Shaft HONDA CIVIC 1997 6.G Workshop Manual

Gountershaft
Inspection (cont'dl
3. Install the parts below on the countershaft sub-assembty, then torque the locknut to 29 N.m (3.0kql.m , 22 blf.ftt .
NOTE: Countershaft locknut has left hand threads.
(=)-----'
v
LOCKNUTLeft hand threads
CONICAL SPRINGWASHER
PARK GEAR/ONE.WAYCLUTCH/1ST GEARASSEMBLY
NEEOLE BEARING
.I ST GEAR COLLAR
TRANSMISSION HOUSINGBEARING
REVERSE GEARCOLLAR
\
14-154
4. Measure the clearance between the 2nd gear andthe 28 mm distance collar with a feeler gauge.
NOTE: Take measurements in at least three places.and use the average as the actuar ctearance.
STANDAFD: 0.10 - 0.18 mm {0.004 - 0.002 inl
lf the clearance is out of tolerance. remove the 2gmm distance collar and measure the width.
Select and install a new distance collar, thenrecheck.
DISTANCE COLLAR, 28 mm
7. Afret selecting a new distance collar, recheck theclearance and make sure it is within tolerance.
OISTANCE COLLAR, 28 mm
No.Part Numb€rwidrh
190503-PCg-00039.00 mm (1.535 in)
290504-PCg-00039.10 mm { 1.539 in)
90505-PCg-00039.20 mm (1.543 in)
90507-PCg-00039.30 mm {1.547 in)
90508-PC9-00039.05 mm (1.537 in)
90509-PCg-00039.15 mm (1.541 in)
790510-PCg-00039.25 mm ( 1.545 in)
I90511-PCg-00038.90 mm (1.531 in)
90512-PCg-00038.95 mm (1.533 in)

One-way Clutch
Disassembly/lnspection/Reassembly
1. Separate countershaft 1st gear from the park gear
by turning the park gear in the direction shown
2. Remove the one-way clutch by prying it up with the
end of a screwdriver.
COUNTERSHAFT 1ST GEARONE-WAY CLUTCHNOTE: lnstall in this direction.
ONE'WAY CLUTCH
COUNTERSHAFT lST GEAR
COUNTERSHAFT lST GEAR
SCREWORIVER
14-155
3. Inspect the parts as followsl
PARK GEARInspecl the park gear
for wear and scorrng.
ONE-WAY CLUTCHInspect the one-way
clutch for damage and
laulty movement.
lST GEABInspect countershalt lst gear
for wear ancl scorlng.
After the parts are assembled, hold countershaft 1st
gear and turn the park gear in the direction shown
to be sure it turns freely. Also make sure the park
gear does not turn in the opposite direction.

Differential
Diff erential Carrier Replacement
L Remove the final driven gear from the differential
carrier.
NOTE: The final driven gear bolts have left-hand
threads.
Pry the snap ring off differential carrier, then remove
the speedometer drive gear and 5 x 10 mm roller.
SNAP RING
3. Install the 5 x l0 mm roller in the differential carrier,
Install the speedometer drive gear with its cham-
fered side facing the carrier. Align the cutout on the
bore of the speedometer drive gear with the 5 x 10
mm roller.
L
14-168,
5. Align the hooked end of the snap ring with the pin-
ion shaft as shown, then install the snap ring in the
differential carrier groovs.
SNAP RINGHooked end Install in this direction.
SPNI G PIN
Install the final driven gear, then tighten the bolts to
the specified torque.
TOROUE: 101 N.m (10.3 kgf'm, 74.5 lbf.ftl
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS10 r 1.O mm1Ol t{.m 11O.3 kgf.m,74.5 lbl.frlLeft-hand rhreads
FINAL DRIVENGEARlnstall in thisdirection.
DIFFERENTIALCARRIER
7. Install a new ball bearing (se€ page 14-157).
Install in this direclon.

