Gear HONDA CIVIC 1997 6.G Workshop Manual

O ATF FEED PIPE
O ATF STRAINER
O SERVO BODY'99 - 00 models servo body has integrally molded
servo detent.
@ SERVO SEPARATOR PLATE
(' SECONDARY VALVE BODY
@ DOWEL P|NS
O SECONDARY SEPARATOR PLATE
@ SERVO DETENT BASE ('96 -'98 models)
O ATF FEED PIPES
(D ATF FEED PIPES
O SHAFT STOP
@ CONTROL SHAFT
€D DETENT ARM SPRING
@ DETENT ARM
(9 DETENT ARM SHAFT
@ FILTER Replace.
(? CHECK BALLS
@ TOROUE CONVERTER CHECK VALVE
@ TOROUE CONVERTER CHECK VALVE SPRING
@ DOWEL PINS
@ LOCK.UP VALVE BODY
@ LOCK-UP SEPARATOR PLATE
@ REGULATOR VALVE BODY
@} DOWEL PINS
@ COOLER RELIEF VALVE SPRING
@ COOLER RELIEF VALVE
@ O-RING Replace.
@ STATOR SHAFT
@ STOP SHAFT
@ ATF FEED PIPE
@ MAIN VALVE BODY
@ ATF PUMP DRIVEN GEAR SHAFT
@ ATF PUMP DRIVEN GEAR
@ DOWEL PINS
65) ATF PUMP DRIVE GEAR
@ MAIN SEPARATOR PLATE
@ SUCTION PIPE COLLAR
@ ATF MAGNET
@ COUNTERSHAFT TOROUE CONVERTER HOUSING
BEARING
@ ATF GUIDE PLATE
@ ToRoUE CONVERTER HOUSING
@ OIL SEAL Replace.
@ MAINSHAFT TOROUE CONVERTER HOUSING
BEARING
@) olL SEAL Replace.
@ LOCK-UP CONTROL SOLENOID FILTER/GASKET
Reolace.
@ LOCK-UP CONIROL SOLENOID VALVE A/B ASSEMELY
@ CONNECTOR BRACKET
TOROUE SPECIFICANONS
Bolt/Nut No.Torque ValugSiz€Remarkg
12 N.m (1.2 kgf.m,8.7 lbnft)6x1,0mm
14-131

1.Remove the 13 bolts securing the end cover, then
remove the cover.
Slip the special tool onto the mainshaft as shown.
MAINSHAFT HOLOER
07GAB - PFs0101
Engage the park pawl with the park gear.
Cut the lock tabs of the mainshaft and countershaft
locknuts using a chisel as shown. then remove the
locknuts and conical spring washers
CAUTION: Keep all of lhe chiseled particles out of
the transmission.
NOTE:
. Mainshaft and countershaft locknuts have left-
hand threads.
. Always wear safety glasses.
4.
cHrs€L
LOCKNUT
LOCK TA8
5.
6.
11.
Remove the special tool from the mainshaft after
removing the locknuts.
Remove the 1st clutch and mainshaft 1st gear assem
bly and mainshaft 1st gear collar from the mainshaft.
7. Remove the park pawl. spring and shaft.
8. Remove the park lever from the control shaft.
9. Using a universal two-jaw puller, remove the park
gear, one way clutch and countershaft 1st gear
assemory.
PULLER(CommerciallY available)
PARK GEAR
10.Remove the needle bearing and the countershaft
1st gear collar from the countershaft
Remove the ATF cooler lines and ATF dipstick.
14-133

Torque Converter Housing/Valve Body
Removal
ATF FEEO PIP€
LOCK-UP VALVEBODY
PIN
6x1.0mm
LOCK-UP SEPARATORPLATE
REGULATORVALVE SODY
DOWEL PIN
COOLER RELIEF VAL
SERVO DETENTSTRAINER
SERVO EODY
SEPARATON
BASE
ATF FEEDPIPES
CONTROLSHAFT
DETENTARM SHAFT
DETENTARM
ATF FEED PIPE
6x1.0mm5 Eolts6x1.0mm3 Eolts
MAIN VALBODY
ATF PUMP
DRIVEN
VALVE BODY
PINGEAR SHAFT
ATF PUMP
MAIN SEPARAPLATE
SECONDARYSEPARATOR PLATE
NOTE: The illustration shows the '96 - 98 models, the '99 - 00 models do not have the servo detent base; the servo detentis integral with the servo body.
L
14-136

