wheel HONDA CIVIC 1999 6.G Repair Manual

Transmission
Removal
@. Mako suro lifts. iacks, and satety stands are placod
properly, and hoi3t bracket are attached to lhe cor-
rect position on the engine {see soction 1}.
. Apply parking brake and block r€ar wheels so tha
vehicle will not roll off stands and fall on you while
working undor it.
CAUTION: Use tender covers to avoid damaging painted
surfaces.
Disconnect the battery negative (-) terminal from
the battery, then remove the positive (+)terminal.
Remove the intake air duct and air cleaner housing
1.
assembly.
3. Remove the starter cables and cable holder from
the starter motor.
STARTER CABLE
STARTER MOTOR
14-304
4, Disconnect the solenoid harness connector, the drivepulley speed sensor connector, and the ground cable
terminals.
DRIVE PULI.-EYSPEED SENSORCONNECTOR
SOLENOIO HARNESSCONNECTOR
Remove the clip, then separate the shift cable from
the control lever,
CAUTION: Take care not to bend the shift cable.
WASHER
WASHER
GROUND CABLE
GROUND CAELE
CONTROL LEVER
S}IIFT CABLE

Transmission
Removal (cont'd)
10. Remove the cotte. pins and castle nuts, then separatethe ball joints from the lower arm (see section 1g).
SELF-LOCKING -=V,
NUT \Replace. oitupea rOax
Remove the right damper fork bolt, then separateright damper fork and damper.
Pry the right and left driveshafts out of the differen-tial.
Pull on the inboard joint to remove the right and leftdriveshafts (see section 16).
Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with cleanengine oil.
Remove the exhaust pipe A.
/\<,\CASTLE I{UT COTTERReplac6.
't 1.
't2.
tJ.
14.
q.
SELF.LOCKINGNUTReplace.
SELF.LOCKING NUTReplace.
14-306
EXHAUST PIPE A
19.
'16, Remove the right front mounvbracket,
ATF COOLER HOSE
17. Remove the ATF cooler hoses at the ATF coolerlines. Turn the ends of the ATF cooler hoses uo toprevent CVT fluid from flowing out, then plug theATF cooler hoses and lines,
NOTE: Check for any sign of leakage at the hosejoints.
18. Remove the engine stiffeners and the flywheel cover.
Remove the eight drive plate bolts one at time whilerotating the crankshaft pullev.
ENGINE STIFFENER

lllustrated Index
Transmission Housing/Flywheel Housing
8G
I
)
H
14-310

C O-RING Replace.
e) OIL SEAL RePlace.' FLYWHEEL HOUSING
O flVWneel }|OUSttttG GASKET Replace
6 DIFFERENTTALASSEMELY
@ lrr plsslce uruE ASSEMBLY
O O-RING Replace
@ DOWEL PIN
€) ATF PUMP ASSEMBLY(O DowEL PlN, 18 x 10 mm
O O-RING Replace.o DowEL PlN, 22 x 10 mm
lrr puup oRve cxltttt
iA SNAP RING
f3 fxaUst St|t|l, zz t 28 mm Selective part
Gt lrr punp ontve spaocxer
O PITOT FLANGE
ito nTF purrap ontve SPRoGKET HUB
(O THRUST WASHERS
@ PITOT PIPE BRACKET
O PITOT LUBRICATION PIPE
@ PITOT PIPEt3 OIL SEAL Replace.
Oa SEt AtitC, SO mm Selective Part
o3 lrr passlce ltnE HoLOER ASSEMBLY
6) o-RING Replace.
€) START CLUTCH ATF FEED PIPE
CO O-RING Replace.
€I FEEO PIPE FLANGE
@ SNAP RING
O' CONNECTOR BRACKET
@ BALL BEARING
6} SNAP RING64 COTTER RETAINER6D CoTTERS,25.5 mm selective Part6t stlnt cLutcH asseMsLv
@ secoruomv ontvE GEAR ASSEMBLY
@ o-RINGS Replace
6) DIFFERENTIAL COVER
rO ttaUSr SntU, zs t 35 mm Selective part
@ SECONDARY GEAR SHAFT
@ PARK PAWL SHAFT
@ PARK PAWL SPRING.1i PARK PAWL
@ TONGUED WASHER REPIACE,
@ PARK ROO HOLDER
@ BALL BEARING
@ o-RING Replace.
@ VEHICLE SPEED SENSOR
@ OIL SEAL Replace.
ft,
)
TOROUE SPECIFICATIONS
6x1.0mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.25 mm
12 N.m (1.2 kgnm,8.7 lbf'ft)
22 N.m (2.2 kgf'm. 16lbf'ft)
26 N.m (2.7 kgf'm, 20 lbf'ft)
29 N.m {3.0 kgf'm, 22 lbift)
14-311