Torque Converter Housing Bearings
Mainshaft Bearing/Oil Seal Replacement
1.Remove the mainshaft bearing and oil seal using
the special tools as shown.
3/8"16 SLIOE HAMMER
ADJUSTAELE BEARINGPULLER, 25 - ilo mm07736 - A01000a
L
14-172
2. Drive in the new mainshaft bearing until it bottomsin the housing using the special tools as shown.
DRIVER077€ - 0010000
lnstall the new oil seal flush with the housing using
the special tools as shown.
DBIVER07749 - 0o l0(xt0
ATTACHMENT,72x75 mfi07746 - 001 0600

Countershaft Bearing Replacement
'1. Remove the countershaft bearing using the special
tools as snown.
3,/8'.16 SLIDE HAMMER{Commerciallv available)
AOJUSTABLEBEARINGPULLER,25-{Omm07736 - A0'1000A
2.
5.
Install the ATF guide plate.
Drive the new bearing into the housing using the
special tools as shown.
ATTACHMENT,62x68mm
0 - 0.03 mm(0 - 0.001 inl
14-173

Transmission Housing Bearings
L
Mainshaft/Countershaft Bearings Replacement
To remove the mainshaft and countershaft bearings
from the transmission housing, expand each snap
ring with snap ring pliers, then push the bearing out
using the special tools and a press as shown.
NOTE: Do not remove the snap rings unless it's
necessary to clean the grooves in the housing.
DRIVER07749 - 0010000
ATTACHMENT,62x68mm
PRESS
\
07746 -
DFIVEB07749 - 0010000
TTACHMENT
ATTACHMENT
. Mainshaft Bearing Installation us€:
ATTACHMENT. 72 x 75 mm
07746 - 0010600. Countershaft Bearing Installation use:
ATTACHMENT, 62 x 68 mm
077/16 - 0010500
IRN{L{r.)n
\bZ
MAINSHAFT BEARING
L
14-174
SNAP RING
Expand each snap ring with snap ring pliers, insert
the new bearing part-way into the housing using
the special tools and a press as shown, Install thebearing with the groove facing outside the housing.
NOTE: Coat all parts with ATF.
Release the pliers, then push the bearing down intothe housing until the ring snaps in place around it.
07749 - 0010000
ATTACHMENT
. Mainshaft Bearing Removal use:
ATTACHMENT, 72 x 75 mm
077/16 - 0010600. Counte6haft Bsaring Removal use:
ATTACHMENT, 62 x 68 mm
07746 - 0010500
After installing the bearing verify the following:
. The snap ring is seated in the bearing and hous-
ing grooves.
. The ring end gap is correct.
(0 - 0.28 in)ENDGAP:0-7mm

Reverse ldler GearPark Stop
lnstallation
1, lnstall the reverse idler gear.
Install the reverse idler gear shaft holder and needle
bearing into the transmission housing, then tighten
the bolts.
6 x 1.0 mm12 N.m ll .2 kgf'm,
8.7 tbf.ftl
GEAR
'1.
Inspection/Adiustment
Set the park lever in the E position.
Measure the distance between the park pawl shaft
and the park lever roller pin as ahown.
STANDARD: 72.9 - 73.9 mm 12.87 - 2.91 inl
PARK PAWLSHAFT
lf the measurement is out of tolerance, select and
install the appropriate park stop from the table
Delow.
PARK STOP
PARK STOP
After replacing the park stop, make sure the dis-
tance is within tolerance.
/A\Measuring\v
MarkPart Numb€rLr12
I24537-PAg-00311.00 mm
(0.433 in)
11.00 mm
(0.433 in)
24538-PAg-00310.80 mm(0.425 in)
10.65 mm
(0.419 in)
24539-PAg-00310.60 mm(0.417 in)
10.30 mm(0.406 in)
14-175

Transmission
Reasembly
NOTE;
. Coat all parts with ATF.. Beplace the following parts:- O-rings- Lock washers- Gaskets- Mainshaft and countershaft locknuts and conical spring washers- Sealing washers
TOROUE: l2 N.m (1.2 ksf'm,8.7 lbf.ft)
6 x 'l.0 mm7 BoltsFEED PIPE: A
LOCK.UP VALVEBODY
LOCK.UP SEPARATORPLATE
REGULATOR VALVEBODY
DOWEL PINS. 2
6xl.0mm1 BoltATF STRAINERATF FEEDPIPES:
a
COOIER RELIEF VALVE
TOROUE CONVENIERCHECK VALVESTATOR SHAFT
O.RING
STOP SHAFT
ATF FEEO PIPE: H
5x1.0mm5 Bolts
DOWEL PINS.
MAIN VALVE BODY
ATF PUMP
SERVO SEPARATORPLAYE
6x1.0mm7 Bolts
SERVO BODY
SECONOARYSEPARATOR PLATE
CONTROL
GEAR SHAFT
ATF PUMP DFIVENGEAR
MAIN SEPARATORPLATE
DOWEL PINS,
/ SHAFI
' -
7r(
t'se - oo ^od"t"t
lli
triTOROUE CONVERTERHOUSING
NOTE: The illustration shows the'96 - 98 modsls, the'99 - 00 models do not have the servo detent base; the servodetent is integralwith the servo bodv.
14-176
L-

