locks HONDA CIVIC 1997 6.G User Guide

Countershaft Assembly
Reassembly (cont'd)
4. Suppon the countershaft on a steel block as shownand install 3rd gear using the special tools and apress.
PRESS
35 mm l.o.07746-0030400
5. Install 4th gear using the special tools and a press.
DRlvER. 40 mm
DRIVER, 40 mm LO.07746 -0030100
ATTACHMENT,
07746- 0030100
ATTACHMENT,
DRIVER, 40 mm l.D.07746-0030100
ATTACHMENT,30 mm l.D.
35 mm LO.07746-0030400
6. Install 5th gear using the special tools and a Dress.
07746-00303005TI{ GEAR
.g
7. Install the bearings in the direction shown using thesDecialtools and a oress.
CAUTION: Install ths bearings with a maximumpressure ot 7.8 kN {800 kgt, 5,786 lbfl.
ATTACHMENT,30 mm l.D.07745 - q'303tl)
*1: 016Y7 engine*2: D16Y5, D16Y8 enginesThin edge of outerrace faces down,
8. Securely clamp the countershaft assemblv in
bench vise with wood blocks.
LOCKNUT
108+0r108N.m(11.0 * 0 - 11.0 kgt m. 79.6 - 0 * 79.6 tbf.ft)
Install the spring washer, tighten the locknut, thenstake the locknut tab into groove.
/rt-\
srySnap ring
lacss up.
\J

Differential
Check lor cracks.
BALL BEARINGCheck for wear and damage.
DIFFERENTIAL
THRUST SHIMSelective part
SPEEDOMETERDRIVE GEAR
10 x 1.0 mm101 N.m (10.3 ksf.m. 74.5 lbt.ftlLeft-hand threads
ffi
FrNAL DRTvEN o*^r'@c'ec'owea'-Zl
BALL BEARINGCheck for wear and damage.
13-30
Backlash Inspection
'1. Place differential assembly on V-blocks, and installboth driveshafts.
OIAL
Measure backlash of both pinion gears.
Standard {New); 0.05 - 0.15 mm {0.002 - 0.006 in)
lf the backlash is not within the standard, reDlacethe differential carrier.
SI

Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEABING PULLER
BALL BEARING
CAUTION: Remove the synchro hubs using a ptess
and the sts€l blocks as shown. Use of a i8w'type
puller can cause damage to th€ gear teeth.
Support sth gear on steel blocks, and press the
mainshaft out of the sth synchro hub, as shown.
3. Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th svnchro hub, as shown.
13-71

Reassembly
CAUTION:
. Press the 3rd/4th and the 5th synchro hubs on the
mainshaft without lubrication.
o When installing the 3rd/,lth and the sth synchro
hubs, support the mainshaft on steel blocks, and
installthe synchro hubs using a prsss.
. Install the 3rd/4th and the sth synchro hubs with a
maximum plessur€ of 19.6 kN (2,000 kg, 14,466 lbl.
NOTE: Refer to page 13-67 for reassembly sequence.
1, Support 2nd gear on steel blocks, then install the
3rd/4th synchro hub using the special tools and a
press, as snown.
NOTE:
. After installing. check the operation of the
3rd/4th synchro sleeve and hub.
. Assemble the 3rd/4th synchro hub and sleeve
together betore installing them on the mainshaft.
Closed end
3RD/4THSYNCHRO HU3DBIVER, 10 mm l.O.07746 - 00301U)
/ lrrlcHlileNr. ss .- t.o.07746 - 0030,100
l.
3RD/{THSYNCHROSLEEVE
2ND GEAR
2. Install the sth synchro hub using the special tools
and a press as snown.
DRIVER, {0 mm l.O.07746 - 0030100
ATTACHMENT,35 mm LD.
sTH SYNCHRO HUB
07716 - 0030,100
3. Install the angular ball bearing using the special
tools and a press as shown.
PRESS
+
DRIVER, 40 mm LD.0?7a6 - It030100

Gountershaft Assembly
Disassembly
1. Securely clamp the countershaft assemblv in a
bench vise with wood blocks.
2. Raise the locknut tab from the groove in the coun-
tershaft, then remove the locknut and the spring
washer.
Remove the ball bearing using a bearing pulle. asshown.
BEARING PULLER
BALL BEARING
13-76
4, Remove the bearing outer race, then remove theneedle bearing using a bearing puller as shown.
BEARING PULLEF
BEARING
CAUTION: Romove the gears using a pr63 and the
stesl blocks as shown, Use of a ,aw-typo puller can
cause damage lo lhe gear tooth.
Support 4th gear on steel blocks, and press thecountershaft out of sth and 4th gears, as shown.
sTH GEAF
{TH GEAR
.(
a
ItI

