Input shaft seal HONDA CIVIC 1996 6.G Workshop Manual
[x] Cancel search | Manufacturer: HONDA, Model Year: 1996, Model line: CIVIC, Model: HONDA CIVIC 1996 6.GPages: 2189, PDF Size: 69.39 MB
Page 61 of 2189
Transmission(cont'd)
MEASUREMENT
Thrust shim,25 x 31 mm thickness
STANDARD {NEW}
rlz-r-osr-o.o+o oolrr1.09 - 1.12 (0.043 0.044)1.16 1.19 (0.046 - 0.047)1.23 1.26 (0.048 0.050)1.30 - 1.33 (0.051 0.052)1.37 - 1.40 (0.054 0.055)1.44 - 1.47 (0.057 0.058)1.51 1.54 (0.059 0.061)1.58 1.61 (0.062 - 0.063)1.65 - 1.68 (0.065 0.066)1.72 1.75 {0.068 0.069)1.79 1 .a2 t0.O10 - 0.012]}1.055 1.085 (0.0415 0.0427)1.125 - 1.155 (0.0443 0.0454)1.195 - ' I.225 (0.0470 0.0482)1.265 - 1.29s (0.0498 0.0510)1.335 1.365 (0.0526 - 0.0537)1.40s - 1.435 (0.0553 - 0.0565)r.475 1.505 {0.0580 0.0593)1.545 1.575 (0.0608 0.0620)1.615 1.645 (0.0636 - 0.0648)1.685 1.71510.0663 - 0.0675)1.755 - 1.785 {0.0691 0.0703)
SERVICE LIMIT
I Wr"r - d-"-"g"d
ii
11
ir
Cotters thickness2.87 - 2.90 (0.1 13 - 0.114)2.97 - 3.00 (0.117 0.118)3.07 -3.10 \0.121 0.122)3.17 - 3.20 (0.125 0.126)
Wear,or damaged
IWear or damaoedATF pump drive sprocket thrust shim, 22 x 28 mmthickness1.12 1.1510.044 - 0.045)1.37 1.40 (0.054 - 0.055)1.62 - 1.65 (0.064 0.065)1.87 - 1.90 (0.074,0.075)2.12 2.15 (0.083 - 0.08s)2.37 2.40 (0.093 0.094)
Wear or damaged
t
{Wear or damagedSecondary gear shaft thrust shim, 25 x 35 rnmthickness2.80 - 2.85 (0.1' t0 - 0.112)2.90 2.95 (0.114 - 0.116)3.00 3.05 (0.118 - 0.120)3.10 -3.15 10.122 0.124)3.20 - 3.25 (0.126, 0.128i3.30 - 3.35 (0.130 0.132)3.40 - 3.4s 10.134 0.136)3.50 3.55 (0.138 - 0.140)3.60,3.65 (0.142 0.144)3.70 - 3.75 (0.146 0.148)3.80 - 3.8510.150 0.152)
Wear or damaged
Wear or damaqedInput shaft feed pipe O.D.Drive pulley leed pipeForward clutch feed pipeInput shaft bushing t.D.Drive pulley feed pipe bushingForward clutch feed pipe bushingDriven shaft feed pipe O.D.Start clutch feed pipe (right side cover side)Driven pulley feed pipeStan clutch feed pipe (ftywheet housing side)Driven pulley shaft bushing LD.Stan clutch feed pipe (right side cover sroerDrive pulley feed pipeStart clutch feed pipe (flywheel housing side)Secondary driven gear sealing ring groove widthStart clutch end plate l.D.Input shaft sealing ring groove widthDnve pullev shaft LD. at sealing ring
Park brake conePark brake pawlPark gear
6.97 - 6.98 (0.274 - 0.27s)11.47 - 1'1.48 (0.4516 0.4520)
7.O0O 7.0t510.2156 - 0.2762]l11.500 11.518 (0.4528 0.4535)
6.97 - 6.9A \0.214 0.275:l11.47 - 11.48 (0.4516 _ 0.4520)8.97 8.98 10.353 - 0.354)
7.000 7.015 (0.2756 - 0.2762)1 1.500 - '11.518 (0.4528 - 0.4535)9.000 9.015 10.354 - 0.355)2.50 2.65 (0.098 0.104)88.900,88.935 (3.500 - 3.501)2.00 2.10 10.079 - 0.083)
5*
6.95 (0.274)
11.45 (0.451)
7.030 (0.277)11.533 (0.4s4)
6.95 (0.274)
11.45 (0.451)
8 95 (0.352)
t.030l0.2t7l1r.533 (0.454)
9.03 (0.356)2.655 (0. r05)Wear or damaged2.105 (0.083)Wear or damaqedShifting deviceano parKbrake control
Wear or other defectWear or other defectWear or other defect
Standardsand Service Limits
CW {cont'd)Section 14
rl
w
3-16
ro
Page 871 of 2189
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
Page 990 of 2189
6) TRANSMISSION HOUSING GASKET Replace'
@ DOWEL PIN
@) ATF FEED PIPE
@ o-RING Replace.
