Transmission HONDA CIVIC 1999 6.G Workshop Manual

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

Description
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clulches/Reverse Brake
The CVT uses the hydraulically-actuated clutches and brake to engage or disengage the transmission gears. When
hydraulic pressure is introduced into the clutch drum and the reverse brake piston cavity, the clutch piston and the reverse
brake piston move. This presses the friction djscs and the steel plates together, locking them so they don't slip. Power is
then transmitted through the engaged clutch pack to its hub-mounted gear. and through engaged ring gear to pinion
gears.
Likewise, when the hydraulic pressure is bled from the clutch pack and the reverse brake piston cavity, the piston releases
the friction discs and the steel plates, and they are free to slide past each. This allows the gear to spin independently on its
shaft, transmitting no power.
Start Clutch
The start clutch, which is located at the end of the driven pulley shaft, engages/disengages the secondary drive gear.
The start clutch is supplied hydraulic pressure by its ATF feed pipes within the driven pulley shaft.
Forward Clutch
The forward clutch, which is located at the end of the drive pulley shaft, engages/disengages the sun gear.
The forward clutch is supplied hydraulic pressure by its ATF feed pipe within the drive pulley shaft.
Reverse Brake
The reverse brake, which is located inside the inte.mediate housing around the ring gear, locks the ring gear in E posi-
tion. The reverse brake discs are mounted to the ring gear and the reverse brake plates are mounted to the intermediate
housing. The reverse brake is supplied hydraulic pressure by a circuit connected to the internal hydraulic circuit.
Planetary Gear
The planetary gear consists of a sun gear, a carrier assembly, and a ring gear. The sun gear is connected to the input shaft
with splines. The pinion gears are mounted to the carrier which is mounted to the fo.ward clutch drum. The sun gear
inputs the engine power via the input shaft to the planetary gear, and the carrier outputs the engine power. The ring gear
is only used for switching the rotation direction of the pullev shafts,
In E. E, and E positions (forward range), the pinion gears don't rotate and revolve with the sun gear, so the carrier
rotates. In E] positjon {reverse range), the reverse brake locks the ring gear and the sun gear drives the pinion gears to
rotate. The pinion gears rotate and revolve in the opposite direction from the rotation direction of the sun gear, and the
carrier rotates with pinion gear revolution.
Pulleys
Each pulley consists of a movable face and a fixed face, and the effective pulley .atio changes with engine speed. The
drive pulley and the driven pulley are linked by the steel belt.
To achieve a low pulley ratio, high hydraulic pressure works on the movable face of the driven pulley and reduces the
effective diameter of the drive pulley. and a lower hydraulic pressure works on the movable face of the drive pulley to
eliminate the steel belt slippage. To achieve a high pulley ratio, high hydraulic pressure works on the movable face of the
drive pulley and reduces the eifective diameter of the driven pulley, and a lower hydraulic pressure works on the movable
face of the driven pulley to eliminate the steel belt slippage.
b
14-198

Electronic Control System ('96 - 98 Modelsl
The electronic control system consists of the Transmission control Module (TcM), sensors, three linear solenoids, and an
inhibitor solenoid. Shifting is electronically controlled under all conditions
The TCIM is located below the dashboard, behind the kick panel on the driver's side'
The TcN4 controls the transmission to reduce engine speed and retain the engine's cooling efficiency when the vehicle is
driven with Iull throttle acceleration
lf the vehicle is continuously driven at full throttle acceleration, the TCM regulates the pulley hydraulic pressure to
increase the pulley ratio, which, as the result. reduces the engine speed and retains the designed cooling efficiency After
the vehicle has been driven at a lower engine speed for a while, the TCM increases the pulley ratio to the original ratio.
For smooth starting in the E position, the TcM sends a signal to the EcM to cut off the rvc clutch {if the A!/c is on) and
increases the engine speed to 900 rpm when the transmission is shifted to the E position'
The start clutch functions to make smooth starting possible. To let the start clutch function properly. the TCM regulates
the start clutch hydraulic pressure based on the entine's negative pressure memorized in the E position'
:
:
z
z
z
S*ond.ry G..r Sh:ft
(cont'd)
14-203

Electronic Gontrol System ('99 - 00 Modelsl
The electronic controt system conststs 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'
fn"pCVirlocatedbelowthedashboard,underthekickpanelonthepassenger'sside'
The pCM controls the transmassion to reduce engine speed and retain the engine's cooling efficiency when the vehicle is
driven with full throftle acceleration
lf the vehicle is continuously driven at lull throttle acceleration, the PCM regulates the pulley hydraulic pressure to
increase the pulley ratio which. as the result, reduces the engine speed and retains the designed cooling efficiency After
the vehicle has been driven at a lower engine speed for a while, the PCM increases the pulley ratio to the original ratio'
i"i ".nl",rr starting in the E position, the PcM cuts off the ,Vc clutch (if the A/c is on) and increases the engine speed to
900 rpm when the transmission is shifted to the E position'
The start clutch functions to make smooth starting possible. To let the start clutch function properly, the PcM regulates
the start clutch hydraulic pressure based on the engine's negative pressure memorized in the E position'
FCM
s*o.d.ry G..t Sh.h
(cont'd)
14-205

