gear shift HONDA CIVIC 1997 6.G Repair Manual

Shift Lever
PUSH KNOB SPRING
SILICONE GREASE
SCBEWN.m {0.3 kgtm.2 lbf ft)
Apply non-hardening thread lock sealant
SCREW3 N.m {0.3 kgif m,2 lblft)
GEAR POSITION INDICATOR PANEL
COVER
SHIFT LEVER ASSEMBLY
SHIFT INDICATOR
BUSHING
-61SILICONE GREASELEVERSHIFT LOCK
SCREW3 N.m {0.3
g
6x1.0mm9.8 N.m {1.0 kgf.m,7.2 tbt.ft)
A/T GEAR POSITION
PLATE
SHIFT LEVER BRACKET BASE
SHIFT LEVER
2/""*"
,.@* _.\__r.\
-Rt \ooru.r.,
A/T GEAR POSITION SWITCH
6x1.0mm9.8 N.m 11.0 kgf.m.7.2lbf.ft)
BASE COLLAA
14-191

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

Description
The Continuously Variable Transmission (CVT) is an electronically controlled automatic transmission with drive and driv
en Oullevs, and a steel belt. The CVT provides non stage speeds forward and one reverse. The entire unit is positioned in
line with the engine.
Transmission
Around the outside of the flywheel is a ring gear which meshes with the starter pinion when the engine is being staned.
The transmission has four parallel shafts: the input shaft, the drive pulley shaft. the driven pulley shaft, and the secondary
gear shaft. The input shaft is in line with the engine crankshaft. The drive pulley shaft and the driven pulley shaft consist of
movable and fixed face pulleys. Both pulleys are linked by the steel belt.
The input shaft includes the sun gear. The drive pulley shaft includes the forward clutch which mounts the carrier assem-
bly on the forward clutch drum. The carrier assembly includes the pinion gears which mesh with the sun gear and the ring
gear. The ring gear has a hub-mounted reverse brake disc.
The driven pulley shaft includes the start clutch and the secondary drive gear which is integral with the park gear' The sec-
ondary gear shaft is positioned between the secondary drive gear and the final driven gear. The secondary gear shaft
includes the secondary driven gear which serves to change the rotation direction. because the drive pulley shaft and the
driven oullev shaft rotate the same direction. When certain combinations of planetary gears in the transmission are
engaged by the clutches and the reverse brake, power is transmitted from the drive pulley shaft to the driven pulley shaft
to provide E, E, E, and El.
Electronic Control'96 - 98 Models:
The electronic control system consists of the Transmission Control Module (TCM), sensors, three linear solenoids, and a
inhibitor solenoid. Shifting is electronically controlled under all conditions'
The TCM is located below the dashboard, behind the kick panel on the driver's side.'99 - 00 Models:
The electronic control svstem consists of a Powertrain Control Module (PCM), sensors, three linear solenoids and an
inhibitor solenoid. Shifting is electronically controlled under all conditions. A Grade Logic Control System to control shift-
ing in E position while the vehicle is ascending or descending a slope.
The PCM is located below the dashboard, under the kick panel on the passenger's side.
Hydraulic Control
The lower valve body assembly includes the main valve body, the Pressure Low (PL) reguiator valve body, the shift valve
body, the start clutch control valve body, and the secondary valve body. They are positioned on the lower part of the
transmission housing.
The main valve body contains the Pressure High (PH) control valve, the lubrication valve, and the pitot regulator valve.
The secondary valve body contains the PH regulator valve, the clutch reducing valve, the start clutch valve accumulator,
and the shift inhibitor valve. The PL regulator valve body contains the PL regulator valve and the PH-PL control valve
which is ioined to the PH,PL control linear solenoid. The inhibitor solenoid valve is bolted on the PL regulator valve body.
The shift valve body contains the shift valve and the shift control valve. which is joined to the shift control linear solenoid.
The start clutch control valve body contains the start clutch control valve, which is joined to the start clutch control linear
solenoid. The linear solenoids and the inhibitor solenoid are controlled by the TCM or PCM. The manual valve body which
contains the manual valve and the reverse inhibitor valve, is bolted on the intermediate housing.
The ATF pump assembly is located on the transmission housing, and is linked with the input shaft by the sprockets and
the sprocket chain. The pulleys and the clutch receive fluid from their respective feed pipes, and the reverse brake receives
fluid from internal hydraulic circuit.
Shift Control Mechanism
Input from various sensors located throughout the vehicle determines which linear solenoid the TCM or PCM will activate.
Activating the shift control linear solenoid changes the shift control valve pressure, causing the shift valve to move. This
pressurizes the drive pulley pressure to the drive pulley and the driven pulley pressure to the driven pulley and changes
their effective pulley ratio. Activating the start clutch control linear solenoid moves the start clutch control valve. The start
clutch control valve uncovers the port, providing pressure to the start clutch to engage it(cont'd)
14-195
,!

