service HONDA CIVIC 2002 7.G Repair Manual

Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
3. Measure the flywheel (A) runout using a dial
indicator (B) through at least two full turns. Push
against the flywheel each time you turn it to take up
the cra nksh aft th rust washer clea rance. lf the
runout is more than the service limit, replace the
flywheel and recheck the runout. Resurfacing the
flywheel is not recommended.
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.15 mm (0.006 in.)
Flywheel Replacement
1. Installthe special tool.
2.
3.
4.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, then remove the tlywheel.
Installthe flywheel on the crankshaft, and install
the mounting bolts fingertight.
Installthe specialtool, then torque the flywheel
mounting bolts in a crisscross pattern in several
sreps.
12 x 1.0 mm103 N.m(10,s kst.m. 76 lbf ftl
(cont'd)
12-11

Reverse Shift Fork Clearance
Inspection
1. Measure the clearance between the reverse idler
gear {A) and the reverse shift fork (B) with a feeler
gauge (C). lf the clearance is more than the service
limit, go to step 2.
Standard: 0.20-0.59 mm (o.oo7 0.024 in.l
Service Limit: r.3 mm {0.051 in.)
Measu re the width of the reverse shift fork.
. lf distance is notwithinthestandard, replacethe
reverse shift fork with a new one.. lf distance is within the standard, replacethe
reverse gear wrln a new one.
Standard: 13.4 13.7 mm (0.527 0.539 in.l
I
Change Lever Clearance Inspection
1.Measure the clearance between change lever (Al
and the select lever (B) with a feeler gauge (Cf. lf
the clearance is more than the service limit, go ro
step 2.
Standard: 0.05 0.25 mm (0.002-0.010 in.)
Service Limit: 0.50 mm {0.020 in.)
2.Measure the groove of the change lever'
. lf distance is not within the standard, replace the
change lever with a new one.
. lf distance iswithinthe standard, replacethe
select lever with a new one.
15.00 15.10 mm (0.591-0.594 in.)Standard:
,tl
I
qI
13-19

Shift Forks Glearance Inspection
NOTE: The synchro sleeve and synchro hub should be
replaced as a set.
1. Measu re the clearance between each shift fork (A)
and its matching synchro sleeve (B). lf the
clearance exceeds the service limit, go to step 2.
Standard: 0.35 0.65 mm {0.014 0.026in.1
Service Limit: 1.0 mm 10.039 in.l
A
l\4easure the thickness of the shift fork fingers.
. lf thethicknessof theshift forkfinger is not
within the standard, replace the shift fork with a
new one.. lf thethicknessof the shift forkfinger iswithin
the standard, replace the synchro sleeve with a
new one.
Standard: 7.4 7.6 mm (0.29-0.30 in.)
2.
3. Measure the clearance between the shift fork (A)
and the shift arm (B). lf the clearance exceeds the
service limit, go to slep 4.
Standard: 0.2-0.5 mm (0.007 0.020 in.)
Service Limit: 0.62 mm (0.024 in.)
Measure the width of the shift arm.
. lf thewidth of theshiftarm is notwithinthe
standard, replace the shift arm with a new one.. lf thewidth of the shift arm iswithinthe standard,
replace the shift fork and shift piece with a new
one.
Standard: 16.9-17.0 mm (0.665-0.669 in.)
4.
13-21

Mainshaft Assembly Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Support the bearing inner race with an appropriate
sized socket (A). and push down on the mainshaft(B).
Measure the clearance bet\iveen 2nd (C) and 3rd (D)
gears with a feeler gauge {E).
. lf the clearance is more than the service limit. go
to step 3.. lf the clearance is within the service limit, go to
step 4.
Standard:0.06 0.16 mm
{0.002 0.006 in.l
Service Limit: 0.25 mm (0.010 in.l
Measure the thickness of 3rd gear.
. lf thethickness of 3rd gearis lessthanthe service
limit, replace 3rd gearwith a new one.. lf thethickness of 3rd geariswithintheservice
limit, replace the 3rd/4th synchro hub with a new
one.
Standard: 23.92-23.97 mm(0.941 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
4. Measure the clearance between 4th gear (A) and
the distance collar (B) with a dial indicator (C).
. lf the clearance is more than the service limit, go
to step 5.. lf the clearance is within the service limit, go to
step 7.
Standard: 0.06 0.16 mnl(0.002 0.006 in.)
Service Limit: 0.25 mm {0.010 in.)
Measure distance O on the distance co[ar.
. lf distance't is notwithin the standard, replace
the distance collar with a new one.. lf distance e is within the standard, go to step 6.
Standard:24.03 24.08 mm
{0.946-0.9/u in.}
(cont'd)
13-23

Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
6. Measure the thlckness of 4th gear.
. lf thethickness of 4th gear is lessthantheservice
limit, replace 4th gear with a new one.. lf thethicknessof 4th geariswithin the service
limit. replace the 3rd/4th synchro hub with a new
one.
Standard: 23.92 23.97 mm
(0.941 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
7. l\4easure the clearance between the distance collar
(A) and sth gear (B) with a dial indicator (C). lfthe
clearance is more than the service limit. go to step
8. lf the clearance is with in the service limit, go to
steD 10.
Standard: 0.06 0.16 mm(0.002-0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
13-24
Standard:
Standard:
Service Limit:
8. Measure distance O on the distance collar.
. lf distance O is notwithinthestandard, replace
the distance collar with a new one.' lf distanceO iswithinthe standard, gotostep9.
24.03 24.08 mm
(0.946 0.947 in.)
9. Measure the thickness of 5th gear.
. lf thethicknessof 5th gearis lessthantheservice
limit, replace 5th gear with a new one.. lf the thickness of sth gear iswithin the service
limit. replace the 5th synchro hub with a new one.
23-92 23.97 mm
10.941 0.944 in.l
23.80 mm (0.937 in.l

