trans HONDA CIVIC 1999 6.G Manual Online

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

Torque Value
A - 15 N.m (1.5 kgf.m, 1'1 lbf.ft)
B - 27 N.m (2.8 kgf.m. 20 lbift)
C - 31 N.m {3.2 kgnm, 23 lbift)
\
O BALL BEARING (*T)
ANGULAR
BALL BEARING {*2I
O 5TH SYNCHRO HUB
O 5TH SYNCHRO SLEEVE
€) SYNCHRO SPRING
o SYNCHRO B|NG
@ 5TH GEAR
@ gz xgt x 23.5 mm
NEEDLE BEARING
@ SPACER COLLAR
@34x39x23mm
NEEDLE BEARING
(D 4TH GEAR
O SYNCHRO RING
C) SYNCHRO SPRING
CO 3RD/4TH SYNCHRO SLEEVE
@ 3RD/4TH SYNCHRO HUB
(} 3RD GEAR
@34x39x27.5mmNEEDLE BEARING
G) MAINSHAFT
G) WASHER
@ SPRING WASHER
@ BALL BEARING
Check for wear and
operation.(E 26x42x7 mm OIL SEAL
Replace.
@ 28 mm PLUG BOLT
5,1 N.m {5.5 kgf'm, /t0 lbt'ft)
@ lsT/zND SELECT SPRING
L. 36.26 mm (1./P8 in)
@ SHIFT ARM SHAFT
@ CLUTCH HOUSING
@ INTEELOCK GUIDE BOLT
39 N.m (4.0 kgf.m, 29 lbf.ftl
@ REVERSE SHIFT HOLDER
@ REVERSE IDLER GEAR
@ REVERSE IDLER GEAR SHAFT
@ 5 x 22 mm SPRING PIN
Replace.
@ 3RD/4TH SHIFT PIECE
@ 5TH/REVERSE SHIFT PIECE
@ MBS SHIFT PIECE
@ 1ST/2ND SHIFI FORK
*1:D16Y7 engine*2: D16Y5, D16Y8 engines
@ 3RD//|TH SHIFT FORK
@ 5TH/REVERSE SHIFT FORK
@ 52 mm SNAP RING
@ 65 mm THRUST SHIM (*11
70 mm THRUST SHIM (*21
Selection, page 13-36
@ OIL GUIDE PLATE
@ wASHER Replace.
@ BACK.UP LIGHT SWITCH
25 N.m (2.5 kgf'm, 18 lbf'ft)
@ sET SCREW
22 N.m {2.2 kgf.m, 16 lbl.ft}
@ WASHER Replace.
@D SPRING 1.31.6 mm (1.2,1inl
@ STEEL BALL 15/16 in)
@ BACK-UP LIGHT
SWITCH HARNESS BRACKET
@ TRANSMISSION HANGER
@ 32 MM SEALING BOLT
25 N.m (2.5 kgf.m, 18 lbt'ft)
@ OIL SEAL
Replace.
@ OIL DRAIN PLUG
39 N.m (4.0 kgf.m, 29 lbf.ft)
@ WASHER Replace.
@} OIL FILLER PLUG
44 N.m (4.5 kgf.m, 33 lbf'ftl
@ WASHER Replace.
@) TRANSMISSION HOUSING
€) CLUTCH LINE BRACKET
@ OIL GUTTER PLATE
@ REVERSE LOCK CAM
@ REVEBSE SELECT SPRING
L. 63.4 mm {2.,196 in)
@ REVERSE SELECT RETAINER
@ SHIFT ARM C
@ SHIFT ARM B
@ INTERLoCK
@ COLLAR
@ SHIFT ARM A
@ SPRING WASHER
@ MAGNET
@ sET BALL SPRING BOLT
22 N.m (2.2 kgf.m, 16 lbf.ftl
@ 14 x 20 mm DOWEL PIN
@ 72 mm THRUST SHIM l*11
80 mm THRUST SHIM (*21
Selection, page '13-33
@ DIFFERENTIAL ASSEMBLY
See page 13-30
@ 14 x 25 x 17.5 mm OIL SEAL
Replace.
@ 35 x 56 x 8 mm OIL SEAL
Replace.
@ SHIFT ROD
@ BOOr
@ OIL GUIDE PLATE
@30x47x21 mm
NEEDLE BEARING (* 1}
30x55x21 mm
NEEDLE BEARING {'2)
@ COUNTERSHAFT
@36x41 x 25.5 mm
NEEDLE BEARING
Check for wear and
operatron.
@ lsT GEAR
@ FRICTION DAMPER
@ SYNCHRO RING
@ SYNCHRO SPRTNG
@ lST/2ND SYNCHRO HUB
@ REVERSE GEAR
@ SYNCHRO SPRING
@ SYNCHRO RING
@ FRICTION DAMPER
@ SPACER
@39x4lx27mm
NEEDLE BEARING
@ 2ND GEAR
@ 3RD GEAR
@ 4TH GEAR
@ sTH GEAR
@) BALL BEARING {* 1}
NEEDLE BEARING (*2}
@ BALL BEARING
@) SPRING WASHER
@ LoCKNUT Replace.
108 - 0- 108 N.m
ftt.o* o- 1r.o kst.m,l
179.6- 0- 79.6 rbtft I

