Block HONDA CIVIC 1998 6.G Repair Manual

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

PCM Terminal Voltage/Measuring Gonditions ('96 - 9g Models)
A/T Control System
The PCM terminal voltage and measuring conditions are shown for the connector terminals that relate to the A"/T controlsystem. The other PCM terminal voltage and measuring conditions are described in section I l.
A l32P) Conn€ctotB I25P) ConnectorC (31P)ConngctorD (16P)Connector
PCM CONNECTOR A I32P}
Terminal NumborSignalDcacriptionMoasuring Conditions/Te.minal Voltage
A1 to A8- see section 1 I -
A9LG1Ground
A10PG1Grou nd
A11IGPlPower supply systemWith ignition switch ON (ll): 8attery voltage
With ignition switch OFF: 0 V
412 to A2l- see section I I -
Ground
423PG2Ground
A'24IG P2Power supply systemWith ignition switch ON (ll): Battery voltage
With ignition switch OFF: 0 V
A25 to A32- see section l1 -
PCM CONNECTOR B (25P}
Terminal NumberSignalDescriptionMeasuring Conditions/T6rminal Voltage
B1LS-Linear solenoid power supply
negative electrode
lgnition switch ON (ll): Pulsing signa.
82Linear solenoid power supplypositive electrode
lgnition switch ON (ll): Pulsing signal
SHAShitt control solenoid valve A
controlIn 2nd gear and 3rd gear in E, E position,
and in @, @ position: Battery voltage
In lst gear and 4th gear in E. E position: 0 V
B4LCBLock-up control solenoid valve B
control
When full lock-up: Battery voltage
When half lock-up: Pulsing signal
B5LCALock-up control sol€noid valve AcontrolWhen lock-up is ON: Battery voltage
With no lock-up: 0 V
86 to 87Not used
B8ATP D3IVT g6ar position switch @ posi-
tion signal input
lnEposition; OV
In other than E position: Battery voltage
Bg to 810Not used
\-
14-42

FCM CONNECTOR D {16P)
\o
14-47
Terminal NumberSignalDo3criptionMeasuring Conditions/Torminal Vohage
D1LCALock-up control solenoid valve A
control
When lock-up is ON: Battery voltage
With no lock-up: 0 V
SHBShift control solenoid valve B
control
In E position, in 1st and 2nd gear in E, E
position: Battery voltage
ln 3rd gear in E, E, in 4th gear in E posi-
tion;0 V
D3LCBLock-up control solenoid valve B
control
When full lock-up: Battery voltage
With half lock-up: Pulsing signal
D4Not used
D5VB SOLLock-up control solenoids, shift
control solenoids and linear
solenoid power supply electrode
with ignition switch oN (ll): Battery voltage
With ignition switch OFF: 0 V
D6ATP RAy'T gear position switch
E position input
tnEposition:0V
In other than E position: Approx. 10 V
SHAShift control solenoid valve A
control
In E] position, in 2nd and 3rd gear in p!, [Q]
position: Battery voltage
In 1st gear in E, @ position, in 4th gear in El
Dosition: 0 V
D8ATP D3A/T gear position switch
E position input
In E position:0V
In otherthan @ position: Approx. 10 V
D9ATP D4Ay'T gear position switch
E position switch
In El position: 0 V
In other than E position: Approx. 5 V
D10NCCountershaft speed sensor signal
input
Depending on vehicle speed: Pulsing signal
When vehicle is stooped: 0 V
D11NMMainshaft speed sensor signal
Inpur
Depending on engine speed: Pulsing signal
When engine is stopped: 0 V
D't2NMSGMainshaft speed sensor ground
D13ATP NPAy'T gear position switch E and
E position input
InE and E positions: 0V
In other than E and E positions: Approx. 10 V
D14AfP 2Ay'T gear position switch
E position input
tnEposition;0V
In other than E position: Approx. 10 V
D16NCSGCountershaft speed sensor
ground

Symptom-to-Component Chart
Hydraulic System (cont'dl
G.
n,
set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
lf the clutch pack is seized or is excessively worn. inspect the other clutches for wear, and check the orificecontrol valves, CPC valve and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lmproper alignment or main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
lf the l st clutch feed pipe guide in the end cover is scored by the mainshaft, inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged. lf the 4th feed pipe is danFaged or out of round, replace the right side cover.
Replace the mainshaft if the bushing for the 1st feed pipe is loose or damaged. lf the 1st feed pipe is darn-aged or out of round, replace it.
A worn or damaged sprag clutch is mostly a result of shifting the transmission inthe wheels rotate in reverse, such as rocking the vehicle in snow.
or E position while
Inspect for damage and wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear u nder pin ion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1,2,3 and 4 if worn or damaged. lf transmission makes a clicking, grinding orwhirring noise,also replace mainshaft 4th gear, reverse idler gear. and countershaft 4th gear in addition to 1, 2, 3 or 4.lf differential pinion shaft is worn, overhaul differential assembly, and replace ATF strainer, and thoroughlyclean transmission, flush torque converter, cooler and lines.lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and final drivengear.
Be very careful not to damage the torque converter housing when replacing the main ball bearing, you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the oroper roors.
Install the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
See flushing procedure, page 14-187 and 188.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the l-2 shift valve is stuck closed, the transmission will not upshift. lf stuck open, the transmission hasno 1st gear.
lf the znd orifice control valve is stuck. inspect the 2nd and 3rd clutch oacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch oacks for wear.
lf the clutch pressure control valve is stuck closed, the transmission will not shift out of 1st gear.
lf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Inspect the frame for collision damage.
14-112

