1996 HONDA CIVIC Elect

Transmission
Reassembly
NOTE: The steel balls are all ofthe same size (5/16 in).
1. Install the magnet and reverse lock cam.
2. Set shift arm A on the clutch housing, then install
the shift rod.
3. Install the spring washer and shift arm A attaching
bolt.
Installthe steel ball, spring, and set ball spring bolt.
Install shift arm B in the interlock, then set it on the
clutch housing.
1.
Insert shift arm shaft in the clutch housing.
Install the collar, spring. and steel ball into the case.
Compress the ball and insert the shift arm shaft,
Install shift arm C in shift arm A, then insert the shift
arm shaft.
Install the reverse select retainer and reverse select
spring onto shift arm shaft.
Install the differential assembly.
5.
8.
9.
10.
A:8x1.0mm3'l N,m (3.2 kgt.m,23 lbf.ft)
6 x 1.0 mm15 N.m 11.5 kgt.m, 11 lbt'ftl
OIL SEALReplace.
SI{IFT ARM C
COLLAR
REVERSE SELECT SPRINGL. 63.4 mm 12.50 in)
REVERSE LOCK CAM
REVERSE SELECT RETAINER
sHtFT ARM ' ___\.*^
rNrERLocK p
|Jiiill---=l@
MAGNET
SET BALL SPRING BOLT22 N.m 12.2 kgl.m, 16 lbf'ftl
SPRINGL. 25.6 mm (1.O1 in)
SHIFT AFM A
CLUTCHHOUSING
SHIFT ARM SHAFT
(cont'd)
13-39
SHIFT ROD
l
BOOT

Transmission
Reassembly lcont'dl
11. Position the 36 mm spring washer and washer onto
the mainshaft bearing.
MAINSHAFT/COUNTERSHAFTSHIFT FORK ASSEMELIES
Tape the mainshaftsplines.
12.
13.
Install the mainshaft, countershaft, and shift fork
assemblies.
NOTE; Align the finger of the interlock with thegroove in the shift fork shaft,
lnstall the spring washer and shift arm B attaching
bolt.I x 1.0 mm31 N.m (3.2 kgl.m, 23 lbt.ft)
IST/2ND SELECT SPRINGL. 36.26 mm 11.428 in)
54 N.m 15.5 kgf.m,40 tbt.ftl
SPf,INGWASHER
GUIDE BOLT
14.
39 N.m 14.0 kgf.m, 29 lbf.frl
Install the 1sv2nd select spring, 28 mm plug bolt.
and interlock guide bolt,
NOTE: Apply Iiquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads of the 28 mm plug bolt
and interlock guide bolt.
13-40
15. Install the reverse idler gear and reverse idler gear
shaft.
REVERSE IDLERGEAR SHAFT
LJ16. Install the reverse shift holder.
REVERSE SHIFT
l5 N.m (1.5 kgf.m,11 lbt.trl
GEAR
6 x 1.0 mm

