1996 HONDA CIVIC Cvt

Transmission
Removal (cont'd)
10. Remove the cotte. pins and castle nuts, then separatethe ball joints from the lower arm (see section 1g).
SELF-LOCKING -=V,
NUT \Replace. oitupea rOax
Remove the right damper fork bolt, then separateright damper fork and damper.
Pry the right and left driveshafts out of the differen-tial.
Pull on the inboard joint to remove the right and leftdriveshafts (see section 16).
Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with cleanengine oil.
Remove the exhaust pipe A.
/\<,\CASTLE I{UT COTTERReplac6.
't 1.
't2.
tJ.
14.
q.
SELF.LOCKINGNUTReplace.
SELF.LOCKING NUTReplace.
14-306
EXHAUST PIPE A
19.
'16, Remove the right front mounvbracket,
ATF COOLER HOSE
17. Remove the ATF cooler hoses at the ATF coolerlines. Turn the ends of the ATF cooler hoses uo toprevent CVT fluid from flowing out, then plug theATF cooler hoses and lines,
NOTE: Check for any sign of leakage at the hosejoints.
18. Remove the engine stiffeners and the flywheel cover.
Remove the eight drive plate bolts one at time whilerotating the crankshaft pullev.
ENGINE STIFFENER

Manual Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Elow out all passages.. Coat all parts with CVT Fluid during assembly.
SPRING SEATREVERSE INHIBITORVALVE SPRING
REVERSE INHIBITORVALVE
MANUAL VALVE
MANUAL VALVE BODYInspect for wear, scratchesand sconng,
14-320

Forward Glutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleaner, and dry them with compressed air.
. Blow out all passages.
. Lubricate all parts with CW Fluid before reassembly.
1. Inspect the check valve; if it's loose, replace the pis-
ton.
CHECK VALVE
Install new O-rings on the clutch pision.
PISTON
14-324
3. Install the piston in the clutch drum. Apply pressure
and rotate to ensure proper seatang,
NOTE: Lubricate the piston O-ring with CVT Fluid
before installing.
CAUTION: Do not pinch thc O-ring by installing the
pistoo with too much torqo.
CLUTCH DRUM
Install the return spring and spring retainer, and
position the snap ring on the retainer.
CLUTCH DRUM

Transmission
Reassembly
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat all parts with CVT Fluid.
. Replace the following parts:- O-rings- Sealing rings- Sealing washers- Gaskets- Start clutch assembly and secondary drive gear assembly8 x 1.25 mm37 N.m {3.8 kgf.m,27 lbtftl
MANUAL VALVE
6x1.0mm12 N m 11.2 kgf.m,8.7 lbl.ft)
LINESREVERSE BRAKEEND PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
END COVEB
DOWELPIN
END COVER GASKET
6x1.0mm12 N.m 11.2 kgtm,8.7 lbtft)THRUST SHIM,25 x 31 mmSelective part
RING GEAR
THRUST WASHER
THRUSTBEARING
8 x 1.25 mm29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATEHOUSING ASSEMBLY
ROLI.IR
SNAPRINGeBH^cMANUALVALVEBOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGSTRANSMISSIONHOUSING GASKETSNAP RING
FORWARD CLUTCH
SNAP RING
SHAFTASSEMALY
DOWEL PtN
SPRING RETAINER/RETURN SPRINGASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14-338
SNAP RING RETAINERTRANSMISSION HOUSING

