trans HONDA CIVIC 2002 7.G Owner's Guide

Glutch
Clutch Replacement (cont'dl
Clutch Disc and Pressure Plate Installation
'L Temporarily install theclutch disc ontothesplines
of the transmission mainshaft, Make sure the clutch
disc slides freely on the mainshaft.
2. lnstallthe ring gear holder.
{P/N 08798-9002)
07LAB-PVo0'100 or0792,1-PD20003
Apply super high temp urea grease (P/N 08798-
9002) to lhe splines (A) of the clutch disc (B), then
install the clutch disc using the special tools.
Installthe pressure plate (A) and the mounting
bolts (B) finger-tig ht.
\---,
/v
07936-3710100
3.
O?ZAF.PRSAIOO
12-12
5. Torque the mounting bolts in a crisscross pattern,
Tighten the bolts in several steps to prevent
warping the diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TOROUE:
25 N.m {2.6 kgt.m, 19 lbt.ft)
o
Remove the special tools.
Make sure the diaphragm spring fingers are all the
same height.
1.

Manual Transmission
SpecialTools
Transmission Fluid Inspection
and Reo1acement ...................-.
Back-Up Light Switch Test ..........
Transmission Removal
Transmission Installation ...........
Transmission Disassemblv ........
Reverse Shift Fork Clearance
lnsoection
Change Lever Clearance
lnsoection
Change Lever Assembly
Disassembly/Reassembly .......
Shift Forks Clearance
Inspection
Shift Forks
Disassembly/Reassembly .......
Mainshaft Assemblv
Clearance Inspection
Mainshaft Disassembly
Mainshaft lnsoection
Mainshaft Reassembly
Countershaft Assemblv
Clearance Inspection
Countershaft Disassembly .........
Countershaft Inspection .............
Countershaft Reassembly ..........
Synchro Sleeve and Hub
Inspection and Reassembly ....
Synchro Ring and Gear
Insoection ....... 13-39
Mainshaft Bearing and Oil Seal
Replacement ........................,... 13-41
Cou ntershaft Bearing
ReDlacement .. 13-42
Mainshaft Thrust Clearance
Adiustment ..... 13-43
Transmission Reassemblv ......... 13-46
Gearshift Mechanism
Replacement ............................ 13-51
M/T Differential
Comoonent Location Index ........ 13-52
Backlash Inspection ..................... 13-53
Final Driven Gear/Carrier
Replacement .. 13-53
Carrier Bearings Replacement ... 13-54
Oil Seal Replacement .................. 13-55
Differential Thrust Clearance
Adiustment ..... 13-56
13-2
| 5-J
tJ-5
13-4
I J-at
13-14
13- 19
13- 19
13-20
13-21
13-22
13-23't3-25
13-26
| 5-2.5
13-31
13-32
13-33
13-34
13-39

Manual Transmission
SpecialTools
Inspection Tool Set,
Must be used with commercially available 3/8" '16 Slide Hammer.
-4
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Ref.No.Tool NumberDescription Oty
(!lar\
ral
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vs802c000015
vs802c000018
07GAJ-PG20']10
07GAJ-PG20130
07JAD-P190100
07NAD-P20A100
07736-A01000B
07746-0010300
07746-0030100
07746-0030300
07749-0010000
l,l
l
Engine Hanger Adapter, 2.0 to 2.4 Liter
Engine Hanger
Mainshaft Holder
Mainshaft Base
Oil Seal Driver
Oil Seal Driver Aftachment
Adjustable Bearing Puller, 20-40 mm
Attachment, 42 x 47 mm
Driver, 40 mm LD.
Driver, 30 mm LD.
Driver
on Tool Set. 07GAJ-PG20102.of Mainshaft
\'---''
13-2

Transmission Fluid Inspection and
Replacement
'1. Park the vehicle on level ground, and turn the
engine OFF.
2. Remove the oilfiller plug (A) and washer (B), check
the condition of the fluid, and make sure the fluid is
at the proper level (C).
lf the transmission fluid is diny, remove the drain
plug (D) and drain the fluid.
A44 N.m{4.5 kgt.m,33 rbr.ftl
Reinstall the drain plug with a new washer, and
refill the transmission fluid to the proper level.
Oil Capacity
1.5 0 (1.6 US (F) at tluid change
1.7 0 {1.8 US qt) at overhaul
Always use Honda Manual Transmission Fluid
(MTF). Using motor oil can cause stiffer shifting
and noise because it does not contain the proper
additives.
Reinstall the oil filler plug with a new washer.5.
13-3
Back-Up Light Switch Test
1. Disconnectthe back-up light switch (A) connector.
Check for continuity between the back up light
swilch 2P connector No. 1 and No.2 terminals.
There should be continuity when the shift lever is in
reverse.
lf necessary, replace the back-up light switch.
Apply liquid gasket (P/N 08718-0001), and install it
on the transmission housing.
2.
3.

