ect HONDA CIVIC 2000 6.G Workshop Manual

Transmission
Reassembly lcont'dl
11. Position the 36 mm spring washer and washer onto
the mainshaft bearing.
MAINSHAFT/COUNTERSHAFTSHIFT FORK ASSEMELIES
Tape the mainshaftsplines.
12.
13.
Install the mainshaft, countershaft, and shift fork
assemblies.
NOTE; Align the finger of the interlock with thegroove in the shift fork shaft,
lnstall the spring washer and shift arm B attaching
bolt.I x 1.0 mm31 N.m (3.2 kgl.m, 23 lbt.ft)
IST/2ND SELECT SPRINGL. 36.26 mm 11.428 in)
54 N.m 15.5 kgf.m,40 tbt.ftl
SPf,INGWASHER
GUIDE BOLT
14.
39 N.m 14.0 kgf.m, 29 lbf.frl
Install the 1sv2nd select spring, 28 mm plug bolt.
and interlock guide bolt,
NOTE: Apply Iiquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads of the 28 mm plug bolt
and interlock guide bolt.
13-40
15. Install the reverse idler gear and reverse idler gear
shaft.
REVERSE IDLERGEAR SHAFT
LJ16. Install the reverse shift holder.
REVERSE SHIFT
l5 N.m (1.5 kgf.m,11 lbt.trl
GEAR
6 x 1.0 mm

Gearshift Mechanism
Overhaul
NOTE:
.Inspectrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts.
. Install the clip as shown.
. Turn the boot so the hole is facing down as shown.. Make sure the boot is installed on the shift rod.
SHIFT LEVER KNOE7.8 N.m {0.8 kgf.m,5.8 lbt.tt)
EXTENSIONBOLT
)
searr'p)) p f*** \-ii,,l?'"
SHIFT -Vvvvvvvvvvvvvvvvl tlourur Replace. | 1 22 N'm 12.2 ksf'm, 16 lbt.ftl
ii,".i'----....-.9 / g-ia',rf,',,"' sELF-LocKrNG Nur
sEAr '6 .rrr*(,o"" o-","o, ;":'i:;u --
CLIP
dul/
/,1: MOUNT
l': I cusHroN ,€\/\/-sSHIFT l / /-LEVER \, et- ffi
PY:,'\1^l lW -"or.o*Dusr .- \5".o.o)@1 -o-E "ot'o'
sHlFr \:/ Q,gD 22 N.m
IiUei__-.....p anecxer ,-/n I I I
?!il, e* ^.-.-n{wl\^fr J"r^r"
7****r
""'%ilf
t@
t1
t\sHrFT LEVER IBALL HOLDER
\
REAR JorN*lr,""17E@
_6,
L\
EXTENSION
SELF-LOCKING NUTReplace.6 x '1.0 mm9.8 N.m {1.0 kgf.m, 7.2 lbf.lr}
tJSPRING PINReplace.
-6r
16 tbf.trl
13-44

