual PDF

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
\
5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engin€s
Part NumberThickness
23931 - PL3 - 8000.60 mm 10.0236 in)
23932-PL3-8000.63 mm (0.0284 in)
c23933-PL3-8000.66 mm (0.0260 in)
D23334-PL3-8000.69 mm 10.0272 in)
E23935-PL3-8000.72 mm (0.0283 in)
F23936 - PL3 8000.75 mm (0.0295 in)
23937-PL3-B000.78 mm (0.0307 in)
23938-PL3-8000.81 mm (0.0319 inl
23939-PL3-8000.84 mm (0.0331 in)
23940-PL3-8000.87 mm {0.0343 in)
23941 - PL3 - 8000.90 mm (0.0354 in)
L23942-PL3-8000.93 mm (0.0366 in)
23943-PL3-8000.96 mm (0.0378 in)
N23944-PL3-8000.99 mm i0.0390 in)
o2394s-PL3-8001.02 mm (0.0102 in)
P23946-PL3-8001.05 mm {0.0413 in}
o23947-PL3-8001.08 mm (0.0{25 in)
23948 - PL3 800'1.1'1 mm (0.0437 4n)
23949-PL3-8001.14 mm (0.0449 inl
T23950-PL3-8001.17 mm (0.0461 in)
23951 - PL3 - 8001.20 mm (0.0472 in)
23952-PL3-8001.23 mm (0.0444 in)
239s3-PL3-8001.26 mm {0.0496 in)
X23954-PL3-8001.29 mm (0.0508 in)
2395s-PL3-8001.32 mm (0.0520 in)
z23956-PL3-8001.35 mm (0.0531 in)
23957-PL3-8001.38 mm (0.0543 in)
A823958-PL3-8001.41 mm (0.0555 in)
AC23959-PL3-8001.44 mm {0.0567 in)
AD23960-PL3-8001.47 mm (0.0579 in)
2396't-PL3-8001.50 mm (0.0591 in)
23962-PL3-8001.53 mm (0.0602 in)
AG23963-PL3-8001.56 mm (0.0614 in)
AH23964-PL3-8001.59 mm (0.0626 in)
23965-PL3-8001,62 mm (0.0638 in)
23966-PL3-8001.65 mm (0.0650 in)
AK23967-PL3-8001.68 mm (0.0661 in)
23968-PL3-8001.71 mm (0.0673 in)
23969-PL3-8001.74 mm (0.0685 in)
AN23970-PL3-8001.77 mm (0.0697 in)
AO23971- PL3 8001.80 mm (0.0709 inl
6. Installthe oil guide plate and selected thrust shim in
ths transmission housing
NOTE:
. Clean the thrust washer, spring washel and
thrust shim thoroughly belore installation.
. lnstall the thrust washer, spring washer and
thrust shim proPerlY.
THRUST SHIM
I
OIL GUIDEPLATE
TRANSMISSIONHOUSING
8.
o
10.
7, Install the thrust washer and spring washer in the
mainshaft.
lnstall the mainshaft in the clutch housing
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings with
several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings'
8 x 1.25 mm
27 N'm t2.8 kgf.m. 20 lbf'ft)
Tap the mainshaft with a plastic hammer.
Check the thrust clearance in the manner doscribsd
below.
CAUnON: Mc.suromont 3hould bo mlde !t room
tomp9laturs.
a. Slide the mainshaft base and the collar over the
mainshaft.
CLUTCHHOUSING
11.
lz.
MAITISHAFT BASE07GAJ-PG20130COLLAF07GAJ -PG20120
{cont'd}
13-37
THRUST WASHER
SPRING WASI{ER

