1996 HONDA CIVIC tools

Clutch Disc
RemovaUlnspection
2.
'1. Remove the clutch disc and special tools.
CLUTCH
CLUTCH ALIGNMENT SHAFToTJAF-pM7012A xltori07936-3710100
Inspect lining of the clutch disc for signs of slipping
or oil. lf it is burned black or oil soaked, replace it.
Measure the clutch disc thickness.
Clulch Disc Thickness:
Standard (Now): 8.5 - 9.1 mm (0.33 - 0.36 in)
Servic€ Limit: 5.5 mm (0.22 inl
CLUTCH
lf the thickness is less than the service limit. .eolacethe clutch disc.
12-8
U
4. Measure the depth from the lining surface to therivets, on both sides.
Rivet Depth:
Standard lNewl: 1.3 - 1.9 mm {0.05 - 0.07 in} min.
Service Limit: 0.2 mm (0.01 in)
lf the depth is less than the service limit, replace the
clutch disc.
CLUTCH DISC

FlywheelClutch Disc, Pressure Plate
Replacement (cont'dl
4. Drive the new ball bearing into the flywheel using
the special tools as shown.
DRIVER07749-0010000
ATTACHMENT,32x35mm07746-OOIOTOO
FLYWHEEL
BEARING
Align the hole in the flywheel with the crankshaft
dowel pin and install the flywheel. Install the
mounting bolts finger-ti9ht.
Install special tool, then torque the flywheel mount-
ing bolts in a crisscross pattern in several steps as
snown.
5.
6.
MOUNTING BOLTS118 N.m (12.0 kgl.m,87 tbf.ft)
RING GEAR HOLDER07LAB-PV00100ol07924 -PO20003
WVa// ,
12-10
Installation
1. Install the special tool.
Y
07936-3710r00
{P/N 08798-90021
RING GEAR HOLDER07LAB-PVOO100ot07924-PD20003
CLUTCH ALIGNMENT SHAFTOTJAF_PM7012A
2.
3.
Installthe clutch disc using the special tools.
Install the pressure plate.
RING GEAR HOLDERoTLAB PV00'l OO
07924 PD20003
OTJAF_PM70124HANOLE07936-3710100
CLUTCH DISC

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S40 Model (All except'99 - 00 2-door Si' SiR)
Manual Transmission
Special Tools ..'.......... 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Troubleshooting '....... 13-4
Transmission AssemblY
Removal ................. 13-5
lnstallation ............. 13-8
lllustrated Index ...............'........."........ 13-10
Transmission Housing
I Removaf .."""""""' 13-12
J R"rr"r"" Shift Holder
Clearance lnspection ....................... 13-13
Reverse ldler Gear
Removal ....'.........." 13-14
Mainshaft, Countershaft, Shift Fork
Disassembly ......'... 13-14
Mainshaft AcsemblY
Index ............... ....... 13-15
Clearance Inspection ..'.................... 13-16
Disassembly .......... 13-17
Inspection ....'......... 13-18
Reassembly ........... 13-19
Countershaft AssemblY
lndex ................ ...... 13-20
Clearance lnspection ."..........'......." 13-21
Disassembly ..."""' 13-22
Inspection .............. 13-23
Reassembly ..'.""... 13-23
Shift Fork AssemblY
lndex ............... ."'... 13-25
Clearance lnspection ."......."........'.. 13'26
MBS Shift Piece Inspection ....-.....'.. 13'27
Synchro Sleeve, Synchro Hub
f nspection/lnstallation .......'...... ".... 13'27
Synchro Ring, Gear
Inspection '....'..".... 13'28
Shift Rod
Removal .'......".""" 13'29
Differential
lndex ......."'...... .'."' 13-30
Backlash Inspection ..........."......."... 13-30
Bearing Beplacement'.............'.".... 13'31
Final Driven Gear Replacement '..... 13-31
Thrust Shim Adiustment ..."........... 13-32
Clutch Housing Bearing
Replacement .......'. 13-34
Mainshaft Thrust Shim
Adiustment '....'..".. 13-36
Transmission
Reassembly ........... 13-39
Oil Seals
Replacement ......... 13-43
Gearshift Mechanism
Overhaul ................ 13-44
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Special Tools
Ref. No. I Tool NumbetDescription(Xy I Page Reference
o
@
o.@
!'5,
@
o
@6
@
@
@(3
OTGAJ PG2O11O
OTGAJ PG2012O
07GAJ - PG20130
07736 - A010004
07746 - 0010300
07746 - 0010400
07746 - 0030100
07746 - 0030300
07746 - 0030400
07749 - 0010000
07JAD - PH80101
07JAD - PH80200
07947 - 6110501 or
07947 - 6110500
Mainshaft Holder
Co lla r
Mainshaft Base
Adjustable Bearing Puller, 25 - 40 mm
Attachment. 42 x 47 mm
Attachment,52 x 55 mm
Driver, 40 mm LD.
Attachment, 30 mm I.D.
Attachment, 3S mm LD.
Driver
Driver Attachment
Pilot. 26 x 30 mm
Seal Driver Attachment
1 13-38
1 13-37
1 I 13-37
1 13-34,35
1 13-34.35
1 13-34,35
1 | 13-19,24
31,32
1 13-19,24
1 13-19,24
r I t3-34,35, 43
1 13-43
1 13,43
1 I 13-43
* Must be used with commercially-available 3/8"-j6 Slide Hammer.
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o
ly tr
IvI

