locknut HONDA CIVIC 1999 6.G Owner's 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

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

O ROLLER
O COLLAR
O o-RING Replace.
@ FEED PIPE FLANGE
@ O-RING Replace.
@ SNAP RING
€) 3RD CLUTCH FEED PIPE
€) COUNTERSHAFT LOCKNUT (FLANGE NUT)
23 x 1.25 mm Replace.
o coNlcAL SPRING WASHER Replace.
@ PARK GEAR
@ ONE.WAY CLUTCH
@ COUNTERSHAFT lST GEAR
@ NEEDLE BEARING
@ COUNTERSHAFT lST GEAR COLLAR
@ o-RlNGs Replace.
@ END covER GASKET Replace.
E) DOWEL PINS
@ PARK PAWL STOP
@ LocK WASHER Replace.
@ PARK STOP Selective part
€D PARK LEVER
@ PARK LEVER SPRING
€D DRAIN PLUG
€) SEALING WASHER Replace
@ o-RING Replace.
@ COUNTERSHAFT SPEED SENSOR
@) PARK PAWL
@ PARK PAWL SPRING
@ PARK PAWL SHAFT
@ LINEAR SOLENOID ASSEMBLY
@ LINEAR SOLENOID GASKET REPIACE.
@) END COVER
@ lsT CLUTCH FEED PIPE
@ O-RINGS Replace.
@ FEED PIPE FLANGE
C) SNAP BING
@ MAINSHAFT LOCKNUT (FLANGE NUTI 21 x 1 25 mm
Replace.
@ CONICAL SPRING WASHER RePlace
@) lST CLUTCH ASSEMBLY
@ o-RlNGs Replace.
€) THRUST WASHER
@) THRUST NEEDLE BEARING
@ NEEDLE BEARING
@ MAINSHAFT lST GEAR
@ MAINSHAFT lST GEAR COLLAR
@) ATF COOLER LINE
@ SEAUNG WASHERS Replace.
@ LINE BOLT
@ ATF DIFSTICK
@ ATF COOLER LINE
@ UNE BOLT
@ SEALING WASHERS Replace.
@ VEHICTT SPEED SENSOR
@ O-RING Replace.
TOROUE SPECIFICATIONS
Bolt/Nut No.Torque ValueSizeRemarks
6B
8F
12A.'l8D
2'tM
23C
'12 N'm (1.2 kgim,8.7 lbift)
14 N.m (1.4 kgf.m, 10 lbf'ft)
22 N.m (2.2 kgf.m, 16 lbf'ft)
28 N.m (2.9 kgf.m, 21 lbf'ft)
49 N.m (5.0 kgf.m, 36 lbf'ft)
78 N.m (8.0 kgf'm, 58 lbf'ft)
103 N.m {10.5 kgf'm,75.9 lbift)
6x1.0mm
6x1.0mm
8 x 1,25 mm
12 x 1.25 mm
18 x 1.5 mm
21 x 1.25 mm
23 x 1.25 mm
Line bolt
Drain plug
Mainshatt locknut: Left-hand threads
Countershaft locknut:
Left-hand threads
14-127

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

Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubricate all parts with ATF during reassembly..Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O_rings.. Locknut has left-hand threads.
LOCKNUT {FLANGE NUTI21 x 1.25 mm78 N.m (8.0 kgl.m,58 lbt.fttReplace.Left-hand threadsSNAP RINGCONICAL SPRING WASHERReolace.
lST CLUTCHASSEMBLYTHRUST WASHER
THRUST NEEOI.EBEARING
4TH GEAN
O-RINGSReplace.
THRUST WASHER
THRUST NEEDLEBEARING
MAINSHAFTCheck splines for excessivewear and oamage.Check bearing surtace for scoring,scratches and excessive wear.
BEARINGBEARINGS
THRUST NEEDLEBEABING
4TH GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST NEEDLEEEARING
2NO GEAB
NEEDLE BEABING
THRUST NEEDLEBEARING
1ST GEAR
1ST GEARCOLLAR
TRANSMISSIONHOUSING BEARING
O-RINGSReplace.
THRUST WASHER, 36.5 x 55 mmSelective part.
SEALING RINGS,35 mm
Install the sealing ringmating faces as shown,
RING,29 mm
NEEDLE BEARING
SET RING
14-148

Inspection
a Clearance Measurement
NOTE: Lubricate all parts with ATF during assembly.
1, Remove the mainshaft bearing from the transmis-
sion housing (see Page 14-1741.
2. Assemble ths parts below on the mainshaft.
NOTE: Do not assemble the O-rings during inspec-
tlon.
LOCKNUTCONICAL SPRIIIG WASHER
SNAP RING
lST CLUTCH ASSEMBLY
TXRUST WASHER
1ST GEAR COLLAR
TRA SMISSIONHOUSII{G BEARING
THRUST WASHER
4TI{ GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST WASHER36.5 x 55 mmSelective part.
THBUST NEEDLEBEARING
2ND GEAR
AEABII{G
IHRUST NEEDLEBEARING
MAINSHAFT
3. Torque the mainshaft locknut to 29 N'm (3.0 kgf'm,
22 tbt,ftl.
NOTE: Mainshaft locknut has left-hand threads.
29 N'm t3.0 kgl'm, 22 lbt'ft)
Hold 2nd gear against the 2nd clutch' then measure
the clearance between 2nd gear and 3rd gear with a
feeler gauge.
NOTE: Take measurements in at least three places,
and use the av€rage as the actual clearance'
STANDARD: 0.05 - 0.13 mm 10.002 - 0.005 in)
THRUST WASHER,36.5 x 55 mm
(cont'd)
1+149

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

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)

Transmission
Reasembly
NOTE;
. Coat all parts with ATF.. Beplace the following parts:- O-rings- Lock washers- Gaskets- Mainshaft and countershaft locknuts and conical spring washers- Sealing washers
TOROUE: l2 N.m (1.2 ksf'm,8.7 lbf.ft)
6 x 'l.0 mm7 BoltsFEED PIPE: A
LOCK.UP VALVEBODY
LOCK.UP SEPARATORPLATE
REGULATOR VALVEBODY
DOWEL PINS. 2
6xl.0mm1 BoltATF STRAINERATF FEEDPIPES:
a
COOIER RELIEF VALVE
TOROUE CONVENIERCHECK VALVESTATOR SHAFT
O.RING
STOP SHAFT
ATF FEEO PIPE: H
5x1.0mm5 Bolts
DOWEL PINS.
MAIN VALVE BODY
ATF PUMP
SERVO SEPARATORPLAYE
6x1.0mm7 Bolts
SERVO BODY
SECONOARYSEPARATOR PLATE
CONTROL
GEAR SHAFT
ATF PUMP DFIVENGEAR
MAIN SEPARATORPLATE
DOWEL PINS,
/ SHAFI
' -
7r(
t'se - oo ^od"t"t
lli
triTOROUE CONVERTERHOUSING
NOTE: The illustration shows the'96 - 98 modsls, the'99 - 00 models do not have the servo detent base; the servodetent is integralwith the servo bodv.
14-176
L-