Transmission
Reassembly
NOTE: The steel balls are all ofthe same size (5/16 in).
1. Install the magnet and reverse lock cam.
2. Set shift arm A on the clutch housing, then install
the shift rod.
3. Install the spring washer and shift arm A attaching
bolt.
Installthe steel ball, spring, and set ball spring bolt.
Install shift arm B in the interlock, then set it on the
clutch housing.
1.
Insert shift arm shaft in the clutch housing.
Install the collar, spring. and steel ball into the case.
Compress the ball and insert the shift arm shaft,
Install shift arm C in shift arm A, then insert the shift
arm shaft.
Install the reverse select retainer and reverse select
spring onto shift arm shaft.
Install the differential assembly.
5.
8.
9.
10.
A:8x1.0mm3'l N,m (3.2 kgt.m,23 lbf.ft)
6 x 1.0 mm15 N.m 11.5 kgt.m, 11 lbt'ftl
OIL SEALReplace.
SI{IFT ARM C
COLLAR
REVERSE SELECT SPRINGL. 63.4 mm 12.50 in)
REVERSE LOCK CAM
REVERSE SELECT RETAINER
sHtFT ARM ' ___\.*^
rNrERLocK p
|Jiiill---=l@
MAGNET
SET BALL SPRING BOLT22 N.m 12.2 kgl.m, 16 lbf'ftl
SPRINGL. 25.6 mm (1.O1 in)
SHIFT AFM A
CLUTCHHOUSING
SHIFT ARM SHAFT
(cont'd)
13-39
SHIFT ROD
l
BOOT

Transmission
Reassembly lcont'dl
11. Position the 36 mm spring washer and washer onto
the mainshaft bearing.
MAINSHAFT/COUNTERSHAFTSHIFT FORK ASSEMELIES
Tape the mainshaftsplines.
12.
13.
Install the mainshaft, countershaft, and shift fork
assemblies.
NOTE; Align the finger of the interlock with thegroove in the shift fork shaft,
lnstall the spring washer and shift arm B attaching
bolt.I x 1.0 mm31 N.m (3.2 kgl.m, 23 lbt.ft)
IST/2ND SELECT SPRINGL. 36.26 mm 11.428 in)
54 N.m 15.5 kgf.m,40 tbt.ftl
SPf,INGWASHER
GUIDE BOLT
14.
39 N.m 14.0 kgf.m, 29 lbf.frl
Install the 1sv2nd select spring, 28 mm plug bolt.
and interlock guide bolt,
NOTE: Apply Iiquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads of the 28 mm plug bolt
and interlock guide bolt.
13-40
15. Install the reverse idler gear and reverse idler gear
shaft.
REVERSE IDLERGEAR SHAFT
LJ16. Install the reverse shift holder.
REVERSE SHIFT
l5 N.m (1.5 kgf.m,11 lbt.trl
GEAR
6 x 1.0 mm

