countershaft HONDA CIVIC 1998 6.G Repair 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

End Cover
Removal
NOTE:
. Cleanall parts thoroughly in solvent or carburetor cleaner, and drywith compressed air,. Blow out all passages,
. When removing the right side cover, replace the following:- O-rings- Mainshaft and countershaft locknuts- Conical spring washgrs- End cover gasket
- Lock washer- Sealing washers
END COVER6 x 1.0 mm BOLT13 Bolts
PARK PAWL
PARK ITVER
LOCK WASHER
COUI{TERSI{AFTLINE AOLT
tST GEAF COLLAR
I
14-132
SEALING WASHERS

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

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

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.

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