1.Install the ATF magnet and suction pipe collar in the
torque converter housing. if necessary.
lnstall the main seDarator plate and the two dowel
pins on the torque converter housang.
Install the ATF pump drive gear, ATF pump driven
gear and ATF pump driven gear shaft on the torque
converter housing.
NOTE; Install the ATF pump driven gear with its
grooved and chamfered side tacing down.
ATF PUMP
ATF PUMP DRIVENGEAR SHAFT
ATF PUMPDRIVEN GEAR
Grooved and chamferedside taces separalorplate.MAIN SEPARATORPLATE
4.Loosely install the main valve body with five bolts.
Make sure the ATF pump drive gear rotates smoothly
in the normal operating direction and the ATF pump
driven gear shaft moves smoothly in the axial and
normal operating directions.
Install the secondary valve body, separator plate
and two dowel pins on the main valve body.
NOTE: Do not installthe bolts.
6. Install the control shaft in the housing with the con-
trol shaft and manual valve together.
7. lnstall the detent arm and arm shaft in the main
valve body, then hook the detent arm spring to the
detent arm,
SERVO SEPARATOR PLATE
DETENT
MANUAL VALVE
DETENT ARM SPRING
15.
14-177
a
10.
11.
Install the servo body and separator plate on the
secondary valve body ('95 - 98 models: seven bolts.'99 - 00 models: eight boltsl.
For '96 - 98 models: Install the servo detent base
and the ATF strainer (two boltsl.
For'99 - 00 models: Install the ATF strainer (one
bolt).
Tighten the five bolts on the main valve body to 12
N.m ('1.2 kgf.m,8.7 lbf.ft).
Make sure the ATF pump drive gear and ATF pump
driven gear shaft move smoothlY'
lf the ATF pump drive gsar and ATF pump driven
gear shaft do not move freely, loosen ths five bolts
on the main valve body, and disassemble the valve
bodies.
Realign the ATF pump driven gear shaft and reassem-
ble the valve bodies, then retighten the bolts to the
specified torque,
CAUTION: Fsilule to align tho ATF pump driven
goar shaft corr.ctly will rscuh in a s€ized ATF pump
drive goar or ATF pump d ven gear shaft.
Install the stator shaft and stop shaft.
Install the bolts and the shaft stop on the secondary
valve body, then tighten the bolts (three boltsl.
Install the torque converter check valve, cooler relief
valve and valve springs in the regulator valve body.
then install the regulator valve body on the main
valve bodv (one bolt).
Install the lock-up valve body on the regulator valve
bodv (seven bolts).
Install the ATF feed pipes in the main valve bodY,
the three ATF feed pipes in the secondary valve and
the four ATF feed pipes in the servo body. (cont'dl
12.
't 3.
14.
PUMP

Transmission
_\,]ffil
Reassembly (cont'd)
TRANSMISSIONHANGER
MAINSHAFTSUB.ASSEMBLY
*''
Ufln
$*U ./
TRANSMISSION HOUSINGMOUNTING BOLTS10 x 1.25 mm4{ N.m {4.5 kg{.m,33 lbI.ft)
TRANSMISSION HOUSING
REVERSE GEARCOLLAR
REVERSE GEAR
LOCK WASHER
SHIFT FORK
MAINSHAFT SPEEDSENSOR WASHER(D16Y7 engine)
MAINSHAFT
COUNTERSHAFTSUB.ASSEMBLY
OIFFER€NTIALASSEMBLY
SPEED
TRANSMISSIONHOUSING GASKET
TOROUE CONVERTERHOUSING
14-178