Manual Transmission
Mainshaft Disassembly (cont'dl
3. Supportthe 3rd gear (A) on steel blocks, and press
the mainshaft out of the 3rd/4th synchro hub (B).
Use of a jaw-type puller can damage the gear teeth.
13-26
Mainshaft Inspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, C, D, and E. lf any part of the mainshaft
is less than the service limit, reDlace it with a new
o ne.
Standard:
A Ball bearing surface (transmission housing side):
27.987 28.000 mm (1.1019 1.1024in.)
B Distance collar surtace:
31.984 32.000 mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000 mm (1.53/t8 1.5354 in.)
D Ball bearing surface (clutch housing side):
27 .977 -27 .990 mm (1.1015 1.1020in.)
E Bushing surface:
20.80 20.85 mm (0.819 0.821 in.)
Service Limit;
A: 27.93 mm 11.100 in.l
B: 31.93 mm |.1.257 in.l
C: 38.93 mm 11.533 in.l
Di 27.92 mm {1.099 in.l
E: 20.75 mm 10.817 in.l
{

2. Inspect the runout by supponing both ends of the
mainshaft. Rotate the mainshaft two complete
revolutions when measuring the runout. lf the
runout is more than the service limit. reolace the
mainshaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-27

Countershaft Assembly Clearance lnspection
1.Measure the clearance between the 1st gear (A)
and the distance collar (B)with a feeler gauge (C).
. lf the clearance is more than the service limit, go
to step 2.. lf the clearance is within the service limit. go to
step 4.
Standard: 0.06 0.16 mm 10.002 0.006in.l
Service Limit: 0.25 mm (0.010 in.l
2. fvleasure the thickness of the distance collar.
. lf thethickness is notwithin the standard, replace
the distance collar with a new one.' lf the thickness is within the standard, go to
Standard:23.03 23.08 mm (0.907 0.909 in.l
3. Measu re the thickness of the 1st oear.
. lf thethicknessof lst gearis lessthanthe service
limit, replace lstgearwith a newone.. lf the thickness of '1st gear is within the service
limit, replace the lst/2nd synchro hub with a new
one.
Standard: 22-92 22.97 mm 10.902 0.904 in.l
Service Limit; 22.87 mm {0.900 in.)
Measure the clearance between the 2nd gear (A)
and 3rd gear (B) with a feeler gauge (C). lf the
clearance is more than the service limit, go to
steD 5.
Standard: 0.06 0.16 mm (0.002 0.006in.)
Service Limit: 0.25 mm {0.010 in.l
4.
(cont'd)
13-31

Manual Transmission
Countershaft Assembly Clearance
Inspection (cont'd)
5. Measure the th ickness of the distance collar.
. lf thethickness is notwithin the standard, replace
the distance collar with a new one.. lf thethickness iswithinthe standard, goto
step 6.
Standard: 28.03 28.08 mm {1.104-1.106 in.)
6. Measure the thickness of the 2nd qear.
. lf thethickness of 2nd gearis lessthan the
service limit, replace 2nd gear with a new one.. lf thethicknessof 2nd geariswithintheservice
limit, replace lhe 1sV2nd synchro hub with a new
one.
Standard: 27 -92-21.97 mm|.1.099 1.r01 in.l
Service Limit: 27.87 mm 11.097 in.)
13-32
Countershaft Disassembly
1.Securely clamp the countershaft assembly in a
bench vlse with wood blocks.
Remove the special bolt (left-hand threads).
Support the ball bearing (A) on steel blocks, then
use a press (B) and an attachment (C)to press the
countershaft out of the ball bearing.
4. Remove the 35 mm shim and distance collar.
I

5. Support 4th gear (A) on steel blocks, then use apress and an attachment (B) to press the
countershaft (C) out ofthe 5th gear.
6.Support 2nd gear (A) on steel blocks, then use a
Dress and an attachment {B} to press the
countershaft (C) out of the 3rd gear.
Cou ntershaft lnspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the countershaft
at points A, B, and C. lf any part of the countershaft
is less than the service limit, replace it with a new
one.
Standard:
A Ballbearing surface ltransmission housing sidel:
30.020 -30.033 mm {1.1819 1.1824in.)
B Distance collar surface;
39.937- 39.950 mm 11.5723 1.572A in.l
C Needle bearing surface (clutch housing side):
35.000 35.015 mm {r.3780-1.3785 in.)
Service Limit:
A: 29.97 mm {1.180 in.)
B: 39.88 mm {1.570 in.l
C: 34.95 mm {1.376 in.)
lnspect the runout by supporting both ends of lhe
countershaft. Rotate the countershaft two complete
revolutions when measuring the runout. lf the
runout exceeds the service Iimit, replace the
countershaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
2.
13-33