Bolt SizeTorque Value
cn
E
F
6x1.0mm
6x1.0mm
8 x 1.0 mm
8 x '1.25 mm
8 x 1.25 mm
8 x 1,0 mm
12 N.m (1.2 kgnm, 8 lbf'ft)
15 N.m (1.5 kgf'm, 11 lbf ft)
15 N.m (l.5 kgf.m, 11 lbift)
24 N'm (2.4 kgim, 17 lbift)
27 N.m (2.8 kgf.m,20 lbf'ft)
30 N.m (3.1 ksf m. 22 lbift)
5i WASHER Replace.6 TRANSMrssioN HouslNG!9 80 mm SHIM@ SHIFT PIECE SHAFT(6' INTERLOCK@ sHrFr PECE6} SHIFT ARM HOLDER@ seucr nnrvtI9 SELECT RETURN SPRING
@ 10 mm SHIM6, 10 mm WASHER@ LOCK COLLARi6sl 3 x l5 mm SPRING PIN Replace.t0 8 mm SPRING WASHERA) CHANGE PIECEll SPRING L.25.6 mm (1.01 in)'' MAGNET?4) CLUTCH HOUSINGta. 14 x 25 x 16 mm OIL SEAL Replace.A sHrFT BooO D|FFERENT|aL ASSEMBLYSee section 15iIO SHIFT ROD BOOT6 OIL GUIDE PLATE@ 33 x 60 x 20 mm NEEDLE BEASINGO BEARING RETAINER PLATElD LocK WASHER Replace..0 couNTERSHAFIA DISTANCE COLLAR6 & x 4I x 22 mm NEEDLE BEARING6. 1sr GEAR@ FRICTION DAMPERO SYNCHRO RING.d SYNCHRO SPRING@ 1ST/2ND SYNCHRO HUB..9i. REVERSE GEARC) DOUBLE CONE SYNCHROO FRICTION DAMPERS SPACER6 T2 x TI x 24 mm NEEDLE BEARING(!' 2ND GEAR61 3RD GEARiD 4TH GEAR@ 5TH GEAR(O NEEDLE BEARING(10 BALL BEARING@ SPRING WASHERf,o LoCKNUT Replace.108 - 0- 108 N'm111.0- 0* 11.0 kgf m,80* 0- 80lbI.ft)IO CLUTCH LINE BRACKET.d BACK.UP LTGHT SWITCH HARNESS BRACKET
:!, ANGULAR BALL BEABING:2, STOP RING:3] TAPER RING..-I NEEOLE BEARINGl!-- SPACERO SYNCHRO RING? SYNCHRO SPRINGE 5TH/REVERSE SYNCHRO SLEEVE...] sTH/REVERSE SYNCHRO HUB
O SYNCHBO EING.11-r sTH GEAR1A 38 x 43 x 26 mm NEEDLE BEARINGI13) SPACER COLLAR[!] /ITH GEAR.T5) SYNCHRO RING
O SYNCHRO SPRING17 3RD/4TH SYNCHRO HUB
O 3RD/4TH sYNcHRo SLEEVE
ii9 38D GEAR8I MAINSHAFT2i WASHERA SPRING WASH€R?I BALL BEARING.a4, 28 x 41 x 7 mm OIL SEAL Replace..2i 35 x 56 x 8 mm OIL SEAL Replace.t-t 14 x 20 mm DowEL PIN
.'] OIL CHAMBER PLATE
O REVERSE IDLER GEAR SHAFT.iI.., REVERSE IDLER GEAR'd REVERSE SHIFI HOLDERait srH/REVERSE sHIFT PIECE'34 5 x 22 mm SPRING PIN Replace.3' 1ST/2ND SHIFT FORK,34' 3RD/4TH SHIFT FORKi9t) srH/nevense sstrr ronx33 OIL GUTTER PLATE!' SNAP RING3d 72 mm THRUST SHIM
@ OIL GUIDE PLATE4t 10 mm WASHER Replaceti REVERSE TDLER GEAR SHAFT BoLT54 N.m {5.5 kgf m, 40lbIft)4N TBANSMISSION HANGER B43] BREATHER CAPA,J TRANSMISSION HANGER AIT' BACK-UP LIGHT SWITCH
I
25 N.m {2.5 kgl.m, 18lblftl14 mm WASHER RePlaceaO 14 mmtt 16 mm16 mm SEALING BOLT29 N.m (3.0 kgf m,22 lbf ft):4s) 32 mm SEALING BoLT25 N m 12.5 kgl m, 18 lbl'ft)40 x 62 x I mm OIL SEAL ReplaceSTEEL BALL D.5/15 iNSPRING L. 30 mm {1.2 in)12 mm WASHER Replace.SET SCREW22 N.m {2.2 kg{ m, 16 lbl ftlOIL DRAIN PLUG39 N.m {4.0 kgf m, 29lbtftlWASHER Replace.OIL FILLER PLUG4,t N.m {4.5 kgl m, 33 lblftl
.!rl00
@l
13-55