13-1 1

Transmission Housing
Removal
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the back-up light switch.
2. Remove transmission hanger.
TRANSMISSIONHANGER
BACK-UP LIGHT SWITCH
Remove the setting screws. washers. springs, and
steel balls.
STEEL BALLSO. 5/16 in
SPRINGL. 31.6 mm I 1.24 inl
13-12
SETTING SCREW
TRANSMISSION HOUSING
6.
4.Loosen the transmission housing attaching bolts in
a crisscross pattern in several steps, then remove
them.
Remove the 32 mm sealing bolt.
Expand the snap ring on the countershaft ball bear-
ing, and remove it from the groove using a pair of
snap ring pliers.
32 mm SEALING EOLT
Separate the transmission housing from the clutch
housing, and wipe it clean of the sealant.
Remove the thrust shim, oil guide plate. and oil gut-
ter plate from the transmission housing.
(o
7.
otLGUTTERTE
SNAP RING

Differential
Thrust Shim Adjustment
1. Install the differential assembly, making sure it bot-toms in the clutch housing, using the special tool asshown.
DRIVER, 40 mm LD.07746 0030100
Install the thrust shim.
NOTE: Install the same size thrust shim that wasremoved.
Y
Install the transmission housing (see page l3-41).
NOTE: Do not apply liquid gasket to the mating sur-face of the clutch housing.
Tighten the transmission housing attaching bolts(see page 13-42).
I x 1,25 mm
27 N.m (2.8 kgt'm, 20 lbf'ft}
Use the special tool to bottom the differential assem-
bly in the clutch housing.
tJ
6. Measure clearance between thrust shim
ing outer race in transmission housing.
and bear-
13-32

7. lf the clearance is more than the standard, select a
new thrust shim from the following table
NOTE: It the clearance measured in step 6 is within
the standard. go to step 10.
Standard: 0 - 0.10 mm l0 - 0.00/t inl
72 mm THRUST SHIM: D16Y7 engin€
\
Part NumberThickness
41441 - PL3 - A001.0 mm (0.0394 in)
41442-PL3-A00'1 .1 mm {0.0433 in)
41443-PL3-A001.2 mm {0.0472 in)
41444-PL3-A001.3 mm (0.0512 in)
41445-PL3-A001.4 mm (0.0551 in)
41446-PL3-A001.5 mm (0.0591 in)
41447-PL3-A001.6 mm (0.0630 in)
41448-PL3-A001.7 mm (0.0669 in)
4r449-PL3-A001.8 mm (0.0709 in)
41450-PL3-A001.05 mm {0.0413 in)
41451-PL3-A001.15 mm (0.0453 in)
41452-PL3-A001.25 mm (0.0492 in)
41453-PL3-A001.35 mm (0.0532 in)
41454-PL3-A00'1.45 mm (0.057'l in)
41455-PL3-A001.55 mm (0.0610 in)
41456-PL3-A001.65 mm (0.0650 in)
41457-PL3-A001.75 mm (0.0689 in)
80 mm THBUST SHIM: D16Y5. D16Y8 engines
Remove the bolts and transmission housing.
Replace the thrust shim selected in step 7, then
recheck the clearance.
Remove the bolts and transmission housing. Apply
liquid gasket to the surface of the transmission
housing and reassemble
8.
9.
10.
Part NumbelThickness
41441 - PL3 - B001.0 mm (0.0394 in)
41442-PL3-8001.1 mm (0.0433 in)
41443-PL3-8001.2 mm (0.0472 in)
41444-PL3-8001.3 mm (0.0512 inl
41445-PL3-8001.4 mm (0.0551 in)
41446-PL3-8001.5 mm (0.0591In)
41447-PL3-8001.6 mm (0.0630 in)
4r 448 - PL3 - 8001.7 mm (0.0669 in)
4 t449 - PL3 - 8001.8 mm (0.0709 in)
41450-PL3-800'1.05 mm (0.0413 in)
41451 - PL3 - 800'1.15 mm (0.0453 in)
41452-PL3-8001.25 mm (0.0492 in)
41453-PL3-B001.35 mm (0.0532 in)
41454-PL3-B001.45 mm (0.0571 in)
41455-PL3-B001.55 mm (0.0610 in)
41456-PL3-8001.65 mm (0.0650 in)
41457-PL3-8001.75 mm {0.0689 in)

