1996 HONDA CIVIC replace

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.
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r]7| 3 x 16 mm SpRtNGI Replace.
R€TURN SPRING
SELECT ARM
13-62

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.
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SHIFT PIECE

Mainshaft Assembly
Clearance Inspection
NOTE: lf replacement is required, always reDlace thesynchro sleeve and the synchro hub as a set.
1. Measure the clearance between 2nd and 3rd oears,
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inlService Limit: 0.3 mm (0.01 inl
2. lf the clearance is more than the service limit, mea-sure the thickness of 3rd gear.
Standard: 34.92 - 3it.97 mm t1.375 - 1.377 intService Limit: 3,1.3 mm (1.350 inl
lf the thickness of 3rd gear is less than the ser-vice limit. replace 3rd gear with a new one.lf the thickness of 3rd gear is within the servicelimit, replace the 3rd/4th synchro hub with a newone.
Id

3. Measure the clearance between 4th gear and the
spacer collar.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inl
Servic€ Limit: 0.3 mm (0.01 inl
It the clearance is more than the service limit, mea-
sure distance @ on the spacer collar
Standard: 26.03 - 26.08 mm {1.025 - 1.027 in}
4TH GEARSIDE
SPACER COLLAE
5. lf distance @ is not within the standard. replace the
spacer collar with a new one. lf distance O is within
the standard. measure the thickness of 4th gear'
Standard: 31.12-31'17 mm {1.237 - 1.239 inl
Service Limh:31.3 mm (1.232 in)
lf the thickness of 4th gear is less than the ser-
vice llmit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one,
(cont'd)
13-69

Mainshaft Assembly
Clearance Inspection (cont'dl
6. Measure the clearance between sth gear and
spacer collar.
Standard: 0.05 - 0.21 mm (0.002 - 0.008 inl
Service limit: 0.3 mm 10.012 inl
lf the clearance is more than the service limit, mea-
sure distance €) on the spacer collar.
Standard: 26.03 - 26.08 mm {1.025 - 1.027 inl
the
1.
5TH GEAB
\
8. lf distance (E is not within the standard, replace the
spacer collar with a new one.
lf distance @ is within the standard, measure the
thickness of 5th gear.
Standard: 31.12-31.47 mm {1.237 - 1.239 in}
Service Limit:31.3 mm {1.232 in)
lf the thickness of 5th gear is less than the ser-
vice limit, replace sth gear with a new one.
lf the thickness of 5th gear is within the servace
limit, replace the 5th synchro hub with a new
one.
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5TH GEAR
3-70
SPACER COLLAB

Mainshaft Assembly
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage. then measure the mainshaft
at points A, B, and C. lf any parts of the mainshaft
are less than the service limit, reDlace mainshaft
with a new one.
Standard:
A: 27.987 - 28.000 mm {1.1018 - 1.1024 in}
B: 37.98i1 - 38.fi)0 mm (1.,|!t5,0 - 1.4960 inl
Ci27.977 - 27.990 mm 11.1015 - 1.1020 inl
Service Limit:
A; 27.940 mm {1.1000 in}
B: 37.930 mm (1./{133 in)
C:27.930 mm (1.0996 inl
(
2. Inspect for runout. lf the runout is more than the
service limit, replace the mainshaft with a new one,
Standard: 0.02 mm 10.0008 inl max.
Ssrvice Limit: 0.05 mm 10.002 inl
NOTE: Suooort the mainshaft at both ends as
shown.
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Inspect for wearano oamage.
Inspect oil passages tor clogging.
13-72

Gountershaft Assembly
Index
DAMPER
ST GEARInspection, page 13-75
EALL EEARING
and operation.
NEEDLE BEARINGlnspect for wearano operaton.
5TH GEAR
4TH GEAR
3RD GEAR
NOTE:
3
The 4th and sth gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4thand 5th gears. however, should be installed with a press before lubricating them.
REVERSE GEAR
LOCKNUT Replace108"0-108N.m
i11.0 - 0- l1.0kgtm,180-0-80lbttr
WASHER
DISTANCECOLLAR
COUNTERSHAFTInspection, page 13-77
NEEDLE BEARING
and operatron,
Inspection, page 13-75
NEEDLE BEARING
ano operatron,
SPACER
FRICTION DAMPER
DOUBLE CONE
Inspection, page 13 81
SYNCHRO SPRING
13-74

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Clearance Inspection
1. Measure the clearance between the 1st gear and
distance collar.
Standard: 0,045 - 0.205 mm
10.002 - 0.008 in)
Service Limit: 0.25 mm (0.01 inl
2. lf the clearance exceeds the service limit. measure
the thicknesses of 1st gear.
lST GEAR
Standard: 29.45 - 29.50 mm {1.159 - 1.161 in}
DISTANCE COLLAR
Standard:@ 36.5 mm (1.4i1in)
@ ,12.0 mm (1.65 in)
@ 30.0 mm (1.18 in)
lf the thicknesses of 1st gear and distance collar
are less than the standard, replace with a new
one.
lf the thicknesses of 1st gear and distance collar
are within the standard, replace the lsv2nd syn-
chro hub with a new one.
3. Measure the clearance between
gears.
Standard: 0.07 - 0.14 mm
(0.003 - 0.006 inl
Servico Limii: 0.24 mm (0.009 in)
the 2nd and 3rd
3RD GEAR
2ND GEAR
4. lf the clearance exceeds the service limit, measure
the thicknesses of znd gear and spacer.
2ND GEAR
Standard: 28.92 - 28.97 mm (1.139 - 1.1't1 inl
'-.
ll-=Jl
71 il
SPACER COLLAR
Standard: 29.07 - 29.09 mm {1.1it4 - 1.1,15 inl
lf the thicknesses of 2nd gear and spacer are less
than the standard, replace with a new one.
lf the thicknesses of 2nd gear and spacer are
within the standard, replace the lsv2nd synchro
hub with a new one.
13-75