HONDA CIVIC 1999 6.G Workshop Manual

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S40 Model (All except'99 - 00 2-door Si' SiR)
Manual Transmission
Special Tools ..'.......... 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Troubleshooting '....... 13-4
Transmission AssemblY
Removal ................. 13-5
lnstallation ............. 13-8
lllustrated Index ...............'........."........ 13-10
Transmission Housing
I Removaf .."""""""' 13-12
J R"rr"r"" Shift Holder
Clearance lnspection ....................... 13-13
Reverse ldler Gear
Removal ....'.........." 13-14
Mainshaft, Countershaft, Shift Fork
Disassembly ......'... 13-14
Mainshaft AcsemblY
Index ............... ....... 13-15
Clearance Inspection ..'.................... 13-16
Disassembly .......... 13-17
Inspection ....'......... 13-18
Reassembly ........... 13-19
Countershaft AssemblY
lndex ................ ...... 13-20
Clearance lnspection ."..........'......." 13-21
Disassembly ..."""' 13-22
Inspection .............. 13-23
Reassembly ..'.""... 13-23
Shift Fork AssemblY
lndex ............... ."'... 13-25
Clearance lnspection ."......."........'.. 13'26
MBS Shift Piece Inspection ....-.....'.. 13'27
Synchro Sleeve, Synchro Hub
f nspection/lnstallation .......'...... ".... 13'27
Synchro Ring, Gear
Inspection '....'..".... 13'28
Shift Rod
Removal .'......".""" 13'29
Differential
lndex ......."'...... .'."' 13-30
Backlash Inspection ..........."......."... 13-30
Bearing Beplacement'.............'.".... 13'31
Final Driven Gear Replacement '..... 13-31
Thrust Shim Adiustment ..."........... 13-32
Clutch Housing Bearing
Replacement .......'. 13-34
Mainshaft Thrust Shim
Adiustment '....'..".. 13-36
Transmission
Reassembly ........... 13-39
Oil Seals
Replacement ......... 13-43
Gearshift Mechanism
Overhaul ................ 13-44
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Special Tools
Ref. No. I Tool NumbetDescription(Xy I Page Reference
o
@
o.@
!'5,
@
o
@6
@
@
@(3
OTGAJ PG2O11O
OTGAJ PG2012O
07GAJ - PG20130
07736 - A010004
07746 - 0010300
07746 - 0010400
07746 - 0030100
07746 - 0030300
07746 - 0030400
07749 - 0010000
07JAD - PH80101
07JAD - PH80200
07947 - 6110501 or
07947 - 6110500
Mainshaft Holder
Co lla r
Mainshaft Base
Adjustable Bearing Puller, 25 - 40 mm
Attachment. 42 x 47 mm
Attachment,52 x 55 mm
Driver, 40 mm LD.
Attachment, 30 mm I.D.
Attachment, 3S mm LD.
Driver
Driver Attachment
Pilot. 26 x 30 mm
Seal Driver Attachment
1 13-38
1 13-37
1 I 13-37
1 13-34,35
1 13-34.35
1 13-34,35
1 | 13-19,24
31,32
1 13-19,24
1 13-19,24
r I t3-34,35, 43
1 13-43
1 13,43
1 I 13-43
* Must be used with commercially-available 3/8"-j6 Slide Hammer.
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o
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IvI

MaintenanceBack-up Light Switch
Transmission Oil
NOTE: Check the transmission oil with the engine OFF
and the vehicle on level ground.
1. Remove the oil filler plug, then check the level and
condition of the oil.
OIL FILLER PLUG/14 N.m (4.5 kgl.m,33 lbl.ft)Proper Level
4.
WASHERReplace.
The oil level must be up to the filler hole. lf it is
below the hole, add oil until it runs out. then rein-
stall the oil filler plug with a new washer.
lf the transmission oil is dirty, remove the drain plug
and drain the oil.
Reinstall the drain plug with a new washer, and refill
the transmission with the recommended oil to the
proper lever.
NOTE: The drain plug washer should be replaced at
every oil change.
Reinstall the oil filler plug with a new washer.
OilCapacity
1.8 f (1.9 US qt. 1.6 lmp qtl at oil change
1.9 { (2.0 US $, 1.7 lmp qt) at overhaul
Always use Genuine Honda Manual Transmission
Fluid {MTF). Using motor oil can cause stiffer shift-
ing because it does not contain the proper addi-
t|ves.
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Replacement
NOTE: To test the back-up light switch, see section 23
1. Disconnect the connector, then remove the back-up
light swirch connector from the connector clamp.
2. Remove the back-up light switch.
25 N.m (2.5 kgf'm, 18lbf'ltl
Install the new washer and back-up light switch
Connect the back-up light switch connector.
ASHER
13-3