60 o-RING Replace.
@) DRIVE PULLEY SPEED SENSOR
@ TRANSMISSION HANGER
@ SNAP RING
@ txaust Sxtfu, zs t 31 mm selective part
@ SALL BEARING
6J RING GEAR6D SNAP RING
@ aevense aRlxe rND PLATE Selective part
@ REVERSE BRAKE DISC
@ REVERSE BRAKE PLATE
@ DISC SPRING6} THNUST WASHER
@} finusr NeeoLr eelnNc
@ THRUST WASHER
@ GARRIER ASSEMBLY
@ THRUST WASHER
@ THRUST NEEDLE BEARING
@} SUN GEAR
@ SEALING RING REPIACE'
@ NEEDLE BEARING
@ INPUT SHAFT
@ NEEDLE BEARING
@ SEALING RING FEPIACE'
@ SEALING RING {RUBBERI Replace'
@ ATF FEED PIPE
O END COVER
O ATF FEED PIPE
O DOWEL PIN
@ O-RING Replace.G) FEED PIPE FLANGE
@ reeo ppe ruruce puru
O] ROLLERO IruTENMEDNTE XOUSING ASSEMBLY
ao corutnoL sxlrr lsseugLv
@ tnlrusmtsstottt ttoustt'tc
@ SHIFT CABLE BRACKET
c) BREATHER CAP
@ oll- SEAL Replace.
@ CONTROL LEVER
G LoCK WASHER Replace.(D secololaY ceaR SHAFT SPEED sENsoR
o) onvel put-uv sPEED SENSOR
@ O-RING Replace.(O SNAP RING6 rnmrsutsstoru xouslNc oRlvEN PULLEY
SHAFT ROLLER BEARING
@ END COVER GASKET REPIACE'
@ o-RING Replace
6o mnruulL vnLVe goDY LINE A
64 MANUAL VALVE BODY LINE B
@ O-RING Replace.
@ DETENT SPRING
O ATF FEED PIPE
@ O-RING Replace.
@ MANUAL VALVE EODY
@ DOWEL PIN
@ r'rllull valve goDY SEPARAToR PLATE
6D SNAP RING
@t roRwlno cturcx ASSEMBLY
@ o-RING Replace
@ SNAP RINGo3 spnlruc aetlrupn/RETURN SPRING ASSEMBLY
@ nevense ennr eBtottt
@ o-RING Feplace.
@ SNAP RING RE'AINER
@ ATF FEED PIPE
.1,
TOROUE SPECIFICATIONS
6x1.0mm
6x1.0mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.25 mm
12 N.m (1.2 kgf'm,8.7 lbf'ft)
14 N.m {1.4 kgf'm, 10 lbift)
37 N.m (3.8 kgf'm, 27 lbf'ft)
26 N.m (2.7 kgf'm,20 lbf'ft)
29 N.m (3.0 kgf'm, 22 lbf'ft)
6B
8B
8F
8G
14-313
rl,
Page 995 of 2189
End Cover/lntermediate Housing
Removal
NOTE:
. Cleanall parts in solvent or carburetor cleansr, and drywith compressed air,. Blow out all passages.