Road Test
NOTE: Warm up the engine to normal operating tem peratu re (the rad iator fan comes on )'
1. Apply parking brake and block the wheels. Start the engine, then shift to E position while depressing the brake
Dedal, Depress the accelerator pedal and release it suddenly. The engine should not stall'
2. Repeat same test in E Position.
3. Test-drive the vehicle on a flat road in the E position. Check that the shift points occur at approximate speeds shown
in the table. Also check for abnormal noise and clutch slippage.
NOTE: Throttle position sensor voltage represents the throttle opening
a. Unbolt the PCM for road testing; refer to page 14-50.
b. Setthedigital multimeter to check the th rottle position sensor voltage between PCM terminals;
. '96 - 98 models: D1 {+) and A9 (-) or 422 (-}.
. '99 - 00 models: C27 (+) andB20t-) orB22{-}.
BACKPROBE ADAPTER
BACKPROBE SET07sAz - 001oq)A{two requiredl
DIGIIAL MULTIMETERlCommercially available)KS-AHM-32-003,or equivalenl
'96 - 98 Modelsr
Wire side ol temale terminals
PCM CONNECTORS
B t25Pl c (31P)
LG1 IBRN/BLK)
I (25P1c (31P}
A t32PtD (16P)
Wire side ol female terminals
'9!t - 00 Models:
1+113

Stall Speed
Test
CAUTION:
. To prev€nt transmission damage, do not t6st stall speed for more than ro sgconds at a time.. Do not shift the levor while raising the engine speed.. Bo sule lo remove the pressure gauge betoro testing stall speed.
'1. Engage the parking brake, and block the front wheels.
2. Connect a tachometer to the engine, and start the engine.
3. Make sure the Ay'C switch is OFF.
4. After the engine has warmed up to normal operating temperature (the radiator fan comes on). shift into E position.
5. Fully depress the brake pedal and accelerator for 6 to g seconds, and note engine speed.
6. Allow two minutes for cooling, then repeat the test in @ and @ positions.
NOTE:
. Stall speed tests should be used for diagnostic purposes only,. Stall speed should be the same in o., E and E positions.
Stall Spsed RPM:
Specification: 2.700 rpm
Service Limit: 2,550 - 2,850 rDm
TROUBLEPROBABLE CAUSE
. Low fluid level or ATF pump outDur. Clogged ATF strainer. Pressure regulator valve sluck closeo. Slipping clutch
. Slippage of 4th ctutch
. Slippage of 2nd clutch
. Slippage of lst clut"tr or. t"t g""io*-*"y "lut"h
Stall rpm high in D., E and E positions
Stall rpm high in El position
Stall rpm high in E posirion
Stall rpm high in E position
Stall rpm low in LDa . El and E positrons. Engine output low. Torque converter one-way clutch slipping
14-116

2nd, 3rd and 4th Clutch Pressure Measurement
1. Set the parking brake, and block both rear wheels securely'
2. Start the engine, and run it the engine at 2,000 rpm'
3. Shift to E position, then measure 2nd clutch pressure
4. Shiftto El position, then measure3rd clutch pressure
5. Shift to E position, then measure 4th clutch pressure'
6. Shift to E position, then measure 4th clutch pressure'
INSPECTION HOI'E(Marked with "3")
2ND CLUTCH PR€SSURE
INSPECTION HOLE
FLUID PRESSURE
standard I sorviqe LimitPRESSURESHIFT LEVER
POStT|()NSYMPTOMPROBABLE CAUSE
2nd ClutchtrNo or low 2nd
pressure
2nd Clutch800 - 850 kPa
(8.2 - 8.7 kgflcm',
120 - 120 psi)
760 kPa
(7.7 kgf/cm', 110 Psil
3rd ClutchtrNo or low 3rd
pressure
3rd Clutch8'10 - 860 kPa
(8.3 - 8.8 kgt/cm',
120 - 130 psi)
760 kPa
(7.8 kgt/cm', 110 Psi)
4th clutchp.lNo or low 4th
presSure
4th clurch
EServo Valve or 4th
Clutch
1+121