Troubleshooting
Reverse Gear Noise Reduction System
Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia.
The resulting speed difference between mainshaft and reverse idler gear produces gear noise.
The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shifting
into reverse, the sth/reverse shjft piece, connected to the shift lever, rotates the cam plate. This causes the sth synchro set
to stop the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be less
gear norse.
NOTE: This system is not a fully-synchronized gear noise reduction system.
Therefore, you may hear gear noise when
O you shift into reverse with the vehicle not yet completely stopped.
@ you shift quickly into reverse during fast idling.
-
Gear noise is oresent when shift-ing into reverce after the engineis started.
Test-drive the vehicle.
ls the gear noise present whenshifting into 5th gear?Beplace the 5th synchro hub and3leeve e3 a set,
Measure the clearance between5th shift fork and 5th synchrosleeve {see page 13'26).
ls the clearance 1.0 mm (0.04
in) or less?
Measure the MBS shift piece pin(see page 13-27).
ls ( 6.8 mm (0.27 in) or more?Replace the MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4

Transmission Assembly
I
Removal
@. Make sure iacks and safety stands are placed prop€dy,
and hoist brackets are atlach€d to correct position on
the enginc.
. Apply parking brake and block rear whosls so car will
nol roll olf stands and lall on you while working under
it.
CAUTION: Use fender covers to svoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the battery'
Drain transmission oil {see page 13-3).
Remove the intake air tube. intake air duct and air
cleaner housing assembly (see section 5).
Disconnect the starter motor cables, transmission
ground wire and back-up light switch connector.
6x1.0 mm BACK-UP LIGHT
9.8 N.m (1.0 ksf.m, 7.2 lbI.ft) swlTcH CoNNECTOR
8x 1 .25 mm8.8 N.m {0.9 kgt.m,6.5 lbf.ftl
\
ARTER
5. Remove the wire harness clamps.
vssCONNECTOR
6. Disconnect the vehicle speed sensor (VSS) connec-
ror.
Remove the clutch line bracket, clutch line clamp,
and slave cvlinder.
CAUTION:
. Do not opsr.te tho clutdh pedal once the 3lavc
cylindor has b6on romoved.
. Tske care not to bend tha clutch lin6.
7.
(cont'd)
13-5

Transmission Assembly
Removal (cont'dl
8. Remove the driveshafts (see section 161.
NOTE: Coat all the precision finished surfaces with
clean engine oil or grease. Tie plastic bags over the
driveshaft ends,
DRIVESHAFT
10 x 1.25 mrn43 N.m 14.4 kgt.m,32 rbf.frl
COTTER PINReplace. SELF12 x 1.25 mm49-59 N.m (5.0 -6.0 kgt.m,36-43 lbf.ft)
9. Remove exhaust pipe A.
Replace.12 x 1.25 mm64 N.m {6.5 kgt.m,47 lbf.tr)
GASKETSReplace.
IF\sELF-LocKtNG NUT.''1/Replace.8 x 1.25 mm16 N.m {1.6 kgf'm,12 tbf.ft)
EXHAUSTPIPE A
SELF-LOCKING NUTReplace.I x 1.25 mm22 N.m (2.2 kgf.m,16 tbt'fr)
SELF-LOCKING NUTReplace.D16Y5, D16Y7 engines:
33 N.m {3.4 kgf.m,25 lbt.ft)D16YB engine:10 x 1.25 mm54 N.m 15.5 kgl'm,40 lbf.ttl
SET RING
13-6
v'10. Remove the shift rod and extension rod.
SI'IIFT BOD
8x22mmSPRING PINReplace.
EXTENSION ROD
PIN PUNCH, 8.O mm(Commercially available)f-
'1'1. Remove the engine stiffeners and clutch cover.
D16Y5, D16Y8 engines:
10 x 1.25 mm44 N.m (4.5 kgt.m,33 tbf.tr)
I x 1.25 mm24 N.m (2.4 kgf.m17 lbt.frl
COVER
8 x 1.25 mm24 N.m 12.4 kgf'tn,17 tbt.tr)