Transmission Housing/Flywheel Housing
Removal
NOTE:
. Cleanall parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.. Blow out all passages.
. When removing the transmission housing/flywheel housing, replace the following:- O-rings- Secondary drive gear assembly- Sta rt clutch assemblv- Flywheel housing gasket
ATF PASSAGE LINEHOLD€R ASSEMBLY
IX)WEL PIN
OIFFERENTIAL ASSEMBLY
SNAP RING
COTTER RETAINER
COTTERS, 25.5 mmSelective part
8 x 125 mm BOLT
O.RINGRsplaco.
VWHEEL HOUSING
EYWIIEEL HOUSING GASKETRoolace.
START CLUTCHASSEMBLYReplace.
ATF PA$gAGEUNE ASSEMBLY
6 x 1,0 mm BOLT
O.RINGReplace.
ATF PUMP DRIVE CHAIN
SNAP RING
THRUST SHIM,25x35mmSeloctive part
SECONDARYGEAR SHAFT
SECONDARY DRIVEGEAR ASSEMBLYReplace.
PARKPAWL SHAFT
THRUST SHIM, 22 r 28 mmSeloctive partGRII{GSReplac€.6 x 1.0 mm BOIT
ATF PUMP DRIVESPROCKET
PfTOT FLANGE
ATF PUMP DRTVESPROC|(ET HUB
THRUST WASHERS
PARK PAWLSPRING
INPUT SHAFT
14-316
DRIVEN PULLEY SHAFT
InANSMISS|O]{ HOUSTNG

)
1.Remove the ATF passage line holder assembly'
Remove the flywheel housing (twenty bolts)'
Remove the ATF passage line assembly (one bolt)
Remove the ATF pump drive sprocket (three bolts),
then remove the ATF pump drive chaan.
Move the pitot flange toward its cutout, then remove
the pitot flange.
PITOT PIPE
Remove the snap ring securing the ATF pump drlve
sprocket hub. then remove the 22 x 28 mm thrust
shim, the ATF pump drive sprocket hub and the thrust
wasners,
Remove the differential assemblY.
Remove the park pawl shaft, the park pawl spring,
and the park Pawl'
Remove the snap ring securing the start clutch, then
remove the cotter retainer and the cotters.
7.
9.
J
14-317
10. Set the special tool on the start clutch' and attach the
oawl of the special tool to the park gear securely as
shown.
CAUTION:
. Do not place tho pawl of the spocial tool on the
start clutch guidc. ll the pawl ot the spocial tool
contacts the 3tart clutch guid€, the start clutch
guido may be damaged.
. Be sure not to allow dust and other foreign par-
ticles to enter into the drivon pull6y shaft'
START CLUTCHREMOVER07TAE - P4V0120
11.Remove the start clutch and the secondary drive
gear assembly using the special tool, then remove
the secondary gear shaft.
START CLUTCHREMOVER07TAE - P4V0120
START CLUTCHASSEMBLYReplace.
START CLUTCHASSEMBLY
PAWL

Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection
1. Measure the distance between the flywheel housing
surface and the ball bearing as shown, then note
the measurement (Measurement A).
FLYWHEELHOUSING
>dt?'
BALL BEARING
EALL FLYWHEELBEARING HOUSTNG
Install the secondary gear shatt in the transmission
housing.
Measure the distance between the transmission
housing surface and the thrust washer mounting
surface of the secondary gear shaft as shown, then
note the measurement (Measurement B).
O
Measuring Distance A
BALL
14-328
Calculate 25 x 35 mm thrust shim thickness bv fol-
lowing formula.
FORMULA;
25 x 35 mm Thrust Shim Thicknoss
= Measurement A - Measurement B + Flywheel
Housing Gasket Thickness: 0.5 mm {0.020 in}
Example:
Measurement A: 32.7 mm (1.287 in)
Moasurem.nt B: 30.! mm {1.185 in}
25 x 35 mm Thrust Shim Thickness
= 32.7 mm (1.287 in) - 30.1 mm (1.185 in)
+ 0.5 mm {0.020 in)
= 3.1 mm (0.122 inl
Select 25 x 35 mm Thrust Shim D.
Select the 25 x 35 mm thrust shim from the follow-
ing the table.
THRUST SHIM, 25 x 35 mm
No.Part NumberThickne3s
90551 - P4V - 0002.8 mm (0.110 in)
B90552-P4V-0002.9 mm (0.114 in)
c90553-P4V-0003.0 mm (0.118 in)
D90554-P4V-0003.1 mm (0.122 in)
E90555-P4V-0003.2 mm (0.126 in)
90556-P4V-0003.3 mm (0.130 in)
G90557-P4V-0003.4 mm (0.134 in)
H90558-P4V-0003.5 mm (0.138 in)
90559-P4V-0003.6 mm {0.142 in)
90560-P4V-0003.7 mm (0.146 in)
K90561 - P4V - 0003.8 mm (0.'150 in)

l.
Oil Seal Removal
Remove the differential assembly.
Remove the oil seal from the transmission housing.
1.
2.
TRANSMISSONHOUSING
OIL SEALR€placa.
3. Remove the oil seal from the flywheel housing.
Oil Seal Installation/Side Clearance
1. lnstall a 2.50 mm (0.098 in) thick 80 mm wide set
ring in the transmission housing.
NOTE: Do not installthe oil seal yet.
TRANSMISSIONHOUStl{G
lnstall the differential assembly into the transmrs-
sion housing using the specialtool as shown
DIFFEREI{NALASSEMBLY(cont'd)
14-331

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)

Flywheel Housing
Input Shaft Oil Seal
l.
8. Install the oil seal in the transmission housing using
the sDecial tools as shown.
DRIVER07749 - 0010d)0
9.Install the oil seal in the flywheel housing using the
soecial tools as shown.
PILOT,26x30mmoTJAD - PH80200DRIVERATIACHMENT, 58 x 72 rnin
0?947 - d'40201
Replacement
1. Remove the input shaft oil seal from the flywheel
housing.
OIL SEAL
Instali the oil seal in the flywheel housing using the
soecialtools as shown.
FLYWHEEL
lmtalled depth:2.5- 3.5 mmro"nri':,ilii.rl
t@
14-333