Manual Transmission
Transmission Removal
SpecialTools Required. Engine hanger adapter.2.0 to 2.4 liter VSB02C000015. Engine hanger VSB02C000018. Engine support hanger, A & Reds AAR'T 12566'. Subframe adaDter EOS02C000011 '
* Available through the Honda Tool and Equipment
Program 888-424-6857
NOTE: Use fender covers to avoid damaging painted
surfaces.
4.
1.
7.
Write down the frequencies for the radio's preset
buttons. Disconnect the negative ( ) cable first,
then the positive ( )cable from the battery.
Remove the battery.
Remove the intake manifold cover {see page g-3).
Remove the air cleaner housing (see page 1 1-162).
Remove the intake air duct {see step 8 on page 5-3).
Remove the battery tray (A).
Disconnect the transmission ground cable (B).
Disconnect the back-up light switch connector (A)
and vehicle speed sensor (VSS) connector (B).
13-4
8. Remove the cable bracket (A). then disconnect the
cables (B) from the top of the transmission housing.
Carefully remove both cables and the bracket
together so as not to bend the cables.
9. Remove the harness clip.
I
HA @
ilB

10. Carefully remove the slave cylinder and clutch line
bracket so as not to bend the clutch line. Do not
operate the clutch pedal once the slave cylinder has
been removed,
Remove the engine wire harness cover (A) by
lifting up on the lock tab (B), then slide the harness
forward offthe aircleaner housing mounting
bracket {C).
11.
12. Attach the special tool to the threaded hole in the
cylinder head.
vsB02c00001s
Installthe engine hanger (A) and the engine support
hanger {B) to the vehicle, then attach the hook to the
sDeciai tool.
tJ.
14.
vs802c000015
Remove the two upper transmission mounting
bolts.
(cont'd)
13-5

Manual Transmission
Transmission Removal (cont'd)
15. Remove the transmission mount bracket (A) and
transmission mounting bolt (B).
Remove the air cleaner bracket {C).
Raise the vehicle, and make sure it is securely
supponed.
Drain the transmission fluid. Reinstall the drain bolt
with a new washer (see page 13-3).
Remove the splash shield.
€Ds
to.
17.
18.
19.
db--qF
13-6
20.
21.
22.
23.
Remove the three way catalytic converter (TWC)
assembly (see step 30 on page 5-5)
Remove the driveshafts (see page 16-3).
Remove the intermediate shaft {see page 16-19).
Remove the front engine mount bracket mounting
bolt.
Remove the three bolts securing the transmission
rear mounI.
24.

25. Support the subframe with the subframe adapter
and a jack.
---
26.
EOS02C000011
Make reference marks (A) on the front suspension
subframe (B) and mounting bolts (C). then remove
the front suspension subframe.
27. Remove the clutch cover.
28. Remove the front engine mount.
Place the transmission iack under the transmission,
and remove the transmission mounting bolts.
29.
(cont'd)
13-7

Manual Transmission
\
12 x 1.25 mm64 N.m{6.5 ksf.m,47 tbf.ft)
30.
Transmission Removal (cont'd)
Pull the transmission away from the engine until
the transmission mainshaft clears the clutchpressure plate, then lower the transmission on the
transmission jack.
Remove the transmission rear mount (A) and the
transmission rear mount bracket {B).
Remove the boot (A), the release fork {B). and the
release bearing (C) from the transmission (D).
32.
13-8
Transmission Installation
Special Tools Required. Engine hanger adapter, 2.0 to 2.4 liter VS802C000015. E ngine hanger VS802C000018. Engine support hanger, A & Reds AAR-T-12566". subframe adaDter EoS02c000011* Available through the Honda Tool and Equipment
Program 888-424-6857
1. Check the two dowel pins are installed in the clutch
housr ng.
Apply super high temp urea grease (P/N 08798-
9002) to the release fork (A) and the release bearing(B). Installthe release fork and the release bearing.
0.4 1.0 g {0.01 0.04 ozl
3. Installthe transmission rear mount bracket (A)and
the transmission rear mount (B).
x 1.25 mmN m {6.5 kgf.m,
Place the transmission on the transmission iack.
and raise it to the engine level.
't2
6447
1.0 '1.6 g{0.04 0.06 oz)

5. Install the transmission mounting
12 x 1.25 mm64 N.m 16.5 kgf m.47 lbt ft)
12 x 1.25 mm64 N.m (6.5 kgf.m,47 lbf.ft)
6. Installthe front engine mount.
12 x 1.25 ftrn64 N.m(6.5 kgf m. 47 lbf.ft)
bolts.
12x 1.25 mm64 N.m(6.5 kst.m,47 lbf ft)
7. lnstallthe clutch cover.
6x1.0mm12 N.m {1.2 kgI.m, 9 lbf ftl
8. Supportthe subframe with the subframe adapter
and a jack.
Installthe front suspension subframe (A) in its
original position by aligning the marks (B) you
made in the removal procedure,
9.
14 x 1.5 mm
(cont'd)
13-9