. When removing the end cover/intermediate housing, replacs the following parts:- O-rings- End cover gasket- Transmission housing gasket- Sealing rings- Sealing washers
8 x 1 .25 mm BOLT
REVERSE BRAKE
{u
END PLATE
6 x 1.0 mm BOLT
Dtsc
PLATE
DISC SPRING
SNAP
THRUST
END COVERGASXETFeplac€.25x31 mmSelective part
RING GEAR
THRUST WASHER
THRUSI NEEDLEBEARING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
SUN GEAR
INPUT SHAFT
SNAP RING
CLUTCH ENDPLATE
sNAP /R|NG I
8 x 1.25 mm BOLT
TRANSMISSTONHOUSING GASKETReplace.
DOWEL PIN
INIERMEDIATEHOUSING ASSEMSLY
FORWARD CLUTCHASSEMBLY
SEALING RING (RUBBER}
Replace.
SNAP RING
o.BINGReplace.
SNAP RINGRETAINER
SPRING RETAINER/RETURN SPRINGS
14-318
HOUSING
Page 996 of 2189
l.
1.
2.
Remove the end cover {three 6 mm bolts, eleven 8
mm bolts).
Remove the manualvalve body lines A and B
3. Remove the snap ring securing the ring gear, then
remove the thrust shim and the ring gear'
4. Remove the snap ring securing the reverse brake
discs and plates, then remove the reverse brake end
plate. brake discs, brake plates, and disc spring'
5. Remove the carrier with the thrust washers and the
thrust needle bearing from the forward clutch
6. Remove the sun gear and the input shaft as a sub
assembly bY Pulling it
The sun gear is press fitted tightly into input shaft'
7. Remove the snap ring securing the forward clutch,
and remove the snap ring securing the forward clutch
end plate, then remove the forward clutch end plate'
8. Reinstall the carrier on the forward clutch, then
secure the carrier with the snap ring on the forward
clutch end Plate.
9. Remove the forward clutch and carrier assembly
together.
'10. lnstall the special tool to remove the snap ring
securing the reverse brake return spring retainer as
snown.
REVERSE BBAKESPRING COMPRESSOR07TAE - PaV0110
11. Compress the return springs. then remove the snap
ring
CAUTION: lf the spring retainer tab is on the
rsverse braks piston, tho spting letainer may be
damaged. Be surs the spring letainer tab is not on
the piston.
SPfiING FETAIiGRTAB
Remove the special tool, then remove the spring
retainer/return spring assembly.
Remove the sealing bolt securing the reverse brake
pressure insPection hole.
Apply air pressure to the inspection hole to remove
the reverse brake Piston
12.
13.
14.
16.'t7
SPBING REYAINER/RETURiI SPRIiIGASSEMALY
REVERSE BNAXEPISTON
o-RrllcsReplace.
FCVERSE BRAKEPRESSURE INS?ECTK)NHOtl
SEALINGWASHERReplace.
8 x 1.25 mm18 N.m 11.8 kgf.m, 13 lbf.ttl
Remove the snap ring retainer from the drive pulley
shaft.
Remove the manual valve body (five bolts)'
Remove the roller and push the control shaft assem-
bly toward the outside of the transmission housing,
then remove the intermediate housing (four bolts)'
SPECIAL TOOL
14-319
Page 1010 of 2189
Flywheel Housing
Input Shaft Oil Seal
l.
8. Install the oil seal in the transmission housing using
the sDecial tools as shown.
DRIVER07749 - 0010d)0
9.Install the oil seal in the flywheel housing using the
soecial tools as shown.
PILOT,26x30mmoTJAD - PH80200DRIVERATIACHMENT, 58 x 72 rnin
0?947 - d'40201
Replacement
1. Remove the input shaft oil seal from the flywheel
housing.
OIL SEAL
Instali the oil seal in the flywheel housing using the
soecialtools as shown.
FLYWHEEL
lmtalled depth:2.5- 3.5 mmro"nri':,ilii.rl
t@
14-333
Page 1014 of 2189
Transmission
Reassembly
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat all parts with CVT Fluid.
