Oil HONDA CIVIC 2003 7.G Workshop Manual

Mainshaft Thrust Clearance Adiustment
Special Tools Required. Mainshaft base 07GAJ-PG20130. Mainshaft holder 07GAJ-PG20110
1. Remove the 72 mm shim (A) and oilguide plate M
from the transmission housing (B).
,5---ov/
Installthe 3rd/4th synchro hub (A), the distance
collar (B), the 5th synchro hub {C). distance collar
(D), and ball bearing (E) on the mainshaft (F), then
installthe assembled mainshaft in the transmission
housing (G).
lnstall the washer (H) on the mainshaft.
Measure distance O between the end of the
transmission housing and washer with a straight
edge and vernier caliper. Measure at three
locations and average the reading.
5.Measure distance @ between the end of the clutch
housing (A) and the bearing inner race (B)with a
straight edge and depth gauge. Measure at three
locations and average the readings.
A
Shim Selection Formula:
6, Select the proper 72 mm shim from the chan.
Follow the example below, and use the
measurements you made in steps 4 and 5:
(Basic Formula)
O+@ (0.8 * 0.11) = shim thickness (maximum)
O + O (0.8 + 0.17) = shim thickness (minimum)
. Add distance O (step 5) to distance O (step 4)
. 0.8 mm (0.031 in): Spring washer, a dimension in
the installation.. 0.11 mm (0.004 in): lvlinimum thrust clearance
. 0.17 mm (0.007 in): Maximum thrust clearance.
(For example)
2.32 + 0.15 - (0.8 + 0.11)= 1.56 mm (0.061 in.)
2.32 + 0.15 - (0.8 + 0.17)= 1.50 mm (0.059 in.)
Take the middle value of the minimum value and
the maximum value, and select the 1.53 mm
(0.060 in.) shim.
{cont'd)
13-/li|

Manual Transmission
Mainshaft Thrust Clearance Adjustment (cont'dl
72 mm Shim
Part NumberThickness
23931-P21-0000.60 mm {0.0236 in.)
B23932-P21-0000.63 mm (0.0248 in.
c23933-P21-0000.66 mm (0.0260 in.D23934-P21-0000.69 mm (0.0271 in.
E23935-P21-0000.72 mm (0.0283 in.
F23936-P21-0000.75 mm (0.0295 in.
23931-P21-0000.78 mm (0.0307 in.-23938-P2'l-0000.81 mm (0.0319 in
23939-P21-0000.84 mm (0.0331 in
J23940-P21-0000.87 mm {0.0343 in,
23941-P21-0000.90 mm (0.0354 in.
L23942.P21-0000.93 mm (0.0366 in.
M23943-P21-0000.96 mm (0.0378 in.
N239 44-P21 .0000.99 mm (0.0390 in.
o23945-P21-0001.02 mm (0.0402 in.P23946-P21-0001.05 mm (0.0413 in.
o23941-P2't-000'l.08 mm (0.0425 in
R23948-P2'l-000'1 .1 1 mm {0.0437 in
23949-P21-000'1.14 mm (0.0449 inT23950-P21-0001.17 mm {0.0461n.
U23951-P21-0001.20 mm 10.0472n.
23952-P21-0001.23 mm (0.0484n.
23953-P21-0001.26 mm {0.0496n.X23954-P21-0001.29 mm (0.0508n.
23955-P21-0001.32 mm (0.0520n.z23956-P21,0001.35 mm (0.0531 in
23957-P21-0001.38 mm (0.0543 in
AB23958-P21-0001.41 mm (0.0555nAC23959-P21-0001.44 mm (0.0567n.
AD23960-P21-0001.47 mm (0.0579n.
AE23961-P21-0001.50 mm (0.0591n.AF23962-P21-OOO1.53 mm (0.0602n.AG23963-P21-000156 mm (0.0614n.
AH23964-P21-0001.59 mm (0.0626n.
AI23965-P21-0001.62 mm (0.0638 in
AJ23966-P21-0001.65 mm (0.0650 in
AK23967-P21-0001.68 mm (0.0661 in
AL23968-P2r -0001.71 mm (0.0673 in.
AM23969-P21-0001.74 mm (0.0685 in.
AN2397 0-P21-0001.77 mm (0.0697 in.AO23971-P2't-OOO1.80 mm (0.0709 in.
13-44
12.
7. Installthe 72 mm shim (A) selected and oil guideplate M in the transmission housing (B).
,6,,-oV
Thoroughly clean the spring washer (A) and
washer (B) before installing them on the clutchhousing side ball bearing {C). Note the installation
direction of the spring washer.
8.
{
10.
11.
9.lnstallthe mainshaft in the clutch housing.
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings withseveral 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
Tap the mainshaft with a plastic hammer.

