ERS HONDA CIVIC 2003 7.G Owners Manual

6.
5. Remove the 8 mm flange bolts in a crisscross
Dattern in several steos.
Remove the transmission hanger A, and
transmission hanger B.
Remove the 32 mm sealing cap (A).
Expand the 72 mm snap ring (B) on the
countershaft ball bearing, and remove it from the
groove using a pair of snap ring pliers.
Remove the transmission housing (C) and
14 x 20 mm dowel pins (D).
7.
L
10. Remove the reverse lock cam.
g
t.l Y
g
11.Remove the reverse idler gear {A) and reverse gear
shaft {B).
(,
^A
(cont'd)
13-17

Manual Transmission
Transmission Disassembly (cont'd)
12. Remove the reverse shift fork.
Apply vinyl tape to the mainshaft splines to protect
the seal, then remove the mainshaft assembly (A)
and countershaft assembly (B) with the shift forks
{C)from the clutch housing (D).
14. Remove the 28 mm spring washer (E) and28mm
washer (F).
t7t1I
13-18
15. Remove the differential assembly (A) and magnet(B ).
Remove the oil gutter plate (A), 72mm shim (B),
and oil guide plate M.
16.

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:
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I
qI
13-19

Manual Transmission
Change Lever Assembly Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
BREATHER CAPTurn the arrow toward the {ronto{ the vehicle, and install it.
SELECT LEVERBe careful not to damage the dust sealwhen installing it.@).1 IlLrl
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DUST COVEB
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7 Fr"irr6-rooa
(P/N 08798-9002)
ROLLER
6x1.0mm12 N.m(1.2 kgl.m,8.7 lbf.ft)
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,.* (A)tace. ix#,,l
H\
lV srxSELECT-z:-=:l-': SPRING
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' -, OIL SEAL,/ ReDlace./-r,s
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INTERLOCK
SHIFT ARM
SELECT STOPPLATE
REVERSE LOCK CAMSTRIKER
SHIFT ARM COVER
WASHER
9.8Nm{1.0 kgf.m, 7.2 lbf.ft)
13-20

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

Special Tools Required. Driver,40 mm 1.D.07746-0030100. Attachment,30 mm l.D. 07746-0030300
NOTE: Refer to the Exploded View as needed during
this procedu re.
2.
4.
'1.Clean all the parts in solvent, dry them, and apply
lubricant to all contact su rfaces except the 3rd/4th
and 5th synchro hubs.
Installthe needle bearing and 3rd gear on the
mainshaft.
Installthe synchro ring and the synchro spring.
Installthe 3rd/4th synchro hub (A) by aligning the
synchro ring fingers (B)with 3rd/4th synchro hub
grooves (C).
-A
lnstallthe 3rd/4th synchro hub {A) using the special
tool.
07746-0030100
6. Installthe 3rd/4th synchro sleeve (A) by aligning
the stops (B)with the 3rd/4th synchro sleeve and
hub. After installing, check the operation of the 3rd/
4th synchro hub set.
@--
7. Installthe synchro spring (A).
Installthe synchro ring (B) by aliging the synchro
cone fingers (C)with 3rd/4th synchro hub grooves
(D).
Installthe 4th gear, needle bearing, distance collar,
needle bearing, and sth gear.
(cont'd)
9.
13-29

Manual Transmission
Mainshaft Reassembly (cont'dl
10. Installthe synchro ring and the synchro spring.
1 '1. Installthe sth synchro hub (A) by aligning the
synchro cone fingers (B) with sth synchro hub
grooves (C).
Installthe 5th synchro hub (A) using the special
tools.
07746-0030100
07746-0030300
13. Installthe 5th synchro sleeve.
12.
13-30
\.
\
14. Installthe synchro spring (A).
Installthe synchro ring (B) by aligning the synchro
cone fingers (C) with sth synchro hub grooves (D).
Installthe MBS distance collar and the tapered
cone ring.
Installthe new ball bearing {A) using the special
tools and a press (B).
t5.
16.
11.
U1
07746-0030100

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