Description
(cont'd)
Gear Sel€stion
The shift lever has six positions: @ pARK, E REVERSE, E NEUTRAL, E DR|VE, g SECOND, and El LOW.
Staning is possible only in E and E positions through the use of a slid6-type, neutrafsafety switch.
Automrtic Transaxle {A/T} Gear Position Indicltor
The A-lT gear position indicator in the instrument panel shows which gear has been selected without having to look downat the console.
PoshionDe3cription
E PARK
E REVEBSE
E NEUTRAL
D DRIVE
E SECOND
E LOW
Front wheels locked; park pawl engaged with the park gear on the driven pulley shaft. The startclutch and the forward clutch released.
Reverse; reverse brake engaged.
Neutral; the start clutch and the forward clutch released.
General driving; the transmission automatically adjusts to keep the engine at the best speed fordriving conditions.
For rapid accelsration at highway speeds; the transmission shifts into a lower range of ratios forbetter acceleration and increased engine braking.
For engine braking and power for climbinO; the transmission shifts into the lowest range of theralros.
l-
14-196

E position
The flow of fluid up to the drive pulley, the driven pulley' and the clutch reducing valve is the same as in E position The
pulley ratio is low b"car"" tt " o riu",i'prti"vi"""v"" t'igtr pressure.(pH) and the drive pulley receives low pressure {PL).
The manual valve is shifted into the B position, and it uncovers the port that leads reverse brake pressure (RVS) to the
reverse inhibitor valve. The inhibitoi Jenoid turns off by means of the TcM or PcM, and reverse inhibitor pressure (Rl) is
appliedtotherightendofthe,"u",""int,iui.o,u,|ve.Thereverseinhibitorva|vemovestothe|eftside,anduncoversthe
port that leads reverse brake pr"a"ur" tivst,o,he reverse brake. clutch reducing pressure (cR) becomes reverse brake
pressure (RVS) at the manuat *r"-, "nJ tro*" to the reverse brake. The reverse brake is engaged, and it locks the ring
gear.
NOTE: When used, "|eft" or "right" indicates direction on the hydraulic circuit'
(cont'd)
14-217

E] position, when the elestronic Gontrol system is faulty'
The flow of tluid up to the drive pulley, the driven pulley' and the start clutch is the same as in El position
The manual valve is shifted into the lE position' and it uncovers the port that leads reverse brake pressure {RVS} to the
reverse inhibitor valve. Reverse ,"nlu-i,"ip*r""i" (Rl) is applied to.the right end of the reverse inhibitor valve because of
afaultyinhibitorsolenoid.The'"t'",""inftiUito'valvemovestotheleftside'anduncoverstheportthatleadsreverse
brake pressure {RVS) to the ,"u"r." ir"t"- cru,ch reducing pressure (cR) becomes reverse brake pressure (RVS) at the
manual valve, and,lows to the ,e
"rs" lr"re. ttre reverse brake is engaged and locks the ring gear' This allows the vehi-
cle to drive in reverse.
NOTE: When used, "left" or "right" indicates direction on the hydraulic circuit'
14-221

Description
Park Mechanism
The park mechanism locks the transmission by engaging the park pawl with the park gear which is integral with the sec-ondary drive gear' The secondary drive gear engages with the secondary driven gear which engages wit-h the final drivengear.
shifting to E position causes the park cone (installed at the end of the park rod) to press the park pawl onto the park gear.Even if the end of the park pawl rides on the top of the park gear teeth, slight movement of the vehicle will cause the parkpawl and the park gear to mesh with each other completely because the park cone receives the tension from the park rodspring The park pawl receives the tension (which acts to separate the park pawl from the park gear) from the park pawlspring.
PARK PAWI-
PARK CONE
START CLUTCH
PABK GEAR
PARK RODPARK PAWL
PARK ROOSPRING
14-222
D