. Replace the following parts:- O-rings- Sealing rings- Sealing washers- Gaskets- Start clutch assembly and secondary drive gear assembly8 x 1.25 mm37 N.m {3.8 kgf.m,27 lbtftl
MANUAL VALVE
6x1.0mm12 N m 11.2 kgf.m,8.7 lbl.ft)
LINESREVERSE BRAKEEND PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
END COVEB
DOWELPIN
END COVER GASKET
6x1.0mm12 N.m 11.2 kgtm,8.7 lbtft)THRUST SHIM,25 x 31 mmSelective part
RING GEAR
THRUST WASHER
THRUSTBEARING
8 x 1.25 mm29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATEHOUSING ASSEMBLY
ROLI.IR
SNAPRINGeBH^cMANUALVALVEBOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGSTRANSMISSIONHOUSING GASKETSNAP RING
FORWARD CLUTCH
SNAP RING
SHAFTASSEMALY
DOWEL PtN
SPRING RETAINER/RETURN SPRINGASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14-338
SNAP RING RETAINERTRANSMISSION HOUSING
Page 1019 of 2189
44. Push the handle of the special tool, then tighten the
nut to seal the secondary drive gear assembly on
the driven pulleY shaft securelY.
STAAT CLUTCH Ii'ISTALIIR07TAE - PaV0130
OF
46.
SHAFTHA'{DI,-E
Pull the handle of the special tool up, and remove
the special tool.
lnstallthe cotters, then measure the clearance Delween
the cotters and the start clutch guide
STANDARD: 0 - 0.13 mm (0 - 0.005 inl
NOTE: Take measurements in at least three places,
and use the average as the actual clearance
GAUGE
lil(il
COTTERS, 25.5 mm
START 1
GAUGCSTART CLUTCH
14-343
47.
48.
lf the clearance is not within the standard, remove
the cotters and measure their thickness
Select and install new cotters, then recheck.
COTTERS, 25.5 mm
After replacing the 25.5 mm cotters, make sure that
the clearance is the standard
lnstall the cotter retainer and the snap rlng
Verify that the outside diameter of the snap ring is
correct.
Minimum 33.9 mm (1.33 in)
SNAP RII{G
lnstall the thrust washers. the ATF pump drrve
sprocket hub and the 22 x 28 mm thrust shim on the
inDUt shaft, then install the snap ring.
49.
50.
52.
THRUST WASXERS
INPUT SHAFT
(cont'd)
No.Part NumberThickness
90429-P4V-0002.9mm(0.114 in)
B90430-P4V-0003.0mm(0.118 in)
c90431 -P4V-0003.1 mm (0.122 ln)
D90432-P4V-0003.2 mm (0.126 in)
SNAPRING\
ATF PUMP DRIVESPROCKET HUB
THFUST SHIM, 22 x 2a mm
Selective pan
Page 1024 of 2189
Transmission
Installation
Flush the ATF cooler as described on pages 14-352and 14-353.
Remove the used grease in the flywheel hub caDand flywheel splines.
Fill the inside of the flywheel hub cap, and coat the fly-wheel hub splines with Super High Temp Urea Grease(P/N 08798 - 9002) as shown.
L
SEALING RING{RUEBER)
SPLINESApply SUPEB HlcH TEMPUREA GREASElPlN 08798 - 90O2t
SUPER HIGH TEMPUREA GREASE(P/N 08798 - !)00211.5-2.5 g 10.05-0.t9 oz)
Install a new sealing ring (rubber) on the inoutshaft, and install two '14 x 20 mm dowel Dins in theflywheel housing.
Install the flywheel securely on the input shaft, theninstallthe starter motor on the flywheel housing.
4,1Nmla.5 kgt.m, 33 tbt.ft)
INPUT SHAFT
STARTER
l4 x 20 mm DOWEL ptN
.4;i "lrj
,i rr,"r., ., a
14-348
FLYWHEEL
MOUI{T74 N.m (7.5 tstm,5a tbtftt
6. Place the transmission on s jack, and raise it to theengine assembly level.
7. Anach the transmission on the engine, then installthe transmission housing mounting bolt and rearengine mounting bolts.
TRANSMISSION HOUSINGMOUNTING BOIT6,1 N.m 16.5 kgl.m,47 tbtttl59 Nrn {6.0 kgl.m. ,€ lbt ftl
WASHER
lnstall the transmission mount bracket. Tighten thelong bolt loosely, and tighten the nuts and bott onthe mount bracket to the specified torque. Thentighten the long bolt to the specified torque.
REAR ENGINE MOUNTINGBOLTReplace.12 x 1.25 mm
12x 1.25 mn6,r N'm 16.5 kgtm,47 tbtftl
l-".--..-,^
G\V
TRANSMISSONMOUNT BRACKET
12 x 1.25 mn