-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

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

Oil Seal Replacement
Special Tools Required. Driver 07749-0010000. Oil seal driver attachment 07NAD-P20A100
1. Remove the differential assembly.
2. Remove the oil seal (A) from the transmission
housing (B).
3. Removetheoil seal (A) fromtheclutch housing (B).
4. Installthe new oil seal in the transmission housinq
with the special tools.
5. Installthe new oil seal in the clutch housing with
the special tools.
13-55

Driveline/Axle
LSpecialTools
a\*
o@
tg r?)
[]
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,0)
Ref. No.Tool NumberDescriDtionOrv
n]
@
o
@
t9
6)
o(D
07GAD-PH70201
07MAC-S100200
07 NAF-SR30101
07xAc-001010A
07746-0010400
07746-0030400
07749-0010000
07947-S800100
Oil Seal Driver
BallJoint Remover, 28 mm
Half Shaft Base
Threaded Adapter, 22 x 1.5 mm
Attachment, 52 x 55 mm
uflver, J5 mm LU.
Driver
Oil Seal Driver
1
1
1
1
1
1
1
1
16-2

Driveline/Axle
Driveshafts Removal (cont'd)
7. Remove the lock pin {A)from the lower arm balljoint castle nut (B), and remove the nut.
NOTE:. To avoid damaging the balljoint, install a hex nut
on to the threads of the ball joint,
. Be careful not to damage the balljoint boot when
installing the remover.
07MAC-S100200
w^'e
Separate the ball joint from the lower arm (C) with
the special tool (see step 3 on page 18-19).
Be careful not to dislodge the lower ball joint from
the knuckle.
Pull the knuckle outward, and remove the
driveshaft outboard joint from the front wheel hub
using a plastic hammer.
9.
.."8
16-4
\
10. Left driveshaft: Pry the inboard joint (A)from the
differential case with a prybar. Right driveshaft:
Drive the inboard joint (A) off of the intermediate
shaft with a drift and hammer. Remove the
driveshaft as an assembly. Do not pull on the
driveshaft (B), because the inboard joint may come
apart. Draw the driveshaft straight out to avoid
damaging the oil seal.
Left driveshaft:
a
t
Right driveshaft:

Driveline/Axle
{Intermediate Shaft Removal
(cont'dl
4. Remove the intermediate shaft (A) from thedifferential. Hold the intermediate shaft horizontaluntil it is clear of the differential to prevent damageto the differential oil seal (B).
16-20
Intermediate Shaft Disassembly
Special Tools Required. Oil seal driver 07947-5800100. Half shaft base 07NAF-SR30101
1. Removetheset ring (A), outerseal (B), and externalsnap ring (C).
Press the intermediate shaft (A) out of theintermediate shaft bearing (B) using a press. Be
careful not to damage the metal rings (C) on theintermediate shaft during disassembly.
LPRESS

Special Tools Required. Driver 07749-0010000. Attachment,52 x 55 mm 07746-0010400. Attachment, 35 mm 1.D.07746-0030400. Oil seal driver 07GAD-PH70201
NOTE: Refer to the Exploded View as needed during
this procedure.
1. Clean the disassembled parts with solvent, and dry
them with compressed air. Do not wash the rubber
parts with solvent.
2. Press the intermediate shaft bearing (A) intothe
bearing support (B) using the special tools and a
press.
07746-0010400
Install, then seat the internal snap ring into the
groove ofthe bearing supPort.
ES
I
PR
3.
PRESS
I
4. Press the intermediate shaft (A) intotheshaft
bearing (B) using the special tool and a press.
07746-0030400
Install, then seat the external snap ring {A) into the
groove of the intermediate shaft (B).
(cont'd)
16-23

Driveline/Axle
Intermediate Shaft Reassembly
(cont'd)
6. lnstallthe outer seal (A) intothebearingsupport(B)
using the special tool and a press.
7. Installthe set ring.
PRESS
I
Pack the interiorofthe outer seal.
16-24
Intermediate Shaft Installation
1. Use solvent or brake cleaner to thoroughly clean
the areas where the intermediate shaft {A) contacts
the transmission (differential), and dry with
compressed air. Insert the intermediate shaft
assembly into the differential. Hold the
intermediate shaft horizontal to prevent damage to
the differential oil seal (B).
2. Installthe llange bolt (A) and two dowel bolts (Bl.
A10 x 1.25 mm39Nm(4.0 kgf.m,29lbf.ft)
Bl0 x 1.25 mm39 N.m(4.0 kgf.m,29 tbf.ftl
(