Synchro ring HONDA CIVIC 1999 6.G Owner's Manual

Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEABING PULLER
BALL BEARING
CAUTION: Remove the synchro hubs using a ptess
and the sts€l blocks as shown. Use of a i8w'type
puller can cause damage to th€ gear teeth.
Support sth gear on steel blocks, and press the
mainshaft out of the sth synchro hub, as shown.
3. Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th svnchro hub, as shown.
13-71

Reassembly
CAUTION:
. Press the 3rd/4th and the 5th synchro hubs on the
mainshaft without lubrication.
o When installing the 3rd/,lth and the sth synchro
hubs, support the mainshaft on steel blocks, and
installthe synchro hubs using a prsss.
. Install the 3rd/4th and the sth synchro hubs with a
maximum plessur€ of 19.6 kN (2,000 kg, 14,466 lbl.
NOTE: Refer to page 13-67 for reassembly sequence.
1, Support 2nd gear on steel blocks, then install the
3rd/4th synchro hub using the special tools and a
press, as snown.
NOTE:
. After installing. check the operation of the
3rd/4th synchro sleeve and hub.
. Assemble the 3rd/4th synchro hub and sleeve
together betore installing them on the mainshaft.
Closed end
3RD/4THSYNCHRO HU3DBIVER, 10 mm l.O.07746 - 00301U)
/ lrrlcHlileNr. ss .- t.o.07746 - 0030,100
l.
3RD/{THSYNCHROSLEEVE
2ND GEAR
2. Install the sth synchro hub using the special tools
and a press as snown.
DRIVER, {0 mm l.O.07746 - 0030100
ATTACHMENT,35 mm LD.
sTH SYNCHRO HUB
07716 - 0030,100
3. Install the angular ball bearing using the special
tools and a press as shown.
PRESS
+
DRIVER, 40 mm LD.0?7a6 - It030100

Gountershaft Assembly
Index
DAMPER
ST GEARInspection, page 13-75
EALL EEARING
and operation.
NEEDLE BEARINGlnspect for wearano operaton.
5TH GEAR
4TH GEAR
3RD GEAR
NOTE:
3
The 4th and sth gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4thand 5th gears. however, should be installed with a press before lubricating them.
REVERSE GEAR
LOCKNUT Replace108"0-108N.m
i11.0 - 0- l1.0kgtm,180-0-80lbttr
WASHER
DISTANCECOLLAR
COUNTERSHAFTInspection, page 13-77
NEEDLE BEARING
and operatron,
Inspection, page 13-75
NEEDLE BEARING
ano operatron,
SPACER
FRICTION DAMPER
DOUBLE CONE
Inspection, page 13 81
SYNCHRO SPRING
13-74

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

Synchro Sleeve, Synchro Hub
Inspection
1,Inspect gear teeth on all synchro hubs and synchro
sleeves for rounded off corners. which indicates
Install each synchro hub in its mating synchro
sleeve and check for freedom of movement.
NOTE: lf replacement is required, always replace
the synchro sleeve and synchro hub as a set.
Installation
When assembling the synchro sleeve and synchro hub,
be sure to match the three sets of longer teeth (120
degrees apart) on the synchro sleeve with the three sets
of deeper grooves in the synchro hub.
CAUTION: Do noi install tho synchro sleeve with its
longer toeth in the synchro hub slots, because it will
damage the spring ring.
SYNCItROSLEEVCLONGER TEETH
13-80

Synchro Ring, Gear
Inspection
'1. Inspect the synchro ring and gear.
A: Inspect the inside of the synchro ring for wear'
B: Inspect the synchro sleeve teeth and matching
teeth on the synchro ring for wear (rounded off).
oo
GOOD WORN
C: Inspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
nn
UUGOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
F: Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks'
2. Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear. Rotate the
ring, making sure that it does not slip
Measure the clearance between the synchro ring
and gear allthe way around.
NOTE: Hold the synchro ring against the gear even-
ly while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.73 - 1.18 mm
(0.029 - 0.0'16 in)
Ssrvice Limit:0.,0 mm {0.02 in}
Double Cone Synchro-to-Geal Clearanc€
Standald:
@: (Outer Synchro Ring to Synchro Con6l
0.5 - 1.0 mm 10.02 - 0.04 in)
@: (Synchro cone to Gearl
0.5 - 1.0 mm (0.02 - 0.04 inl
O: {Outer Synchlo Ring to Gear)
0.95 - 1.68 mm (0.037 - 0.066 in)
Service Limit:
@: 0.3 mm {0.01 in}
@: 0.3 mm {0.01 in)
O: 0.6 mm t0'02 inl
lf the clearance is less than the service limit, replace
the synchro ring and sYnchro cone.
SYNCHRO SPRING
SYNCHRO RING
t
SYNCHRO CONE
13-81

Mainshaft Thrust Clearance
Adjustment
1. Remove the 72 mm thrust shim and oil guide platefrom the transmission housing.
4.
TFANSMISSIONHOUSING
72 mm THRUST SH|M
TRAt{SMtSStONHOUSINGOIL GUIOE PLATE
lnstall the 3rd/4th synchro hub. spacer collar,5thsynchro hub. spacer, and ball bearing on the main_shaft, then install the above assembly in the trans_mission housing.
lnstall the washe[ on the mainshaft,
Measure distance @ between the end of the trans-mission housing and washer.
NOTE;
. Use a straight edge and vernier caliper.. Measure at three locations and average the read_ing.ENO otlnA sMtsstoNHOUSINGMAINSHAFT
3RD/irTH SYNCHRO HUB
SPACCR COLLAR
5TH SYNCHRO HUB
o
B
13-88
AALL BEARING
V.
5. Measure distance @ between the end of the clutchhousing and bearing inner race.
NOTE;
. Use a straight edge and depth gauge.. Measure at three locations and average the read-ings.
Select the prcpet 72 mm thrust shim from the chartby using the formula below.
NOTE: Us€ only one 72 mm thrust sntm.
Shim Selection Formula:
From the measurements you made in steps 4 and 5:. Add distance O lstep 5) to distance @ (step 4).
. From this number, subtract 0.93 (which is themidpoint of the flex range of the clutch housingbearing spring washer).
. Take this number and compare it to the availableshim sizes in the chart.
{For example)
B;2.39
+ C: 0.22- 0.93
2.61 = 1.68
Try the 1.68 mm (0.0661 in) shim.
INNER RACE ot EALL BEARING