Component Locations
36 - 98 Models
BRAKE SWITCH
DRIVEN PULLEYSPEED SENSOR
INHIBITOR SOLENOID
ENGINE CONTROLMODULE IECMI
SECONDARY GEAR SHAFTSPEEO SENSOR
AUTOMATIC TRANSAXLE (A/T}GEAR POSITION SWITCI{
MANIFOLD ABSOLUTE
VEHICLE SPEEO SENSOR{vss}
IMAPI SENSOR
THROTTI.I POSITION {TPISENSOR
PH.PL CONTROLLINEAR SOLENOID
/i/ i,' / ,','4
,i/:1
t"--.---.- i,,
-_,-:-_a.--:
il
START CLUTCH CONTROLLINEAR SOLENOIDPULLEY
SHIFT CONTROLLINEAR SOLENOTD
$r,
14-224
h
SPEED SENSOR

'99 - 00 Models
CONTROL
AUTOMATIC TRANSAXLE IA/TI
GEAR POS]TION SW]TCH
MANIFOLD ABSOLUTESECONDANY GEAR SHAFT
SPEED SENSORIMAPI SENSOR
VEHICLE SPEED SENSOR
tvss)
THROTTLE POS]TION ITP)SENSOR
PH.PL CONTBOLLINEAB SOLENOIO
DNVEN PUL]-EY
SPEED SENSOR
START CLUTCH CONTROL
PULLEY
SHIFT CONTROLLINEAR SOLENOIO
LINEAR SOIENOID
SPEED SENSOR
14-225

TCM Terminal Voltage/Measuring Gonditions
('96 - 98 Modelsl
TCM Terminal Loc.tions
TCM-A l25P) Connecto.
TCM CONNECTOR A (26P}
TCM-B (22P) Connectot
2418910111213
1115161720232526
Terminal NumbetSignalDsscriptionMoasuring Conditions/Torminsl Vohrgo
A1SC LS_Stan clutch control linear solenoidpower supply negative electrodeEngine idling, E position:Approx. 0.4 VHLC LS-PH-PL control linear solenoid Dowersupply negative electrodeEngine idling, E position:Approx. 0.7 V
Shift control linear solenoid oowersupply negative electrodeEngine idling, E position:Approx. 0.8 V
A4LG1Ground
NEEngine speed signal inputWith engine running: Pulsing signalA6Not used
A7ATP LA/f gear position switch El positionsignal inputInEposition:OVIn other than El position: Approx. 1O VA8ATP Sly'T gear position switch E positionsignal inputIn lg position: 0 VIn other than E position: Approx. 10 VA9ATP DA{/T gear position switch E positionsignal inputIn lll position: 0 VIn other than E position: Approx. 10 VAr0ATP NPA,/T gear position switch E or Eposition signals inputInEorEposition:oVIn otherthan E orE position: Approx. 1O VA11ATP RA,/T gear position switch E positionsignal inputIn lE position: 0 VIn other than E position: Approx. 1O VA.12tGlPower supply systemWith ignition switch ON (ll): Banery voltsgeWith ignition switch OFF: 0 VA13PG1Ground
414Start clutch control linea. solenoidpower supply positive electrodeEngine idling, E position:Approx. 2.5 VA15HLC LS+PH-PL control line8|. solenoid powersupply positive electrodeEngine idling, El position:Approx. 5.0 VA16SH LS+Shift control linear solonoid oowersupply positive electrodeEngine idling, E position:Approx. 6.0 V417Ground
A18Not used
A19Not used
420D INDE indicator light controlWhen l9l indicator light comes on: Approx. jO VWhen lll indicator lighr OFF: 0 VA2'lNot used
422Not used
VBUBack-up power systemAlways battery voltage424Not used
A.25tG1Power supply systemWith ignition switch ON (lt): Baftery voltageWith ignition switch OFF:0 VPG1Ground
L
14-228