NOTE;
. Clean all parts thoroughly in solvent or carburetor
cleaner, and dry with compressed air.
. Blow out all passages.
. When removing the valve body, replace the O-ring.
l, Remove the ATF feed pipes from the servo body,
secondary valve body and main valve body.
For'96 - 98 models: Remove the ATF strainer and
servo detent base (two bolts).
For'99 - 00 models: Remove the ATF strainer (one
bolt).
Remove the servo body and servo separator plate
{'96 - 98 models: seven bolts,'99 - 00 models: eight
bolts).
Remove the secondary valve body, shaft stop and
secondary separator plate (three bolts).
Remove the lock-up valve body and separator plate
{seven bolts).
Remove the regulator valve body (one boltl.
Remove the stator shaft and stop shaft.
Remove the detent spring from the detent arm. then
remove the control shaft from the to.que converter
housing.
Remove the detent arm and detent arm shaft from
the main valve body.
Remove the main valve body (five bolts).
NOTE: Do not let the eight check balls fall outofthe
main valve body when removing the main valve
body.
Remove the ATF pump driven gear shaft, then remove
the ATF pump gears.
Remove the main separator plate and two dowel
pins.
7.
't'1.
10.
12.
14.
13. CIean the inlet opening of the ATF strainer thor-
oughly with compressed air. then check that it is in
good condition, and the inlet opening is not clogged.
INLET OPENING
Test the filter by pouring clean ATF fluid through
the inlet opening. Beplace the ATF strainer if it is
clogged or damaged.
NOTE: The ATF str8iner can be reused if it is not
clogged.
14-137

ATF Pump
Inspection
1. Install the ATF pump gears and ATF pump driven
gear shaft in the main valve body
NOTE:
. Lubricate all parts with ATF during inspection.
. Install the ATF pump driven gear with its grooved
and chamfered side facing up as shown.
MAIN VALVE BODY
ATF PUMP ORIVEN GEAR
Grooved and chamfe.ed side
2. Measure the side clearance of the ATF pump drave
and driven gears.
ATF Pump Gears Side {Radial) Clearance:
Standard (New):
ATF Pump Drive Gear
0.105 - 0.1325 mm {0.004 - 0.q)5 in}
ATF Pump Drivsn Gear
0.035 - 0.0625 mm (0.0014 - 0.0025 inl
MAIN VALVE SOOY
YZ]
o?
ATF PUMPDRIVE GEAR
ATF PUMPDRIVEN GEARInspect teeth for wear and damage
lnspect teeth for wear and damage.
3. Remove the ATF pump driven gear shaft. Measure
the thrust clearance of the ATF pump driven gear-
to-valve bodY.
ATF Pump Drive/Drivon Gear Thrust {Axial} Cloarance:
Standard (Now): 0.03 - 0.05 mm 10'001 - 0.002 inl
Sorvice Limit: 0.07 mm (0.003 in)
1+141

Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubricate all parts with ATF during reassembly..Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O_rings.. Locknut has left-hand threads.
LOCKNUT {FLANGE NUTI21 x 1.25 mm78 N.m (8.0 kgl.m,58 lbt.fttReplace.Left-hand threadsSNAP RINGCONICAL SPRING WASHERReolace.
lST CLUTCHASSEMBLYTHRUST WASHER
THRUST NEEOI.EBEARING
4TH GEAN
O-RINGSReplace.
THRUST WASHER
THRUST NEEDLEBEARING
MAINSHAFTCheck splines for excessivewear and oamage.Check bearing surtace for scoring,scratches and excessive wear.
BEARINGBEARINGS
THRUST NEEDLEBEABING
4TH GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST NEEDLEEEARING
2NO GEAB
NEEDLE BEABING
THRUST NEEDLEBEARING
1ST GEAR
1ST GEARCOLLAR
TRANSMISSIONHOUSING BEARING
O-RINGSReplace.
THRUST WASHER, 36.5 x 55 mmSelective part.
SEALING RINGS,35 mm
Install the sealing ringmating faces as shown,
RING,29 mm
NEEDLE BEARING
SET RING
14-148