Shift Valve BodY
The shift valve body contains the shift valve and the shift control valve. Both are ioined to the shift control linear solenoro.
r tl'ft1il1rf"","" is controred by shift varve pressure (sV) from the shift contror varve. The shift varve distributes pH
pi""aur" "nO PL pressure to drive pulley and the driven pulley' to shift the transmission'
t t*"rilf:::lr';ivarve contrors the shift varve in accordance with the throttre opening and vehicle speed rhe shift
control valve is convorr"o uv ti" "iirt "ontrol linear solenoid, which is controlled by the TcM or PcM When the elec-
tronic control system is faulty, t;; snift controt uutue "witches the shift inhibitor valve to uncover the port leading the
pitot regulator pressure to the start clutch
CONTROL VALVE
VALVE BODY
T;J:"i"""1ff"t""ilody contains the manuar varve and the reverse inhibitor varve. The manuat varve bodv is borted to the
intermediate houslng
. ManualValve
The manual valve mechanicallY uncovers/covers the fluid passage according to the shift lever position'
'
ff:e;;;.'::'?Xftl::T",* is contro ed by the reverse inhibitor pressure (Rl). lt intercepts the hvdraulic circuit to the
reverse brake while the vehicle is moving forward at speeds over approximatelv 6 mph (10 km/h)'
REV€RSE INHIBITORVALVE
MANUAL VALVEBODY
SHIFT CONTROL
MANUAL VALVE
14-211

Description
Hydraulic Flow (cont'd)
lll position, when th€ electronic control system is fauhy.
when the electronic control svstem (linear solenoids and sensors) is faulty, the transmission uses the pitot pipe pressure(PP) to 311o- rh" u"hicle to drive.
when all linear solenoids and sensors are off because of a faulty electronrc control system, clutch reducing pressure (cR)flows to the start clutch control valve, the manual valve, the PH-PL control valve, and the shift control valve. clutch reduc-ing pressure (cR) becomes shift varve pressure (sV) at the shift contror varve, and shift varve pressure {sv) is appried tothe left end of the shift valve and the right end of the shift inhibitor valve. The shift valve moves to the right side. anduncovers the pon that leads high pressure (PH) to the drive pulley and uncovers the po.t tlr"t r""1" ro,,"-pressure (pL) tothe driven pulley At this time, the pulley ratio is high, The shift inhibitor valve moves to the left side, and uncovers theport that leads shift inhibitor pressure (Sll to the pitot lubrication pipe and the pitot regulator valve. tne prtot lubricationpipe discharges fluid inside of the pitot flange, and discharged fluid enters into the pitot pipe and it is applied to the leftend of the pitot regulator valve. The pitot regulator valve moves lo the right side, and uncovers the port that leads pitotregulator pressure (PR) to the shift inhibitor valve. Pitot regulator pressure {pR) becomes start clutch pressure {sc1 at theshift inhibitor valve, and is applied to the stan clutch. The stan clutch rs engaged. The forward clutch pressure (FWD) isapplied to the forward crutch, and the forward crutch is engaged. This alows the vehicre to drive.
NOTE: When used. "|eft" or ,,right', indicates direction on the hydraulic circuit.
14-220
I.

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

TCM CONNECTOR B (22P}
Terminal NumbelSignalDescriptionMeasuring Conditions/Terminal Voltage
B1SOL INHInhibitor solenoid controlWith inhibitor solenoid ON: Baftery voltage
With inhibitor solenoid OFF: 0 V
82MAP (PB)-M an if old Absol r-rte Pressure IMAP)
sensor signal inPUtWith iqnition switch ON (ll): Approx.2.5 V
With e;gine adling: Approx. 1.0 V (depending on
engine speed)
B3Not used
B4TPS-Throttle Position (TP) sensor signal
input
With ignition switch ON (ll) and throftle fully open:
4.14 - 4.42 VWith ignition switch ON (ll) and throttle fully
closed: 0.44 - 0.56 V
VSSVehicle Speed Sensor (VSS) signal
Inpur
With ignition switch ON (ll) and rotating front
wheelsr 0-5Vcycle
TMBData communication with ECM:
Transmission control data outpUt
With ignilion swltch UN lll): rulslng slgnar
81TMAData communication with EClvl:
PGM Fl control data inPut
With ignition swltch uN {ll,: l-ulslng slgnal
B8NDN SGDriven pulley speed sensor ground
B9NDNDriven pulley speed sensor signal
input
ln other thTnE and E position: Pulsing signal
810NDRDrive pulley speed sensor signal
Input
-tn ottrer ttran E ana E position: Pulsing signal
811Not used
812STOP SWBrake switch signal inPutWith brake pedal depressed: Battery voltage
With brake pedal released: 0 V
813DIAG-H(TXD/RXD)Data communication:Diagnostic trouble code outPut
Wittr ignitio.r s*itct' ON (ll): Approx 5.0 V
814Se-ice ctrect signatWith ignition switch ON (ll) and service check
connector oPen: APProx.5 V
With iqnition switch ON (ll) and service check
"onn"itot. connect"d with special tool: 0 V
Secondary gear shaft speed sensor
signal input
Depending on vehicle speed: Pulsing signal
When vehicle is stoPped: 0 V815VEL
816VEL SGSecondary gear shaft speed sensorgrouno
817NDR SGDrive pulley speed sensor ground
818HBRK SWParking brake switch signal inPutWith parking brake lever pulledr 0 V
With parking brake lever released: Battery voltage
819Not used
B20VREF+5 V relerenceWith ignition switch ON (ll): Approx 5 V
821Not used
Not used