1996 HONDA CIVIC fork

S4C Model ('99 - 00 2-door Si, SiR)
Manual Transmission
Special Tools ............' 13-46
Maintenance
Transmission Oi1 ...................'.......... 13-47
Back-up Light Switch
Repfacement ...""" 13'47
Transmission Assembly
Removal ......'.......... 13-/tB
lnstallation ............. 13-52
lllustrated lndex ................................... 13-54
Transmission Housing
Removal ................. 13-55
Beverse Shift Holder, Reverse ldler Gear
Clearance lnspection ...................".. 13-57
Removal ................. 13-58
Change Holder Assembly
Clearance lnspection .................".... 13-59
Removal ....,,........... 13-61
Disassembly/Reassembly ............... 1 3-62
Mainshaft, Countershaft, Shift Fork
Removal ................. 13-63
Shift Rod
Removal .........."'.... 13-64
Shift Fork Assembly
lndex ................ ...... 13-65
Clearance lnspection .............'......... 13'66
Mainshaft Assembly
lndex ............"" ...... 13-67
Clearance lnspection ....................... 13-68
Disassembly .......... 13-71
fnspection '."'.......', 13'72
Reassembly .......'... 13-73
Countershaft Assembly
fndex ................ "....13-71
Glearance Inspection'......'...........'... 1 3'75
Disassembly .......... 13-76
fnspection .'............13'77
Reassembly "......... 13'78
Synchro Sleeve, Synchro Hub
Inspection .............. 13'8C
Installation ............. 13-80
Synchro Ring, Gear
Inspection .'............ 13-81
Differential
lndex ................ ...... 13-82
Backlash Inspection ..."..........."'...... 1 3-82
Final Driven Gear Replacement ...... 13-83
Bearing Replacement ....."'.......""'.. 13-83
Thrust Shim Adiustment ......""'..... 13-84
Clutch Housing Bearing
Replacement ..'...... 13-86
Mainshaft Thrust Glearance
Adiustment '.........'. 13-88
Transmission
Reassembly ."'....... 13-91
Oil Seals
Replacement ..'...... 13-96
Gearshift Mechanism
Overhaul ................ 13-97
\

9. Remove the three upper transmission mounting
bolts and lower starter motor mounting bolt.
'10. Remove the engine splash shieid.
TRANSMISSIONMOUNTINGBOLTS12 x 1.25 mm
6,1 N.m (6.5 kgd m, 47 lbf'ft|
STARTERMOTORMOUNTINGBOLT10 x 1.25 mm
a,t N.m 14.5 kgl.m.
33 tbf.trl
CONNECTOE
11. Disconnect the heated oxygen sensor (HO2S) con-
nector, then remove exhaust pip€ A.
H02S
SELF.LOCKING NUTReplace.8 r 1.25 mm16 N.m (1.6 kgf.m, 12lbf'ft)
Replace.10 x 1,25 mm54 N.m {5.5 kgf.m,'lll lbf.ft)
12. Remove the cotter pins and loosen the castle nuts,
then separate the ball joints from the lower arm
(see section 18).
13. Remove the right damPer fork.
10 x 1.25 mma3 N.m lil.a kgf.m, 32 lbf'ft| ,
SELF.LOCKING NUTR6place.12 x 1.25 mm6a N.m (6.5 kgl.m,47 rbf ft)
RIGHTDAMPERFORK
CASTI.T NUT12 x 1,25 mma9 - 59 N.m (5.0 - 6.0 kgtm,36 - i(t lbf.ftl
(cont'd)
!-
ria -11: \/-/
't'''-a
SPLASH SHIELD
13-49