12.
D16Y7 engine:
ENGINESTIFFENER
10 X 1.25 mmIt4 N'm (4.5 kqf'm,33 lbf'ltl
Install the bolts in the cylinder head and attach a
chain hoist to the bolts, then lift the engine slightly
to unload the engine and transmission mounts.
CHAIN HOIST
13. Remove the sDlash shield,
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8 x 1.25 mm24 N.m {2.4 kgl.m,
SPLASH SHIELD
14. Remove the right front mounvbracket.
'lO x 'l.25 mm44 N'm (4.5 kgl.m,33 rbf.frl
Replace.12 x 1.25 mm
64 N.m t6.5 kgf.m,47 lbf'ft)
Place a jack under the transmission.
Remove the transmission mount bracket and mount.16.
TRANSMISSIONMOUNTTRANSMISSIONBRACKET
(cont'd)
13-7

Transmission Assembly
Removal(cont'd)
17. Remove the three upper transmission mounting
bolts and the lower starter mounting bolt,
STARTERMOUNTINGBOLT10 x 1.25 mm44 N.m (4.5 kgf.m,33 rbnftl
TRANSMISSIONMOUI{TING EOLTS12 x 1.25 mm& N.m (6.5 kgt'm,47 lbl.ftl
18. Remove the rear mount bracket bolts and transmis-
sion mounting bolts.
12 x 1.25 mm64 N.ft 16.5 kgl.m,47 lbl.ftl
SPECIAL BOLTReplace.'ll x 1.5 mm84 N.m (8.5 kgf.m, 61 lbf.ftl
SPECIAL BOLTReplace.14 x 1,5 mln84 N.m (8.5 kgl.m, 61
WASI{ERREARMOUNTBRACKET
rbl.ftt
Pull the transmission away from the engine until it
clears the mainshaft. then lower it on the transmis-
sion jack.
CAUTION: Take caro not to b6nd tho clutch lin€.
1(|
Installation
Install the transmission assembly in the reverse order of
removal.
Before installing, check that the two dowel pins are
installed in the clutch housing.
When installing the starter cable, make sure that the
crimped side of the ring terminal is facing out (see
section 23).
Apply grease to the parts as shown, then install the
release fork and release bearing,
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
RELEASE FORK BOLT12 x 1.25 mm29 N'm 13.0 kgt,m,(P/N 08798-90021
22 tbl.ttlR€LEASEBEARING
J
RELEASEFORK8()07
ra
{PiN 08798-9002)
tP/N 08798-900210.3-0.9 g
10.01-0.03 ozl

. Torque the mounting bolt and nuts in the sequence
shown.
O 12 x 1.25 mm64 N.m {6.5 kgt.m,47 lbf.fr)
@ 12 x 1.25 mm74 N.m (7.5 kgl'm,54 tbt.fr)
Check that the bushings are not twisted or offset.
Install the clip as shown.
SHIFT ROD
Turn the boot so the hole is facing down.
Make sure the boot is installed on the shift rod.
O) 12 x 'l.25 mm64 N.m 16.5 kgl.m,47 tbt.ft)
I
a
a
a
a
8 x 1.25 mmN.m t2.2 kgt.m, l6 lbl'tt)
6 x 1.0 mm9.8 N.m (1.0 kgl.m.7.2 tbf.tr)
. Apply grease to the slave cylinder push rod.
NOTE: Use only Super High Temp Urea Grease
{P/N 08798 - 9002}.
CLUTCHUNE
a
a
(P/N-6tl
08798-9002)
8 x 1.25 mm22 N.m 12.2 kgl.n.16 tbf.frl
. Turn the breather cap so that the "F" mark points at
the front of the car as shown.
Refill the transmission with the recommended oil
(see page 13-3).
Connect the positive (+) cable first, then the negative
(-) cable to the battery.
Check the clutch oDeration,
Shift the transmission and check for smooth opera-
tion.
Check the front wheel alignment (see section 18).
FRONT
13-9

lllustrated lndex
!
Refer to the drawing below for transmission disassembly/reassembly,
Clean all the parts thoroughly in solvent and dry with compressed air.
I luuricate attthe parts with oil before reassembty.
NOTE:
. This transmission uses no gaskets betvveen the major housings; use liquid gasket (PiN 08718-0001 or08718-0003)
(see page 13-41).
. Always clean the magnet @ whenever the transmission housing is disassembled.
. Inspect all the bearings for wear and operation.
a6_
'%/t'*.
k+-o
-{-g}.-_a
13-10