Inspection
a Clearance Measurement
NOTE: Lubricate all parts with ATF during assembly.
1, Remove the mainshaft bearing from the transmis-
sion housing (see Page 14-1741.
2. Assemble ths parts below on the mainshaft.
NOTE: Do not assemble the O-rings during inspec-
tlon.
LOCKNUTCONICAL SPRIIIG WASHER
SNAP RING
lST CLUTCH ASSEMBLY
TXRUST WASHER
1ST GEAR COLLAR
TRA SMISSIONHOUSII{G BEARING
THRUST WASHER
4TI{ GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST WASHER36.5 x 55 mmSelective part.
THBUST NEEDLEBEARING
2ND GEAR
AEABII{G
IHRUST NEEDLEBEARING
MAINSHAFT
3. Torque the mainshaft locknut to 29 N'm (3.0 kgf'm,
22 tbt,ftl.
NOTE: Mainshaft locknut has left-hand threads.
29 N'm t3.0 kgl'm, 22 lbt'ft)
Hold 2nd gear against the 2nd clutch' then measure
the clearance between 2nd gear and 3rd gear with a
feeler gauge.
NOTE: Take measurements in at least three places,
and use the av€rage as the actual clearance'
STANDARD: 0.05 - 0.13 mm 10.002 - 0.005 in)
THRUST WASHER,36.5 x 55 mm
(cont'd)
1+149

Countershaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricate all parts with ATF before reassembly'
. tnrp"",,n",t -"t needle bearings and the needle bearings for galling and rough movement'
. Before installing the O-rings. wrap the shaft splines with tape to prevent damaging the O-rings
. Locknut has left-hand threads
LOCKNUT (FLANGE NUT}
23 x 1.25 mm103 N.m
{10.5 kgf'm, 75.9 lbf'tt)
Replace.Left'handlhreads
CONTCAL SPRING
WASHERReplace.
GEAR
CLUTCH
1ST GEAR
BEARING
lST GEAR COLLAR
TRANSMISSIONHOUSING BEARING
REVERSE GEAR
NEEDLEBEARING
SELECTOR
SELECTOR
4TH GEAR
NEEDLE BEARING
DISTANCE COLLAS,
28 mmSelective pa .
COUNYERSHAFTCheck splines lor excesslve
wear and damage
2'{D GEAR
THRUST NEEDLEBEARING
3RD GEAB
NEEDLE BEARING
3RD GEAR COLLAR
THRUST NEEDLE EEARING
SPLINEO WASHER
3RD CLUTCH ASSEMBLY
Check bearing surface for scoring'
scratches and excessive wear'
Replace.
1+151

Countershaft
Disassembly/Reassembly
1. Using a hydraulic press, press out the countershaftwhile supporting 4th gear.
NOTE: Place an attachment between the press andthe countershaft to prevent damage to the shaft.
CAUTION: Do not allow the countershaft to fall andhit the g.ound when pressed clear.
14-152
2. Assemble the parts on the countershaft as shownoetow.
NOTE;
. Lubricate all parts with ATF during assembly.. Before installing the O-rings, wrap the shaft splineswith tape to prevent damaging the O_rings.
4TH GEAR
NEEDLE EEARING
DISTANCE COLLAR, 28 mmSelective part.
2ND GEAR
THRUST NEEOLE BEARING
3RD GEAR
NEEDI.E EEARING
3RO GEAR COLLAR
THRUST NE€OLE BEARING
SPLINED WASHER
3RD CLUTCH ASSEMBLY
O.RINGSReplace.
COUNTERSHAFT

3. Install the reverse selector hub on the countershaft
sub-assembly, and then press the reverse selector
hub using the special tool and a press as shown'
Inspection
r Clearance Measurement
NOTE; Lubricate all parts with ATF during assembly
1. Remove the countershaft bearing from the trans-
mission housing (see page l4-174)
2. Installthe parts below on the countershaft using lhe
special tool and a press as described on this page
NOTE: Do not assemble the O-rings during inspec-
tion.
REVERSE SELECTOR
HUB
4TH GEAR
NEEDLE BEARING
DISTANCE COLLAR, 28 mm
Selectave Part.
2ND GEAR
THRUST NEEDLE BEARING
3RD GEAR
BEARING
3RD GEAR COLLAR
THBUST NEEDLE BEARING
SPLINEO WASHER
3RD CLUTCH ASSEMBLY
(conl'd)
14-153