Transmission Assembly
lnstallation
Install the transmission assembly in the reverse order of
removal.
. Before installing, check that the two dowel pins are
installed in the clutch housing.
. When installing the starter cable. make sure that the
crimped side of the ring terminal is facing out (see
section 23).
. Apply grease to the parts as shown, then install the
release fork and release bearing.
NOTE; Use only Super High Temp Urea Grease(P/N 08798 -9002).
RELEASE FORK BOLT29 N.m 13.0 kgf.m,22 tbllrl
(P/N 08798 - 9rD2l
-R1
tP/N 08798 -
13-52
CLIP
L f ;
Torque the mounting bolt and nuts in the sequence
shown.
Check that the busings are not twisted or offset.
@ t2 x 1.25 mm6,t N.m 16.5 kgtm,47 lbf.ft)O t2 x 1.25 mm6,r N.m (6.s kg{.m,17 tbf.ft)
O 12 x 1.25 mm7ilNm17.5kgf.m,5it lbt ft)
I
Install the alip and the spring pin on the change joint
as snown.
Turn the shift rod boot so the hole is facing down as
snown.
Make sure the shift rod boot is installed on the changerod.
CHANGE ROO
FL.- SPRING PINll heptace,
8 mm PINPUNCH
/ "*,*
lo,iD(
CHANGE ./EXTENSfoN ( ^ st
l?rffi
l\K

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

Mainshaft, Countershaft, Shift Fork
Removal
1.Remove the mainshaft and the countershaft assem-
blies with the shift forks from the clutch housing.
NOTE: Tape the mainshaft spline before removing
the mainshaft and the countershaft assemblies.
Remove the spring washer and the washer'
v
MAINSHAFT
COUNTERSHAFT
Remove the differential assembly from the clutch
housing.
Tape the
splrnes.
WASHER
DIFF€RENTIAL ASSEMBLY
4. Remove the chamber Plate.
CLUTCH HOUSING
CHAMEEF PLATE
CLUTCH HOUSING
13-63

Shift Fork AssemblY
lndex
-A erior ro reassemblinq. clean all the parts in solvent, dry them and apply lubricant to any contact pans
I
mm PIN PUNCH
sTH/REVERSESI{IFT FORK
3RD/4TH SHIFT FORK

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub shouldbe replaced as a set.
1. Measure the clearance between each shift fork andits matching synchro sleeve.
Standard: 0.35 - 0.65 mm {O.Olit - 0.026 inlService Limit: 1.0 mm t0.04 inl
SHIFT FOBK
lf the clearance is more than the service limit. mea_sure the thickness of the shitt fork finoers.
Standard: 7.4 - 7.6 mm (0.291 - 0.299 in)
lf the thickness of the shift fork frngers rs notwithin the standard, replace the shift fork with anew one.
lf the thickness of the shift fork fingers is withinthe standard, replace the synchro sleeve with a
13-66
3. Measure the clearance between the shift piece andthe shift fork shafts.
Standard: 0.2 - 0.5 mm (0.008 - 0.02 inlService Limit: 0.8 mm {0.03 in)
lf the clearance is more than the service limit. mea-sure the width of the shift Diece.
Standard: 11.9 - 12.0 mm (0.469 - 0.it72 in)
lf the width of the shift piece is not within thestandard, replace the shift piece with a new one.lf the width of the shift piece is within the stan_dard, replace the shift fork with a new one.
t,
SHIFT PIECE

Transmission
ReassemblY
1. Install the new oil seal
2. Set the change Piece.
3. Install the shift rod
4. Install the steel ball' the spring, and the set screw'
5. Install the spring washer and change piece attach-
ing bolt.
6. Install the shift rod boots.
8x1.0mm31 N.m 13.1 kg-m,22lb-ltl
CHANGEPIECE
@:4OIL SEALReplace.SPRINGWASHER
7. Install the oil chamber Plate'
6 x '1.0 mm12 N.m (1.2 kg-m,9lb-ft|
SPRING
, /L.256fim B()(
@ / t't o'ti"l I
{zw"y-6@
q
10.
Set the spring washer and the washer'
lnstall the mainshaft, the countershaft, and the shift
fork assemblies.
NOTE: Align the finger of the interlock with the
groove in the shift fork shaft.
SHIFT FORKS
13-91