differential HONDA CIVIC 1999 6.G Owner's Guide

Differential
Oil Seal Installation/Side Clearance (cont'dl
3. Installthe flywheel housing, and tighten the bolts.
DOWEL PIN
1 .25 mmN m (3.0 kgt m,22 lbf.ttl8x29
uigE
14-332
4. Measure the clea.ance between the 80 mm set ring
and outer race of the ball bearing in the transmis-
sion housing.
STANDARD: 0 - 0.15 mm (0 - 0.006 in)
lf the clearance is more than the standard, select a
new set ring from the table, and install it.
SET RING, 80 mm
NOTE: lf the clearance measured in steD 4 is stan-
dard, it is not necessary to perform steps 7 and 8.
Remove the flywheel housing.
Replace ttle 2.50 mm (0.098 in) set ring, 80 mm with
the one ot the correct thickness selected in steD 5.
6.
7.
Part NumberThickness
904'r4-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
2.50 mm (0.098 in)
2.60 mm (0.102 in)
2.70 mm (0.106 in)
2.80 mm (0.110 in)
2.90 mm (0.114 in)
3.00 mm (0.118 in)

Transmission
17.
Installation (cont'd)
Install I new set ring on the end of each driveshaft.
Install the right and left driveshafts (see section 16).
CAUTION: While instatling the drive3hafts in thedifferential, be sure not to allow dust and olher for-aign particles to enter into tho transmission.
NOTE:
. Clean the areas where the driveshafts contact thetransmission {differential} thoroughly with sol-vent or carburetor cleaner, and drv with com-
Dressed air.
. Turn the right and left steering knuckle fully out-wa.d, and slide each driveshaft into the differen-tial until you feel its set ring clip engage the sidegear.
Install the damper fork, then install the right and leftball joints to each lower arm with the castle outsand new cotter pins.
19.
10 x 1.25 mm43 N.m{4.4 kgf.m, 32 lbf.ftl
SELF-LOCKING NUTReplace.12 x 1.25 mm6l N.m
CASTI.I'12 x 1.25 mm
{6.s ksr.m. 47 tbr.ftr l! _ ll ffiteo
- s.o tet'.,
14-350
20. Install the splash shietd.
aa
I6I6*
"a,a s
21.
SECONOARY GEARSHAFT SPEEDSENSOB CONNECTOR
6 x 1.0 mm9.8 t{.m 11.0 kgt.m,7.2 tbf.trl
Connect the vehicle speed senso. connector. thedriven pulley speed sensor connector and the sec-ondary gear shaft speed sensor connector,
6x1,0mm12 N.m {1.2 kg{.m, 8.7 tbf,ft)
DRIVEN PULLEYSPEED SENSORCONNECTOR
E.
6 x 1.0 m.rl'12 N.m {1.2 kg{.m,8.7 tbf.fo

Driveshafts
Removal (cont'd)
8. Remove the cotter pin from the lawer arm ball joint
castle nut. and remove the nut.
Install a 12 mm hex nut on the ball joint. Be sure
that the hex nut is flush with the ball joint pin end,
or the threaded section of the ball joint pin might be
damaged by the special tool.
Use the special tool as shown in section 18, to sepa-
rate the ball joint and lower arm. Be careful not to
damage the ball joint boot.
NOTE: lf necessary, apply penetrating type lubri,
cant to loosen the ball joint.
Pry the driveshaft assembly with a screwdriver, as
shown, to force the set ring at the driveshaft endpast the groove.
10.
11.
3.5 mm
07MAC - SL00200
SCREWDRIVER
16-4
12. Pull the inboard joint, and remove the driveshaft
from the differential case as an assembly. Do notpull on the driveshaft; the inboard joint may come
apart. Use care when prying out the assembly, andpull it straight to avoid damaging the differential oil
seat.
13. Pull the knuckle outward, and remove the driveshaft
outboard joint from the front wheel hub using aplastic hammer.
SCREWDRIVER
DRIVESHAFT

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl

Intermediate Shaft
Removal
Drain the transmission oil or fluid {see section 13 or
r 4).
Remove the left driveshaft (see page 16-3).
Remove the three dowel bolts.
OOWEL BOLTS'10 x 1.25 mm
Remove the intermediate shaft from the differential.
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
'1.
2.
3.
INTERMEDIATE SHAFT
16-20
Disassembly
NOTE: Be careful not to damage the metal rings on theintermediate shaft during disassembly.
1. Remove the set ring.
2. Remove the intermediate shaft outer seal from theDeaflng suppon.
3. Remove the external circlip,

lnstallation
1. lnsert the intermediate shaft assembly into the dif-
ferential.
CAUTION: Hold the intermodiate shaft horizontal
to prevent damag€ to the difterential oil seal'
NOTE: Clean the areas where the intermediate shaft
contacts the transmission (differential) thoroughly
with solvent or carburetor cleaner, and dry with com-
Dressed air,
2. Install the three dowel bolts, then tighten them'
DOWEL BOLTS10 x 1.25 mm39 N.m {i1.0 kgf'm, 29 lbf'ftl
lz
16-23