Bolt SizeTorque Value
cn
E
F
6x1.0mm
6x1.0mm
8 x 1.0 mm
8 x '1.25 mm
8 x 1.25 mm
8 x 1,0 mm
12 N.m (1.2 kgnm, 8 lbf'ft)
15 N.m (1.5 kgf'm, 11 lbf ft)
15 N.m (l.5 kgf.m, 11 lbift)
24 N'm (2.4 kgim, 17 lbift)
27 N.m (2.8 kgf.m,20 lbf'ft)
30 N.m (3.1 ksf m. 22 lbift)
5i WASHER Replace.6 TRANSMrssioN HouslNG!9 80 mm SHIM@ SHIFT PIECE SHAFT(6' INTERLOCK@ sHrFr PECE6} SHIFT ARM HOLDER@ seucr nnrvtI9 SELECT RETURN SPRING
@ 10 mm SHIM6, 10 mm WASHER@ LOCK COLLARi6sl 3 x l5 mm SPRING PIN Replace.t0 8 mm SPRING WASHERA) CHANGE PIECEll SPRING L.25.6 mm (1.01 in)'' MAGNET?4) CLUTCH HOUSINGta. 14 x 25 x 16 mm OIL SEAL Replace.A sHrFT BooO D|FFERENT|aL ASSEMBLYSee section 15iIO SHIFT ROD BOOT6 OIL GUIDE PLATE@ 33 x 60 x 20 mm NEEDLE BEASINGO BEARING RETAINER PLATElD LocK WASHER Replace..0 couNTERSHAFIA DISTANCE COLLAR6 & x 4I x 22 mm NEEDLE BEARING6. 1sr GEAR@ FRICTION DAMPERO SYNCHRO RING.d SYNCHRO SPRING@ 1ST/2ND SYNCHRO HUB..9i. REVERSE GEARC) DOUBLE CONE SYNCHROO FRICTION DAMPERS SPACER6 T2 x TI x 24 mm NEEDLE BEARING(!' 2ND GEAR61 3RD GEARiD 4TH GEAR@ 5TH GEAR(O NEEDLE BEARING(10 BALL BEARING@ SPRING WASHERf,o LoCKNUT Replace.108 - 0- 108 N'm111.0- 0* 11.0 kgf m,80* 0- 80lbI.ft)IO CLUTCH LINE BRACKET.d BACK.UP LTGHT SWITCH HARNESS BRACKET
:!, ANGULAR BALL BEABING:2, STOP RING:3] TAPER RING..-I NEEOLE BEARINGl!-- SPACERO SYNCHRO RING? SYNCHRO SPRINGE 5TH/REVERSE SYNCHRO SLEEVE...] sTH/REVERSE SYNCHRO HUB
O SYNCHBO EING.11-r sTH GEAR1A 38 x 43 x 26 mm NEEDLE BEARINGI13) SPACER COLLAR[!] /ITH GEAR.T5) SYNCHRO RING
O SYNCHRO SPRING17 3RD/4TH SYNCHRO HUB
O 3RD/4TH sYNcHRo SLEEVE
ii9 38D GEAR8I MAINSHAFT2i WASHERA SPRING WASH€R?I BALL BEARING.a4, 28 x 41 x 7 mm OIL SEAL Replace..2i 35 x 56 x 8 mm OIL SEAL Replace.t-t 14 x 20 mm DowEL PIN
.'] OIL CHAMBER PLATE
O REVERSE IDLER GEAR SHAFT.iI.., REVERSE IDLER GEAR'd REVERSE SHIFI HOLDERait srH/REVERSE sHIFT PIECE'34 5 x 22 mm SPRING PIN Replace.3' 1ST/2ND SHIFT FORK,34' 3RD/4TH SHIFT FORKi9t) srH/nevense sstrr ronx33 OIL GUTTER PLATE!' SNAP RING3d 72 mm THRUST SHIM
@ OIL GUIDE PLATE4t 10 mm WASHER Replaceti REVERSE TDLER GEAR SHAFT BoLT54 N.m {5.5 kgf m, 40lbIft)4N TBANSMISSION HANGER B43] BREATHER CAPA,J TRANSMISSION HANGER AIT' BACK-UP LIGHT SWITCH
I
25 N.m {2.5 kgl.m, 18lblftl14 mm WASHER RePlaceaO 14 mmtt 16 mm16 mm SEALING BOLT29 N.m (3.0 kgf m,22 lbf ft):4s) 32 mm SEALING BoLT25 N m 12.5 kgl m, 18 lbl'ft)40 x 62 x I mm OIL SEAL ReplaceSTEEL BALL D.5/15 iNSPRING L. 30 mm {1.2 in)12 mm WASHER Replace.SET SCREW22 N.m {2.2 kg{ m, 16 lbl ftlOIL DRAIN PLUG39 N.m {4.0 kgf m, 29lbtftlWASHER Replace.OIL FILLER PLUG4,t N.m {4.5 kgl m, 33 lblftl
.!rl00
@l
13-55

