ERS HONDA CIVIC 2003 7.G Workshop Manual

Manual Transmission
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Countershaft Reassembly
Exploded View
SPECIAL BOLTEeplace.118 N.m (12 kgf m, 87 lbf ft)
BALL BEARINGCheck for wear andoperation.Note the direction of installation.
35 mm SHIM
REVERSE GEAR
1ST/2ND SYNCHRO HUB
SPRING
TRIPLE CONE SYNCHRO
1ST GEAR
NEEDLE BEARINGCheck for wearano opera!on.
DISTANCE COLLAR
ANCE COLLAR
GEAR
4TH GEAR
Check for wear andoperation.
DISTANCE COLLAR
FRICTION DAMPERCheck for wear and damage.
TRIPLE CONE SYNCHRO
SYNCHRO SPRING
COUNTERSHAFT
13-34

Special Tools Required. Driver, 40 mm l.D.07746-0030100. Aftachment.30 mm 07746-0030300
NOTE: Refer to the Exploded View as needed during
lhis procedure.
1. Clean all parts in solvent, dry them, and apply
lubricantto all contact surfaces.
Installthe dislance collar, needle bearing, and 1st
gear onto the countershaft.
Install the triple cone synchro assembly (A) by
aligning the synchro cone fingers (B) with 'lst gear
grooves (C), then install the synchro spring {D).
3.
Installthe '1st/2nd synchro hub (A) by aligning the
synchro cone fingers (B)with 1sV2nd synchro hub
grooves (C).
5. Installthe reverse gear.
13-35
6. Installthe synchro spring (A).
lnstall the triple cone synchro assembly (B) by
aligning the synchro cone fingers (C) with the
1sv2nd synchro hub grooves (D).
Installthe distance collar (A) and friction damper(B) by aligning the friction damper fingers (C) with
the 1sv2nd synchro hub grooves (D).
1.
8.
(cont'd)

Manual Transmission
10.
Countershaft Reassembly (cont'dl
9.Install the needle bearing.
Installthe 2nd gear (A) by aligning the synchro
cone fingers (B) with znd gear grooves (C).
'l 1.Supoort the countershaft (A) on the steel blocks,
then install the 3rd gear (B) using the special tool
and a press (C). Do not exceed the maximum
Dressure.
14,700 N (1,500 kgf,3,307 lbflmax.
07746-0030100
13-36
L,
12. Install the 4th gear (A) using the specialtool and a
press (B). Do not exceed the maximum pressure.
B14,700 N {1,500 kgt,3,307 lbf) max.
07746-0030100
Installthe 5th gear (A) using the special tool and a
press (B). Do not exceed the maximum pressure.
14,700 N (1.500 kgl,3.307 lbf) max.
07746-0030100
I

Manual Transmission
Countershaft Reassembly (cont'd)
11.Support ball bearing (A) on steel blocks (B), then
use a press (C) and an attachment (D) to press the
countershaft (E) out of the ball bearing.
lf necessary, installthe 35 mm shim selected in
step 16, then recheck the clearance,
Install the distance collar (A).35 mm shim, and new
ball bearing (B) using the specialtools and a press
(c).
46-0030r00
18.
19.
13-38
20. Tighten the new special bolt (A) (left-hand threads).
'l18 N.m (12 kgf.m,87 tbf.ftl

\
Synchro Sleeve and Hub Inspection
and Reassembly
1. lnspectthe gearteeth on ali synchro hubs and
synchro sleeves for rounded off corners, which
indicate wear.
2. Install each synchro hub (A) in its mating synchro
sleeve (B), and check for freedom of movement. Be
sure to match the three sets of longer teeth (C) (120
degrees apart) on the synchro sleeve with the three
sets of deeper grooves (D) in the synchro hub. Do
not install the synchro sleeve with its longer teeth
in the 1sv2nd synchro hub slots (E) because it will
damage the spring ring.
NOTE; lf replacement is required, always replace
the svnchro sleeve and svnchro hub as a set.
Synchro Ring and Gear Inspection
1.Inspect the inside of each synchro ring (A) for wear.
Inspect the teeth (Bi on each synchro ring for wear
(rounded off).
Example of synchro ring teeth
Inspect the teeth (C) on each synchro sleeve and
matching teeth on each gear for wear (rounded off).
Example ofteeth and gear teeth
(cont'd)
I
Il
GOOD
synchro sleeve
GOOD
/\
I
WORN
tl
WORN
13-39