S4C Model ('99 - 00 2-door Si, SiR)
Manual Transmission
Special Tools ............' 13-46
Maintenance
Transmission Oi1 ...................'.......... 13-47
Back-up Light Switch
Repfacement ...""" 13'47
Transmission Assembly
Removal ......'.......... 13-/tB
lnstallation ............. 13-52
lllustrated lndex ................................... 13-54
Transmission Housing
Removal ................. 13-55
Beverse Shift Holder, Reverse ldler Gear
Clearance lnspection ...................".. 13-57
Removal ................. 13-58
Change Holder Assembly
Clearance lnspection .................".... 13-59
Removal ....,,........... 13-61
Disassembly/Reassembly ............... 1 3-62
Mainshaft, Countershaft, Shift Fork
Removal ................. 13-63
Shift Rod
Removal .........."'.... 13-64
Shift Fork Assembly
lndex ................ ...... 13-65
Clearance lnspection .............'......... 13'66
Mainshaft Assembly
lndex ............"" ...... 13-67
Clearance lnspection ....................... 13-68
Disassembly .......... 13-71
fnspection '."'.......', 13'72
Reassembly .......'... 13-73
Countershaft Assembly
fndex ................ "....13-71
Glearance Inspection'......'...........'... 1 3'75
Disassembly .......... 13-76
fnspection .'............13'77
Reassembly "......... 13'78
Synchro Sleeve, Synchro Hub
Inspection .............. 13'8C
Installation ............. 13-80
Synchro Ring, Gear
Inspection .'............ 13-81
Differential
lndex ................ ...... 13-82
Backlash Inspection ..."..........."'...... 1 3-82
Final Driven Gear Replacement ...... 13-83
Bearing Replacement ....."'.......""'.. 13-83
Thrust Shim Adiustment ......""'..... 13-84
Clutch Housing Bearing
Replacement ..'...... 13-86
Mainshaft Thrust Glearance
Adiustment '.........'. 13-88
Transmission
Reassembly ."'....... 13-91
Oil Seals
Replacement ..'...... 13-96
Gearshift Mechanism
Overhaul ................ 13-97
\

MaintenanceBack-up Light Switch
\
Transmission Oil
NOTE: Check the oil with the engine OFF. and the vehi-
cle on level ground.
1. Remove the oil filler plug, then check the level and
condition of the oil.
OIL FILLER PLUGia4 N.m {{.5 kgf'm,Proper Level33 tbtfrl
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.
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 oil to the proper level.
NOTE: The drain plug washer should be replaced at
every oil change.
Reinstallthe oilfiller plug with a new washer.
Oil Capacity
2.2 f {2.3 US. qt, 1.9 lmp. qtl at oil change.
2.3 f {2./f US. qt. 2.0 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-
tives.
OIL FILLER PLUGila N.m {4.5 kgf.m, 33 lbt'ftl
Replace.
\1,
Replacement
NOTE: To check the back-up light switch, see section 23.
1. Disconnect the connector, then remove the back-up
light switch connector from the connector clamp.
2. Remove the back-up lighr switch.
AACK.UP25 N.m 12.5 kgf.m, 18 lbf'tt)Replace.
lnstall the new washer and the back-up light switch.
Check the transmission oil level.4.

Transmission Assembly
l
,
{
Removal
@Make sure iacks and safoty stands are placad plop-
erly (3ee section l).
Apply parking braks and block rear wheels so car
will not roll off stands and fall on you while working
under il.
CAUTION: Us6 fonder cove6 to avoid damaging painted
sudaces.
Disconnect the negative (-) cable from the battery,
then the positive (+l cable.
Drain the transmission oil. then reinstall the drain
plug with a new washer (see page 13-47).
Remove the intake air duct and the air cleaner hous-
ing assembly (see s€ction 5).
Disconnect the back-up light switch connector and
the transmission ground wire.
Remove the lower radiator hose clamp from the
transmission hanger B.
L
8 x 1 .25 mm22Nm12.2kgl'm,
LOWER RADIATORHOSE CLAMP
16 rbtft)
13-48
7.
Bemove the wire harness clamps.
Disconnect the starter motor cables and the vehicle
speed sensor (VSS) connector.
8 x 1.25 mm8.8 N.m (0.9 kgf.m,6.5 tbtftl
STARTERMOTORCABLES
8. Remove the clutch line bracket and the slav6 cylin-
oer.
NOTE: Do not operate the clutch pedal once the
slave cylinder has been removed.
\J