Change Holder AssemblY
,Glearance InsPection
1.Measure the clearance between the shift piece and
the shift arm holder.
Standard: 0.1 - 0.3 mm {0.004 - 0.012 in)
service Limit: 0.6 mm {0.02 in)
lf the clearance is more than the service limit, mea-
sure the width of the groove in the shift piece'
Standard: 8.1 - 8 2 mm {0'319 - 0.323 in}
lf the width of the groove is not within the stan-
dard, replace the shift piece with a new one'
lf the width of the groove is within the standard,
replace the shift arm holder with a new one'
SHIFT PIECE
SHIFT ARM HOLDER
SHIFT PIECE
4.
3. Measure the clearance between the select arm and
the interlock.
Standard: 0.05 - 0.20 10 002 - 0.008 inl
Service Limit:0.45 mm (0.018 inl
lf the clearance is more than the service limit, mea-
sure the width of the interlock.
Standatd: 9.9 - 10.0 mm (0.390 - 0.39't in)
lf the width is not within the standard, replace
the interlock with a new one.
lf the width is within the standard, replace the
select arm with a new one.(cont'd)
INTERLOCK
13-59

Change Holder Assembly
Clearance Inspection (cont'd)
7. Measure the clearance between the select arm andthe 10 mm shim.
Standard: 0.01 - 0.2 mm (0.0004 - 0.008 in)
lf the clearance is not within the standard, selectand install the appropriate l0 mm shim for the cor-rect clearance from the chart below.
mm Shim
8.
SELECT ARM
l0 mm SHIM
Part NumberThickness
24435-689-0000.8 mm (0.031 in)
B24436-589-0001.0 mm (0.039 in)
c24437-689-0001.2 mm (0.047 in)
D24438-689-0001.4 mm (0.055 in)
E24439-689-0001.6 mm {0.063 in)
13-60
I
9. Measure the clearance between the shift arm holderand the change piece.
Standard; 0.05 - 0.35 (0.fi)2 - 0.014 inlService Limit: 0.8 mm (0.03 in)
lf the clearance is more than the service limit. mea_sure the groove of the change piece.
Standard: 12.05 - 12.15 mm {0.i[7it4 - 0.47txt inl
lf the groove is not within the standard, replacethe change piece with a new one.lf the groove is within the standard, replace theshift arm holder with a new one.
vo
SHIFT ARM HOLOER
CHANGE PIECE

UO
11. Measure the clearance between the select arm and
the change Piece.
Standard: 0.05 - O'25 mm 10'002 - 0'010 in)
Servica Limii: 0.5 mm {0.02 in)
lf the clearance is more than the service limit, mea-
sure the width of the change Plece.
Standard: 12.05 - 12.15 mm {0.47'|{ - 0 47tI| inl
CHANGE PIECE
lf the width is not within the standard, replace
the change Piece with a new one'
lf the width is within the standard, replace the
select arm with a new one.
't2.
a
a
SELECT ARM
Removal
1. Bemove the shift piece shaft. then remove the shift
piece and the interlock.
SHIFT PIECE SHAFT
INTERLOCK
2. Remove the change holder assembly'
13-61

Change Holder Assembly
Disassembly/Reassembly
I P'io' to '"""sembring, crean aI the pans in sorvent, dry them and appry lubricant to any contact surfaces.
l0 mm SH|M
I
,o mm wAsHEF
t/
@@d.
r]7| 3 x 16 mm SpRtNGI Replace.
R€TURN SPRING
SELECT ARM
13-62

Differential
Index
FINAL DRIVEN GEARInspect tor wear and damage.
80 mm SHIMSelection, page'13,84
101 N.m {10.3 kgtm,74.5 lbf.ft)Left-hand threadsBALL BEAFINGInspect foa wear and ooeration.
13-82
Backlash Inspection
1. Place the differential assembly on V-blocks and installboth axles.
Measure the backlash of both pinion gears. lf thebacklash is not within the standard, replace the dif,ferential carrier.
Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inl
DIAL INDICATOR