Gountershaft Assembly
Reassembly
CAUTION:
. Pross 4th and sth gears on the countershaft without
lubrication.
. When installing ilth and sth geafs, support the shaft
on steel blocks, and install the gears using a press.
. Install ilth and sth gear with a maximum pressure of
25.5 kN (2,600 ksf, 18,806lbf).
NOTE; Refer to page 13-74 for reassembly sequence.
'1. Install the distance collar and the needle bearinos
on the countershaft.
COUNTERSHAFT
Install the friction damper, the synchro ring, and the
synchro spring on 1st gear.
Install the 1sv2nd synchro hub by aligning the fin-
gers on the friction damper and the grooves in the
1sv2nd synchro hub, as shown.
lST/2NO
13-78
lSI GEAR
insteps2-6onthe
{
4.lnstall the reverse gear.
Install the synchro spring. and the double cone
synchro as shown.
Assemble the friction damper, the needle bearing,
and 2nd gear, then install them by aligning the fin-gers on the friction damper and the grooves in the
1sv2nd synchro hub with the fingers of the double
cone synchro and the grooves on 2nd gear, as
snown.
Installthe spacer.
FRICTION DAMPER
Install the parts assembled
countershaft.
;
2ND GEAR

9. Support the countershaft on a steel block, and
install 4th gear using the special tools and a press.
as 5nown.
ATTACHMENT,35 mm LD.07746 - 0030400
Support the countershaft on a steel block, and
install 5th gear using the special tools and a press,
as shown.
ATTACHMENT, 30 mm I,D,07746 - 0030300
10.
\
'1'1. Install the needle bearing, then install the ball bear-
ing using the special tools and a press as shown.
PRESSDRIVER,40 mm LD.07746 - 0030100
ATTACHMENT,30 mm LD.07746 - 0030300
J.-12.Securely clamp the countershaft assembly in a
bench vise with wood blocks.
lnstall the spring washer, tighten the locknut, then
stake the locknut tab into the groove.
LOCKNUT
108- 0- 108N.m 111.0- 0- 11.0kgt.m,
80+ 0* 80 lbf'ftl
WOOD BLOCKS
13-79

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

One-way Clulch
The one-way clutch is positioned between the countershaft 1st gear and the park gea., with the park gear splined to the counter-
shatt, The 1st gear provides the outer race surface, and the park gear provides the inner race surface. The one-way clutch
locks up when power is transmitted from the mainshaft 1st gear to thetountershaft 1st gear. The lst clutch and gears
remain engaged in the 1st, 2nd. 3rd, and 4th gear ranges in the p!1, p! or L?l position.
However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches/gears are applied in the E, E or @ position.
This is because the increased rotational speed of the gears on the countershaft overrides the locking "speed range" of the
one-way clutch. Thereafter, the one-way clutch free-wheels with the 1st clutch still engaged.
zNO CLUTCH ,lTH CLUTCH
1ST CLUTCH
MAINSHAFT
COUNTERSHAFT
ONE.WAY CLUTCH
INSIDE OF ONE.WAYCLUTCHSplaned with countershaft
disengage outsideand inside oI the
3RO CLUTCH
OUTSIDE OF ONE.WAYCLUTCH
PANK GEAR
The sprags engage/
OVER-RIDINGLOCKING SPEED CONDITIONLOCKING CONDITION
14-5

The following symptoms can be caused
by improper repair or assembly
Check these items,on th€^ ltems on thePROBABLE CAUSE DUE TO NOTES ListIMPROPER REPAIR List
Vehicle creeps in N position.R1, R2
Vehicle does not move in &l or Pll position.R4
Transmission locks up in E position.R3, R11
Excessive drag in transmission.R6K,R
Excessive vibration, rpm related.R7
Noise with wheels moving onlY.R5
Main seal pops out.R8
Various shifting problems.R9, RlO
PROBABLE CAUSE DUE TO IMPROPER REPAIR
lmproper clutch clearance.
lmproper gear clearance.
Park lever installed upside down.
one-way {sprag) clutch installed upside down.
Reverse selector hub installed upside down.
ATF pump binding.
Torque converter not fully seated in ATF pump.
Main seal improperly installed.
Springs improperly installed.
Valves improperly installed.
Shift fork bolt not installed.
14-11