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
\
5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engin€s
Part NumberThickness
23931 - PL3 - 8000.60 mm 10.0236 in)
23932-PL3-8000.63 mm (0.0284 in)
c23933-PL3-8000.66 mm (0.0260 in)
D23334-PL3-8000.69 mm 10.0272 in)
E23935-PL3-8000.72 mm (0.0283 in)
F23936 - PL3 8000.75 mm (0.0295 in)
23937-PL3-B000.78 mm (0.0307 in)
23938-PL3-8000.81 mm (0.0319 inl
23939-PL3-8000.84 mm (0.0331 in)
23940-PL3-8000.87 mm {0.0343 in)
23941 - PL3 - 8000.90 mm (0.0354 in)
L23942-PL3-8000.93 mm (0.0366 in)
23943-PL3-8000.96 mm (0.0378 in)
N23944-PL3-8000.99 mm i0.0390 in)
o2394s-PL3-8001.02 mm (0.0102 in)
P23946-PL3-8001.05 mm {0.0413 in}
o23947-PL3-8001.08 mm (0.0{25 in)
23948 - PL3 800'1.1'1 mm (0.0437 4n)
23949-PL3-8001.14 mm (0.0449 inl
T23950-PL3-8001.17 mm (0.0461 in)
23951 - PL3 - 8001.20 mm (0.0472 in)
23952-PL3-8001.23 mm (0.0444 in)
239s3-PL3-8001.26 mm {0.0496 in)
X23954-PL3-8001.29 mm (0.0508 in)
2395s-PL3-8001.32 mm (0.0520 in)
z23956-PL3-8001.35 mm (0.0531 in)
23957-PL3-8001.38 mm (0.0543 in)
A823958-PL3-8001.41 mm (0.0555 in)
AC23959-PL3-8001.44 mm {0.0567 in)
AD23960-PL3-8001.47 mm (0.0579 in)
2396't-PL3-8001.50 mm (0.0591 in)
23962-PL3-8001.53 mm (0.0602 in)
AG23963-PL3-8001.56 mm (0.0614 in)
AH23964-PL3-8001.59 mm (0.0626 in)
23965-PL3-8001,62 mm (0.0638 in)
23966-PL3-8001.65 mm (0.0650 in)
AK23967-PL3-8001.68 mm (0.0661 in)
23968-PL3-8001.71 mm (0.0673 in)
23969-PL3-8001.74 mm (0.0685 in)
AN23970-PL3-8001.77 mm (0.0697 in)
AO23971- PL3 8001.80 mm (0.0709 inl
6. Installthe oil guide plate and selected thrust shim in
ths transmission housing
NOTE:
. Clean the thrust washer, spring washel and
thrust shim thoroughly belore installation.
. lnstall the thrust washer, spring washer and
thrust shim proPerlY.
THRUST SHIM
I
OIL GUIDEPLATE
TRANSMISSIONHOUSING
8.
o
10.
7, Install the thrust washer and spring washer in the
mainshaft.
lnstall the mainshaft in the clutch housing
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings with
several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings'
8 x 1.25 mm
27 N'm t2.8 kgf.m. 20 lbf'ft)
Tap the mainshaft with a plastic hammer.
Check the thrust clearance in the manner doscribsd
below.
CAUnON: Mc.suromont 3hould bo mlde !t room
tomp9laturs.
a. Slide the mainshaft base and the collar over the
mainshaft.
CLUTCHHOUSING
11.
lz.
MAITISHAFT BASE07GAJ-PG20130COLLAF07GAJ -PG20120
{cont'd}
13-37
THRUST WASHER
SPRING WASI{ER

Mainshaft Thrust ShimI
I
Adjustment (cont'dl
b.Attach the mainshaft holder to the mainshaft asfollows:
NOTEI
. Back-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip istoward the transmission.
. Align the mainshaft holder's lip around thegroove at the inside of the mainshaft splines,then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
MAINSIIAFTHOLDER07GAJ-PG20110
d.
Seat the mainshaft fully by tapping on the end witha plastic hammer.
Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base.
u
e. Zero a dial gauge on the end ofthe mainshaft.
MAINSHAFT HOLDER07cAJ_PG20110
Turn the mainshaft holder bolt clockwise: stop turn,ing when the dial gange has reached its maximummovement. The reading on the dial gauge is theamount of mainshaft end olav.
CAUTION: Turning the mainshaft holder bolt morethan 60 degre€s after the needle ot the dial gauge
stops moving may damage the iransmission.
lf the reading is within the standard. the clearance iscorrecl.
lf the reading is not within the standard, recheck theshim thickness.
Standard: 0.11 - 0.18 mm {0.00it - 0.007 in}
t.
\,J