9. Remove the three upper transmission mounting
bolts and lower starter motor mounting bolt.
'10. Remove the engine splash shieid.
TRANSMISSIONMOUNTINGBOLTS12 x 1.25 mm
6,1 N.m (6.5 kgd m, 47 lbf'ft|
STARTERMOTORMOUNTINGBOLT10 x 1.25 mm
a,t N.m 14.5 kgl.m.
33 tbf.trl
CONNECTOE
11. Disconnect the heated oxygen sensor (HO2S) con-
nector, then remove exhaust pip€ A.
H02S
SELF.LOCKING NUTReplace.8 r 1.25 mm16 N.m (1.6 kgf.m, 12lbf'ft)
Replace.10 x 1,25 mm54 N.m {5.5 kgf.m,'lll lbf.ft)
12. Remove the cotter pins and loosen the castle nuts,
then separate the ball joints from the lower arm
(see section 18).
13. Remove the right damPer fork.
10 x 1.25 mma3 N.m lil.a kgf.m, 32 lbf'ft| ,
SELF.LOCKING NUTR6place.12 x 1.25 mm6a N.m (6.5 kgl.m,47 rbf ft)
RIGHTDAMPERFORK
CASTI.T NUT12 x 1,25 mma9 - 59 N.m (5.0 - 6.0 kgtm,36 - i(t lbf.ftl
(cont'd)
!-
ria -11: \/-/
't'''-a
SPLASH SHIELD
13-49

Transmission Assembly
Removal(cont'd)
14. Remove the driveshafts and the intermediate shaft(see section 16).
NOTE: Coat all precision the finished surfaces with
clean engine oil or grease. Tie plastic bags over the
driveshaft ends,
Remove the bolt, then disconnect the change elden-
sion.
Remove the clip and the spring pin, then disconnectthe change rod.
8x22mmSPRING PINCLIP Replace.
15.
13-50
17. Remove the front and the rear engine stiffensrs.
18. Remove the clutch cover.
CLUTCH COVER
6x1.0mm12 N.m (1.2 kg{.m,9 tbf.ftl
x 'l .25 mm
tJ
24 N.m {2.4 kgt m,17 rbt ftl

Transmission Assembly
lnstallation
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 BOLT29 N.m 13.0 kgf.m,22 tbllrl
(P/N 08798 - 9rD2l
-R1
tP/N 08798 -
13-52
CLIP
L f ;
Torque the mounting bolt and nuts in the sequence
shown.
Check that the busings are not twisted or offset.
@ t2 x 1.25 mm6,t N.m 16.5 kgtm,47 lbf.ft)O t2 x 1.25 mm6,r N.m (6.s kg{.m,17 tbf.ft)
O 12 x 1.25 mm7ilNm17.5kgf.m,5it lbt ft)
I
Install the alip and the spring pin on the change joint
as snown.
Turn the shift rod boot so the hole is facing down as
snown.
Make sure the shift rod boot is installed on the changerod.
CHANGE ROO
FL.- SPRING PINll heptace,
8 mm PINPUNCH
/ "*,*
lo,iD(
CHANGE ./EXTENSfoN ( ^ st
l?rffi
l\K

. Apply grease to the slave cylinder push rod.
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
6x1.0mm9.8 N'm (1.0 kgl m,
7.2 tbl.ft)
-6,4- 9m2)
Refillthe transmission with oil (see page 13-47).
Connect the positive (+) cable first, then the negative
( - ) cable to the battery.
Check the clutch oPeration.
Shift the transmission, and check for smooth opera-
tion.
Check the front wheel alignment (see section 181.
(P/N 08798
8 x 1 .25 mm22N.n 12.2 kgl'm,16 tbf.ftl
a
a
a
a

lllustrated Index
t
Refer to the drawing below for transmission disassembly/reassembly.
Clean all the parts thoroughly in solvent and dry with compressed air.
I Luoricate att the pans with oil before reassembly.
NOTE:
. This transmission uses no gaskets between the majorhousings; use liquid gasket (P/N 08718-0001 or08718-0003)
(see page '13-93).
. Always clean the magnet @ whenever the transmission housing is disassembled.
. Inspect all the bearings for wear and operation.
?-c
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13-54