1996 HONDA CIVIC Air

Driveshafts
Reassembly
U.S. and Canada-Producad Driv€shafts
Note these items during reassembly'
. Clean the disassembled parts with solvent, and dry them thoroughly with compressed air, Do not wash the rubberpans with solvent.
o ;..jl@l : Thoroughly pack the inboard joint and both joint boots with the joint grease included in the new driveshaft
ser,
Grease quantity:
lnboard Joint115 - 135 g (4.0 - 4.8 oz)
Outboard Joint115 - 135 g (4.0 - 4.8 oz)
. The'98 Canada model and all '99 - 00 models uses a TPE (Thermoplastic Polyester Elastomerl outboard joint boot. Use
the ear clamp type boot band in the outboard joint boot set.
STOP RING('96 - 98 models)
-6rPack cavity with grease.
DYNAMIC DAMPER
OOUBI.S LOOP BANDReplace.
INBOARD BOOT
-6lPack cavity with grease.
EAB CLAMP BANDReplace.
STOP RINGReplace.
EAR CLAMP BANDReplace.
DRIVESHAFT
OUTBOARDBOOT ITPE)
-6ll
, Pack cavity with grease.
EAR CLAMP BANDReplace.
-G.1
CIRCLIP
16-8
OUTBOARD JOINT

Driveshafts
Reassembly (cont'dl
Japan-Produced Driveshafts
Note these items during reassembly.
. Clean the disassembled pans with solvent, and dry them thoroughly with compressed air. Do not wash the rubber
parts with solvent.
o r@l : Thoroughly pack the inboard joint and both joint boots with the joint grease included in the new driveshaft
set.
Grease quantity:
Inboard Joint
1600 DOHC WEC engine130 - 140 9 (4.6 - 4.9 oz)
Except 1600 DOHC VTEC engine110 - 120 g (3.9 - 4.2 oz)
Splines (Al0.5 - 1.0 g (0.018 - 0.035 oz)
Outboard Joint
'1600 DOHC WEC engineRubber boot 90 - 'l 00 g (3.2 - 3.5 oz)TPE boot; 105 - 115 9 (3.7 - 4.1 oz)
Except 1600 DOHC VTEC engineRubber boot 70 - 80 g |'2.5 - 2.8 ozlTPE boot 95 - 105 g (3.4 - 3.7 oz)
{1600 DOHC VTEC angine)
SET RINGReplace.
-6{@INBOARD BOOT
-6;Pack cavity with grease.
Pack cavity with grease.
DYNAMIC DAMPER
DYNAMICReplace.
DOUA|.I Lq)P BANDReplace.
(Rubber typc)LOOP BANDReplace.
Pack cavity with grease-
CLAMP BAND
],*"u, ,"^S
/ t'.t$ ,''
,/s
-'-
OUTBOARD BOOTIRUEBER)
16-10
tttt t*' -----_.r...-
._
Replace.

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl

Disassembly
Press the intermediate shaft out of the shaft bearing
using the special tools and a press as shown.
Remove the internal circliP
Press
I
SUPPORT BASEATTACHMENT07JAF - SH20400INTERNAL CIBCLIP
BEARING SUPPORT RING
Check for damage or distortion
6. Press the intermediate shaft bearing out ot the bear-
ing support using the special tools and a press as
shown.
HANOLE DRIVER
0?749 - 00'10000
Press
I
DRIVER ATTACHMENT,12x47 mm07746 - 0010300FLOATING RUBBEB
DAMPERCheck for deterioration
and oamage.SUPPORT BASE
ATTACHMENT07JAF _ SH20it00
BEARING SUPPORT
Check for damage
I sErR'NG
A4 Reolace
VUOUTER SEALReplace.(cont'd)
ReassemblY
NOTE:
. clean the disassembted parts with solvent, and dry them thoroughly with compressed air' Do not wash the rubber
parts with solvent.
. Becareful not to da mage the metal ringson the intermediate shaftduring reassembly'
BEARING SUPPORT RINGDOWEL BOLTS10 x 1.25 mm39 N.m 14.0 kgf.m,29 lbIftl
EXTERNAL CIRCLIP
Pack the interiorof the outer seal.2.0-35s10.07-012oz)
INTERNAL CIRCLIP
INTERMEDTATE SHAFT BEARING
Replace,
INTERMEDIATE SHAFT RING
lJ
16-21

lnstallation
1. lnsert the intermediate shaft assembly into the dif-
ferential.
CAUTION: Hold the intermodiate shaft horizontal
to prevent damag€ to the difterential oil seal'
NOTE: Clean the areas where the intermediate shaft
contacts the transmission (differential) thoroughly
with solvent or carburetor cleaner, and dry with com-
Dressed air,
2. Install the three dowel bolts, then tighten them'
DOWEL BOLTS10 x 1.25 mm39 N.m {i1.0 kgf'm, 29 lbf'ftl
lz
16-23

Component Locations
tlndex
Manual Steering
NOTE:
. lf an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged dur-
ing transit. storage or service, it should be deployed (see section 24)'
o Before removing the gearbox, remove the driver's airbag assembly and steering wheel
. After insta lling the gearbox, check the wheel alignmentand adjust if necessary
SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS
section 124) before performing repairs or service'
STEERING WHEELRemoval/lnstallation, Page 17'35
Disassembly/FeassemblY, page 17-36
DRIVER'S AIRBAG ASSEMBLY
Removal/lnstallation, see section 24
STEERING COLUMNRemoval/lnstallation, Page 17-37
Inspection, page 17'38
CABLE REELRemoval/lnstallation, see section 24
IGNTTION SWITCH
See section 23
STEERING GEARBOXRack Guide Adiustment, Page 17-5
Removai, page 17'5Disassembly, Page 17_7Reassembly, page 17_9Installation, page 17 13TIE.ROD END BALL JOINT
Ball Joint Boot Replacement, page 17-68
J
t,
17-3

Steering Gearbox
l.r
Rack Guide Adjustment
NOTE: Perform the rack guide adjustment with the
wheels in the straight ahead position.
1. Loosen the rack guide screw locknut with the spe-
cial tool, then loosen the rack guide screw.
LOCKNUT WRENCH, 40 mm07916 - SA5000r
Tighten the rack guide screw until it compresses the
spring and seats against the rack guide, then loosen
rt.
Retighten the rack guide screw to 4 N'm (0.4 kgf m,
2.9 lbf.ft), then back it off to specified angle.
Specilied Return Angle: 30' max.
Tighten the locknut while holding the rack guide
Check for tight or loose steering through the com-
plete turning travel.
Recheck steering effort (see page 17-4).
4.
RACK GUIDE SCREW
l,z
Removal
NOTE: Using solvent and a brush, to wash any oil and
dirt off the gearbox. Blow dry with compressed air.
1. Raise the front of vehicle, and support it on satety
stands in the proper locations (see section I ).
2. Remove the front wheels.
3. Remove the steering wheel (see page 17-35).
4. Remove the steering loint cover
Remove the steering joint lower bolt, and discon-
nect the steering joint by moving the joint toward
the column.
(cont'd)
17-5
STEERING JOINT COVER
LOWER BOLT
STEERING JOINT

Reassembly
NOTE:
. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip the rubber parts in solvent.
. Alwavs replace the non reuseable parts with new ones before assembly
. Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
-6,1
PINION OUST SEALReplace.RACK ENO BUSHING
\
^lr
r@
-6i
GEARBOX MOUNTING CUSHIONS
V."^pR,NG,3smm
tr
a/
^$'q0

")*o''o"'"'*
DISC WASHER
RACK GUIDE
(cont'd)
17-9
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