1996 HONDA CIVIC Elect

The following symptoms can be caused
by improper repair or assembly
Check these items,on th€^ ltems on thePROBABLE CAUSE DUE TO NOTES ListIMPROPER REPAIR List
Vehicle creeps in N position.R1, R2
Vehicle does not move in &l or Pll position.R4
Transmission locks up in E position.R3, R11
Excessive drag in transmission.R6K,R
Excessive vibration, rpm related.R7
Noise with wheels moving onlY.R5
Main seal pops out.R8
Various shifting problems.R9, RlO
PROBABLE CAUSE DUE TO IMPROPER REPAIR
lmproper clutch clearance.
lmproper gear clearance.
Park lever installed upside down.
one-way {sprag) clutch installed upside down.
Reverse selector hub installed upside down.
ATF pump binding.
Torque converter not fully seated in ATF pump.
Main seal improperly installed.
Springs improperly installed.
Valves improperly installed.
Shift fork bolt not installed.
14-11

Symptom-to-Component Chart
Hydraulic System (cont'dl
G.
n,
set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
lf the clutch pack is seized or is excessively worn. inspect the other clutches for wear, and check the orificecontrol valves, CPC valve and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lmproper alignment or main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
lf the l st clutch feed pipe guide in the end cover is scored by the mainshaft, inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged. lf the 4th feed pipe is danFaged or out of round, replace the right side cover.
Replace the mainshaft if the bushing for the 1st feed pipe is loose or damaged. lf the 1st feed pipe is darn-aged or out of round, replace it.
A worn or damaged sprag clutch is mostly a result of shifting the transmission inthe wheels rotate in reverse, such as rocking the vehicle in snow.
or E position while
Inspect for damage and wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear u nder pin ion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1,2,3 and 4 if worn or damaged. lf transmission makes a clicking, grinding orwhirring noise,also replace mainshaft 4th gear, reverse idler gear. and countershaft 4th gear in addition to 1, 2, 3 or 4.lf differential pinion shaft is worn, overhaul differential assembly, and replace ATF strainer, and thoroughlyclean transmission, flush torque converter, cooler and lines.lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and final drivengear.
Be very careful not to damage the torque converter housing when replacing the main ball bearing, you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the oroper roors.
Install the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
See flushing procedure, page 14-187 and 188.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the l-2 shift valve is stuck closed, the transmission will not upshift. lf stuck open, the transmission hasno 1st gear.
lf the znd orifice control valve is stuck. inspect the 2nd and 3rd clutch oacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch oacks for wear.
lf the clutch pressure control valve is stuck closed, the transmission will not shift out of 1st gear.
lf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Inspect the frame for collision damage.
14-112

Accelerate to about 35 mph (57 km/h) so the transmlssion is in 4th, then shift from Dl position to Z position The
vehicle should immediately begin slowing down from engine braking'
CAUTION: Do not shift from -91 or -Dd position to E position at speeds ov6r 63 mph {100 km/hl; You mav damage
the transmission.
Check for abnormal noise and clutch slippage in the following positions'
E (2nd Gear) Position
ll Accelerate from a stop at full throttle. check that there is no abnormal noise or clutch slippage.
b. Upshifts and downshifts should not occur with the selector in this posirion'
E (Reverse) Position
i"ccelerate from a stop at fullthrottle, and check for abnormal noise and clutch slippage'
Test in B (Park) Position
Park the vehicle on slope (approx. l6'), apply the parking brake' and shift into E position Belease the brake; the veh'
cle shou,d nol move
1+115