Change Holder AssemblY
,Glearance InsPection
1.Measure the clearance between the shift piece and
the shift arm holder.
Standard: 0.1 - 0.3 mm {0.004 - 0.012 in)
service Limit: 0.6 mm {0.02 in)
lf the clearance is more than the service limit, mea-
sure the width of the groove in the shift piece'
Standard: 8.1 - 8 2 mm {0'319 - 0.323 in}
lf the width of the groove is not within the stan-
dard, replace the shift piece with a new one'
lf the width of the groove is within the standard,
replace the shift arm holder with a new one'
SHIFT PIECE
SHIFT ARM HOLDER
SHIFT PIECE
4.
3. Measure the clearance between the select arm and
the interlock.
Standard: 0.05 - 0.20 10 002 - 0.008 inl
Service Limit:0.45 mm (0.018 inl
lf the clearance is more than the service limit, mea-
sure the width of the interlock.
Standatd: 9.9 - 10.0 mm (0.390 - 0.39't in)
lf the width is not within the standard, replace
the interlock with a new one.
lf the width is within the standard, replace the
select arm with a new one.(cont'd)
INTERLOCK
13-59

Change Holder Assembly
Clearance Inspection (cont'd)
7. Measure the clearance between the select arm andthe 10 mm shim.
Standard: 0.01 - 0.2 mm (0.0004 - 0.008 in)
lf the clearance is not within the standard, selectand install the appropriate l0 mm shim for the cor-rect clearance from the chart below.
mm Shim
8.
SELECT ARM
l0 mm SHIM
Part NumberThickness
24435-689-0000.8 mm (0.031 in)
B24436-589-0001.0 mm (0.039 in)
c24437-689-0001.2 mm (0.047 in)
D24438-689-0001.4 mm (0.055 in)
E24439-689-0001.6 mm {0.063 in)
13-60
I
9. Measure the clearance between the shift arm holderand the change piece.
Standard; 0.05 - 0.35 (0.fi)2 - 0.014 inlService Limit: 0.8 mm (0.03 in)
lf the clearance is more than the service limit. mea_sure the groove of the change piece.
Standard: 12.05 - 12.15 mm {0.i[7it4 - 0.47txt inl
lf the groove is not within the standard, replacethe change piece with a new one.lf the groove is within the standard, replace theshift arm holder with a new one.
vo
SHIFT ARM HOLOER
CHANGE PIECE

UO
11. Measure the clearance between the select arm and
the change Piece.
Standard: 0.05 - O'25 mm 10'002 - 0'010 in)
Servica Limii: 0.5 mm {0.02 in)
lf the clearance is more than the service limit, mea-
sure the width of the change Plece.
Standard: 12.05 - 12.15 mm {0.47'|{ - 0 47tI| inl
CHANGE PIECE
lf the width is not within the standard, replace
the change Piece with a new one'
lf the width is within the standard, replace the
select arm with a new one.
't2.
a
a
SELECT ARM
Removal
1. Bemove the shift piece shaft. then remove the shift
piece and the interlock.
SHIFT PIECE SHAFT
INTERLOCK
2. Remove the change holder assembly'
13-61

Change Holder Assembly
Disassembly/Reassembly
I P'io' to '"""sembring, crean aI the pans in sorvent, dry them and appry lubricant to any contact surfaces.
l0 mm SH|M
I
,o mm wAsHEF
t/
@@d.
r]7| 3 x 16 mm SpRtNGI Replace.
R€TURN SPRING
SELECT ARM
13-62

Differential
Index
FINAL DRIVEN GEARInspect tor wear and damage.
80 mm SHIMSelection, page'13,84
101 N.m {10.3 kgtm,74.5 lbf.ft)Left-hand threadsBALL BEAFINGInspect foa wear and ooeration.
13-82
Backlash Inspection
1. Place the differential assembly on V-blocks and installboth axles.
Measure the backlash of both pinion gears. lf thebacklash is not within the standard, replace the dif,ferential carrier.
Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inl
DIAL INDICATOR