I
)r'
Reassembly
CAUTION: When installing the 3rd/4th and 5th synchro
hubs, support th€ shaft on steel blocks, and insiall the
synchro hubs using a press.
NOTE: Refer to page 13-15 for reassembly sequence.
1. Support 2nd gear on steel blocks' then install the
3rd/4th synchro hub using the special tools and a
oress.
ATTACHMENT,35 mm LO.07746-OO3O/+OO
' ,2I{D GEAR
Install the 3rd/4th synchro sleeve by aligning the
stops of the 3rdl4th synchro sleeve and hub.
NOTE; After installing, check the operation of the
3rd/4th svnchro hub set
SYf{CHRO SLEEVE
3. Install the sth
ano a press.
synchro hub using the special tools
DRIV€R, 40 mm I O.
07746 -0030'100
ATTACHMENT,30 mm l.D.07746 -O030300
sTH SYNCHRO HU8
Install the ball bearing in the direction shown using
the special tools and a Press.
DRIVER, iO mm l.D.
07746 - lxxlollx'
ATTAGHMENT, 30 mm l.D.
077i16 - 00303qt
BAI-L BEARING
Ball cage faces uP
*1: D16Yt engane*2: Dl6Y5, D16Y8 6ngines
13-19

Countershaft Assembly
Reassembly (cont'd)
4. Suppon the countershaft on a steel block as shownand install 3rd gear using the special tools and apress.
PRESS
35 mm l.o.07746-0030400
5. Install 4th gear using the special tools and a press.
DRlvER. 40 mm
DRIVER, 40 mm LO.07746 -0030100
ATTACHMENT,
07746- 0030100
ATTACHMENT,
DRIVER, 40 mm l.D.07746-0030100
ATTACHMENT,30 mm l.D.
35 mm LO.07746-0030400
6. Install 5th gear using the special tools and a Dress.
07746-00303005TI{ GEAR
.g
7. Install the bearings in the direction shown using thesDecialtools and a oress.
CAUTION: Install ths bearings with a maximumpressure ot 7.8 kN {800 kgt, 5,786 lbfl.
ATTACHMENT,30 mm l.D.07745 - q'303tl)
*1: 016Y7 engine*2: D16Y5, D16Y8 enginesThin edge of outerrace faces down,
8. Securely clamp the countershaft assemblv in
bench vise with wood blocks.
LOCKNUT
108+0r108N.m(11.0 * 0 - 11.0 kgt m. 79.6 - 0 * 79.6 tbf.ft)
Install the spring washer, tighten the locknut, thenstake the locknut tab into groove.
/rt-\
srySnap ring
lacss up.
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Clutch Housing Bearing
Replacement
Mainshaft
1. Remove the ball
shown.
bearing using the special tool as
3i8 " -16 SLIDE HAMMER(Commercially available)
ADJUSTAELE BEARINGPULLER, 25-40 mm07736-AO10004
2, Remove the oil seal from the clutch housing,
CLUTCH
Replace.
13-34
l.
3, Drive the new oil seal into the clutch housing usingthe specialtools as shown.
ATTACI{MENT, 42 x 47 mm07746 -0010300
CLUTCHHOUSING
Drive the ball bearing into the clutch housing usingthe special tools as shown.
ATTACHMENT, 52 x 55 mm DRIVER07746 001040007749-0010000
t./
07749 -0010000

Cou ntershaft
1. Remove the needle bearing using the special tool as
shown. then remove the oil guide plate
3/g " -16 SLIDE HAMMER
{Commercially available)
PULLER, 25-40 mm07736-AO1000A
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2. Install the oil guide Plate, then
bearing into the clutch housing
tools as shown.
d rive the needle
using the special
'1: ATTACHMENT, 42 x 47 mm
07746-0010300*2: ATTACHMENT, 52 x 55 mm
07746 -0010400
ORIVER07749 -0010000
CLUTCHHOUSING
NEEOLE BEAFING
GUIDE PLATE
NEEOLE BEARING
*1: D16Y7 enqine*2: D16Y5, D16Y8 engines
OIL GUIDE PTATE
13-35