O ROLLER
O COLLAR
O o-RING Replace.
@ FEED PIPE FLANGE
@ O-RING Replace.
@ SNAP RING
€) 3RD CLUTCH FEED PIPE
€) COUNTERSHAFT LOCKNUT (FLANGE NUT)
23 x 1.25 mm Replace.
o coNlcAL SPRING WASHER Replace.
@ PARK GEAR
@ ONE.WAY CLUTCH
@ COUNTERSHAFT lST GEAR
@ NEEDLE BEARING
@ COUNTERSHAFT lST GEAR COLLAR
@ o-RlNGs Replace.
@ END covER GASKET Replace.
E) DOWEL PINS
@ PARK PAWL STOP
@ LocK WASHER Replace.
@ PARK STOP Selective part
€D PARK LEVER
@ PARK LEVER SPRING
€D DRAIN PLUG
€) SEALING WASHER Replace
@ o-RING Replace.
@ COUNTERSHAFT SPEED SENSOR
@) PARK PAWL
@ PARK PAWL SPRING
@ PARK PAWL SHAFT
@ LINEAR SOLENOID ASSEMBLY
@ LINEAR SOLENOID GASKET REPIACE.
@) END COVER
@ lsT CLUTCH FEED PIPE
@ O-RINGS Replace.
@ FEED PIPE FLANGE
C) SNAP BING
@ MAINSHAFT LOCKNUT (FLANGE NUTI 21 x 1 25 mm
Replace.
@ CONICAL SPRING WASHER RePlace
@) lST CLUTCH ASSEMBLY
@ o-RlNGs Replace.
€) THRUST WASHER
@) THRUST NEEDLE BEARING
@ NEEDLE BEARING
@ MAINSHAFT lST GEAR
@ MAINSHAFT lST GEAR COLLAR
@) ATF COOLER LINE
@ SEAUNG WASHERS Replace.
@ LINE BOLT
@ ATF DIFSTICK
@ ATF COOLER LINE
@ UNE BOLT
@ SEALING WASHERS Replace.
@ VEHICTT SPEED SENSOR
@ O-RING Replace.
TOROUE SPECIFICATIONS
Bolt/Nut No.Torque ValueSizeRemarks
6B
8F
12A.'l8D
2'tM
23C
'12 N'm (1.2 kgim,8.7 lbift)
14 N.m (1.4 kgf.m, 10 lbf'ft)
22 N.m (2.2 kgf.m, 16 lbf'ft)
28 N.m (2.9 kgf.m, 21 lbf'ft)
49 N.m (5.0 kgf.m, 36 lbf'ft)
78 N.m (8.0 kgf'm, 58 lbf'ft)
103 N.m {10.5 kgf'm,75.9 lbift)
6x1.0mm
6x1.0mm
8 x 1,25 mm
12 x 1.25 mm
18 x 1.5 mm
21 x 1.25 mm
23 x 1.25 mm
Line bolt
Drain plug
Mainshatt locknut: Left-hand threads
Countershaft locknut:
Left-hand threads
14-127

O LocK WASHER Replace,
O REVERSE SHIFT FORK
O COUNTERSHAFT REVERSE GEAR COLLAR
G) COUNTERSHAFT REVERSE GEAR
@ NEEDLE BEARING
@ REVERSE SELECTOR
O REVERSE SELECTOR HUB
@ COUNTERSHAFT 4TH GEAR
O NEEDLE BEARING
@ DISTANCE GOLLAR, 28 mm Selective part
O COUNTERSHAFT 2ND GEAR
@ THRUST NEEDIE BEARING
@ COUNTERSHAFT 3RD GEAR
@ NEEDLE BEARING
@ COUNTEBSHAFT 3RD GEAR COLLAR
@ THRUST NEEDLE BEAFING
O SPLINED WASHER
@ 3RD CLUTCH ASSEMBLY
@ O-RtNGs Replace.
@ COUNTERSHAFT
@ SNAP RING
@ THRUST WASHER
€) THRUST NEEDTE BEARING
@} MATNSHAFT 4TH GEAR/REVERSE GEAR
@i NEEDLE BEARINGS
@ THRUST NEEDLE EEARING
@) MAINSHAFT 4TH GEAR COLLAR
@ 2ND/4TH CLUTCH ASSEMBLY
@ o-RlNGs Replace.
@ THRUST WASHER,36.5 x 55 mm Sel€ctive part
@ THRUST NEEDLE BEARING
@ MAINSHAFT zND GEAR
@ NEEDLE BEARING
@ THRUST NEEDLE BEARING
@ MAINSHAFI
@ S€ALING RINGS, 35 mm
@ SEALING RING,29 mm
@} NEEDIE BEARING
@ SET RING
@ sHrFT CONTROL SOLENOID VALVE A/B ASSEMSLY
@ HARNESS CLAMP BRACKET
@ SHIFT COI,ITROL SOI"ENOID FILTER/GASKET Replace.
@ CONNECTOR BFACKET
@D TNANSMISSION HANGER
@ BREATHER CAP
@ MAINSHAFT SPEED SENSOR
@ MATNSHAFT SPEED SENSOR WASHER {Dl6Y' ongine}
@ O-RING Replace.
@ SNAP RING
@ MAINSHAFT TRANSMISSION HOUSING BEARING
@ OOUNIERSHAFT TRANSMISSION HOUSING BEARING
@ REVERSE IDLER GEAR SHAFT HOLDER ASSEMBLY
@ NEEDI.E BEARING
@ olL SEAL Replace.
@ SET RING, fll mm Selective part
@ rnANsMrssloN HouslNG
@ REVERSE IDI."ER GEAR
@ DowEL PINS
@ TRANSMISSION HOUSING GASKET Replace.
@ DIFFERENfIAL ASSEMBLY
@ OIL SEAL Replace.
@ TOROUE CONVERTER HOUSING
TOROUE SPECIFICANONS
Boh/Nut No.Torquo valueSizeRomarks
6B
10A
12 N.m {1.2 kgf.m,8.7 lbf.ft)
14 N.m (1.4 kgf'm, 10lbf'ft)
44 N.m (4.5 kgf.m, 33 lbf'ft)
6x1.0mm
6x1.0mm
10 x 1.25 mm
14-129

Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubricate all parts with ATF during reassembly..Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O_rings.. Locknut has left-hand threads.
LOCKNUT {FLANGE NUTI21 x 1.25 mm78 N.m (8.0 kgl.m,58 lbt.fttReplace.Left-hand threadsSNAP RINGCONICAL SPRING WASHERReolace.
lST CLUTCHASSEMBLYTHRUST WASHER
THRUST NEEOI.EBEARING
4TH GEAN
O-RINGSReplace.
THRUST WASHER
THRUST NEEDLEBEARING
MAINSHAFTCheck splines for excessivewear and oamage.Check bearing surtace for scoring,scratches and excessive wear.
BEARINGBEARINGS
THRUST NEEDLEBEABING
4TH GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST NEEDLEEEARING
2NO GEAB
NEEDLE BEABING
THRUST NEEDLEBEARING
1ST GEAR
1ST GEARCOLLAR
TRANSMISSIONHOUSING BEARING
O-RINGSReplace.
THRUST WASHER, 36.5 x 55 mmSelective part.
SEALING RINGS,35 mm
Install the sealing ringmating faces as shown,
RING,29 mm
NEEDLE BEARING
SET RING
14-148

Inspection
a Clearance Measurement
NOTE: Lubricate all parts with ATF during assembly.
1, Remove the mainshaft bearing from the transmis-
sion housing (see Page 14-1741.
2. Assemble ths parts below on the mainshaft.
NOTE: Do not assemble the O-rings during inspec-
tlon.
LOCKNUTCONICAL SPRIIIG WASHER
SNAP RING
lST CLUTCH ASSEMBLY
TXRUST WASHER
1ST GEAR COLLAR
TRA SMISSIONHOUSII{G BEARING
THRUST WASHER
4TI{ GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST WASHER36.5 x 55 mmSelective part.
THBUST NEEDLEBEARING
2ND GEAR
AEABII{G
IHRUST NEEDLEBEARING
MAINSHAFT
3. Torque the mainshaft locknut to 29 N'm (3.0 kgf'm,
22 tbt,ftl.
NOTE: Mainshaft locknut has left-hand threads.
29 N'm t3.0 kgl'm, 22 lbt'ft)
Hold 2nd gear against the 2nd clutch' then measure
the clearance between 2nd gear and 3rd gear with a
feeler gauge.
NOTE: Take measurements in at least three places,
and use the av€rage as the actual clearance'
STANDARD: 0.05 - 0.13 mm 10.002 - 0.005 in)
THRUST WASHER,36.5 x 55 mm
(cont'd)
1+149

Mainshaft
Inspection (cont'd)
5.lf the clearance is out of tolerance, remove thethrust washer and measure the thickness.
THRUST WASHER
6. Select and install a new washer, then recheck.
THRUST WASHER 36.5 x 55 mm
After replacing the thrust washer, make sure theclearance is within tolerance.
7.
No.Part NumberThickness
190441 - P4P - 0104.00 mm (0.157 in)
90442-P4P-0104.05 mm (0.159 in)
90443-P4P-0104.10 mm (0.'161 in)
490444-P4P-0104.15 mm (0.163 in)
90445-P4P-0104.20 mm (0.165 in)
90446-P4P-0104.25 mm (0.167 in)
790447-P4P-0104.30 mm (0.169 in)
890448-P4P-0104.35 mm (0.171 in)
90449-P4P-0104.40 mm (0.173 in)
1090450-P4P-0004.45 mm (0.175 in)
b
14-150