Manual Transmission
Countershaft Bearing Replacement
Special Tools Required. Adiustable bearing puller,20-40 mm 07736-A0tOOOB. Oil seal driver 07JAD-AP190100. Slide hammer, commercially available
1. Remove the bearing set plate (A)from the clutchhousing (B).
Remove the needle bearing (A) using the special
tool and a commercially available 3/8" - 16 slidehammer (B), then remove the oil guide plate C.
07736-A010008
13-42
3. Position the oil guide plate C and new needle
bearing (A) in the bore of the clutch housing (B).
Installthe needle bearing using the specialtool.
Installthe bearing set plate (A) wirh bolts (B).
B6x 1.0 nn12N.m {1.2 kgt m,8.7 tbf.ft)
(

Manual Transmission
Transmission Reassembly
NOTE: Priorto reassembling, clean allthe parts in
solvent, dry them, and apply lubricant to any contact
surfaces.
1. Install the magnet (A) and differential assembly (B).
n-",-o
l;-D
Install the 28 mm spring washer (A) and 28 mm
washer (B) over the ball bearing (C). Note the
installation direction of the spring washer {A).
Apply vinyl tape to the mainshaft splines (D) toprotectthe seal. Installthe mainshaft and
countershaft (E) into the shift forks {F}. and install
them as an assembly.
13-46
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4. Install the reverse shift fork.
6x1.0mm15 N.m (1.5 kgf.m,11 lbf.ft)
f.)
Installthe reverse idler gear (A) and reverse gear
shaft (B) by aligning the mark {C)with the reversegear shaft hole (D).
(

-26 x 1,0 mmz/ / 15 N.m--' / {1 5 kgf m,€t I 11 tbf.ft)
Fl g
E
6, lnstallthe reverse lock cam.
Select the proper size 72 mm shim (A) according to
the measurements made during the Mainshaft
Thrust Clearance Adjustment (see page '13-43),
Installthe oil gutter plate (B), oilguide plate l\4, and
72 mm shim into the transmission housing (C).
7.
8. Remove the dirt and oil f rom the tramsmission
housing sealing surface. Apply liquid gasket (P/N
08718-0001) to the sealing surface. Be sure to seai
the entire circumference of the bolt holes to
prevent oil leakage.
NOTE: lf 5 minutes have passed after applying
liquid gasket, reapply it and assemble the housings.
Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
- - -Liquid gasket
{cont'd)
13-47

Manual Transmission
Transmission Reassembly (cont'dl
9. Install the 14 x 20 mm dowel pins (A).
34 N.m(3.5 kgf.m,25 rbf.ft)
Set the tapered cone ring (B) as shown. Place the
transmission housing over the clutch housing,
being careful to line up the shafts.
10.
13-48
11. Lower the transmission housing the rest of the wayas you expand the 72 mm snap ring {C). Release
the snap ring so it seats in the groove of the
countershaft bearing.
12. Check that the 52 mm snap ring is securely seatedin the groove of the countershaft bearing.
Dimension O as instalted: 3.3 6.0 mm
{0.13 0.24 in.l
Apply liquid gasket (P/N 08718-0001) to the threads
of the 32 mm sealing cap {D), and install it on thetransmission housing,
Install the transmission hangers A. and B, and the
8 mm flange bolts finger-tight.
13.
't4.
15.
8 x 1.25 mm27 N.m(2.8 kgf.m.20 rbf.ft)
(t
\A
e././
Tighten the 8 mm flange bolts in a crisscross
Pattern In several steDs.
(

16. Remove the dirt and oil from the shift iever cover
sealing surface. Apply liquid gasket (P/N 08718-
0001) to the sealing surface.
NOTE: lf 5 minutes have passed after applylng
liquid gasket. reapply it and assemble the housings.
Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
- - -Liquid gasket
17. Installthe 8 x 14 mm dowel pins (A). clutch line clip
bracket (B), and change lever assembly (C).
12 N.m (1.2 kgf.m,9lbt ft)
18. Apply liquid gasket (Pi N 08718-0001) to the threads
of the interlock bolt (D), and install it on the
transmission housing.
6x1.0mm
19. Installthe drain plug (A), filler plug (B), and 10 mm
flange bolt (C) with new washers.
A39Nm(4.0 kgf m,33 tbl.ft)
20.
/..l-.=,'-Bg ^ 44N.m
@ Ut !?iJl'.'l,''
R\-: \
-.-t ?0, ,.ru ^44 N m {4.5 kgt m,33lbf.ft}
Installthe detent bolts (A), spring, and steel balls
with new washers.
{3.0 kgf.m.22lbf.ft)
Apply liquid gasket {P/N 08718-0001}to the threads
oithe back-up light switch (B), and install it in the
transmission housing.
(cont'd)
21.
13-49