1.
7.
lnstall the ATF feed pipe in the transmission hous-
ing, and install the three ATF feed pipes with new
O-rings in the transmission housing,
Install the two dowel pins and new transmission hous-
ing gasket on the transmission housing.
Push the control shaft assembly toward the outside
of the transmission housing, then install the inter-
mediate housing assembly (four bolts).
lnstall the manual valve body separator plate and
the two dowel pins on the intermediate housing,
then install the rnanual valve body with the detent
spring (five bolts).
Put the control shaft assembly back, then install the
roller in the intermediate housing.
lnstall the reverse brake piston in the intermediate
housing.
Install the spring retainer/return spring assembly on
the reverse brake Piston.
NOTE: Installthe return springs on the spring guides
of the reverse brake piston securely
tnstall the special tool to compress the return spring
as shown.
REVERSE BRAKESPRING COMPRESSOR07TAE - P4V0110
6.
L
1
CAUTION: lf the spring retainer tab is on the reverse
brakc piston, the spring rstainer may be damaged'
Be sure the spring retainer tab is not on the piston'
rp
SPECIALTOOL REVERSEBRAKE
-^
14-339
10.
9.
14.
Compress the return springs, then install the snap
ring in the intermediate housing above the spring
retainer.
Verify that the snap ring end gap is correct'
Mini
/,,- '-t,,,,.
// \i/ ',r
'1 ,
.r' //'/. .-J?RINGSNAP
mum 15 mm 10.59 in)
Soak the reverse brake discs thoroughly in CVT
Fluid for minimum 30 minutes.
Installthe disc spring on the reverse brake piston'
Starting with a reverse brake plate, alternately
install the reverse brake plates and discs lnstall the
reverse brake end plate, and the snap ring'
Measure the clearance between the reverse brake
end plate and the top disc with a dial indicator' Zero
the dial indicator with a reverse brake end plate
lowered, and lift it up to the snap ring The distance
that the reverse brake and plate moves is the clear-
ance between the reverse end plate, and the top
disc.
NOTE: Take measurements in at least three places'
and use the average as the actual clearance'
STANDARD: 0.45 - 0.75 mm (0.018 - 0'030 in)
{cont'd)
11.
12.
13.

22. Install the shift cable end on the control lever, and
install the shift cable on the shift cable bracket'
CAUTION: Take care not to bend the shift cable'
23. lnstall the clip in the direction shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLEERACKET
WASHERIPLASTIC)
CONTROL LEVER
24, Connect the solenoid harness connector. the drive
pulley speed sensor connector. and the ground
cable terminals.
6x1.0mm12 N.m {1.2 kgf.m.8,7 rbtft)
GROUND CABLETERMINAL 6x1.0mm
GROUNDTERMINAL
12 N.m {1.2 kgf'm,8.7lbtfrl
DRIVE PULLEYSPEED SENSORCONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cable on the starter motor.
and install the cable holder.
NOTE: When installing the staner motor cable. make
sure that the crimped side of the ring terminal is
facing out (see section 23).
STARTEB
BMOUNTING NUT
9 N.m (0.9 kgf m,7 lbf ft)
26. Install all removed connectors and clamps'
27. Install the distributor.
28. Install the intake air duct and air cleaner housing
29.
assemDly.
Refill the transmission with the recommended
Genuine Honda CVT Fluid (see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
Connect the battery positive (+) terminal first, then
the negative (-l terminal to the battery'
Check the ignition timing (see section 23).
Start the engine. Set the parking brake, and shift the
transmission through all gears three times Check
shift cable adjustment (see page 14-355).
Check the front wheel alignment (see section 18)
Let the engine reach operating temperature (the
radiator fan comes on) with the transmission in lXl
or E position, then turn it off and check fluid level'
Perform the start clutch calibration procedure on
page 14-293.
Road test as described on pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351

l.
17.Make sure the transmission is in the E] position.
Fill the transmission with cvT Fluid, and run the
engine for 30 seconds or until approximately 0 95 {
(1.0 US qt.,0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the cooler
return hose to the transmission (see page 14-355)
Refill the transmission with CVT Fluid to the proper
level (see page 14-299).
18.
'19.
.l ,
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with water
and pressurize the can. Flush the discharge line to
ensure that the unit is clean.
2, lf discharge liquid does not foam, the orifice may be
blocked.
3. To clean, disconnect the plumbing from the tank at
the large couPling nut.
FILTER
\
\- 0--D
i
I
O.RING
Remove the in-line tilter from the discharge side and
clean if necessary'
The fluid orifice is located behind the filter. Clean it
with the pick stored in the bottom of the tank han-
dle. or blow it clean with air. Securely reassemble
all parts.
COUPLINGNUT
II
-@q
\ORIFICE
FILLER CAP
14-353

)
Brake Pedal
Pedal Height
1. Disconnect the brake switch connector, loosen the
brake switch locknut, and back off the brake switch
until it is no longer touching the brake pedal,
2. At the carpet cutout, measure the pedal height from
the right side center of the pedal pad.
PUSHRODLOCKNUT
Standard Pedal Height (with carpet removed):
M/T: 156.5 mm 16.16 inl
A/T, CVT: 161 mm (5 5/16 in)
3. Loosen the pushrod locknut, and screw the pushrod
in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten
the locknut firmly.
NOTE: Do not adiust the pedal height with the
Dushrod depressed.
It
PUSHROO LOCKNUT15 N.m(1.5 kgf.m. 11 lbI.ft)
POINT ICUTOUTI
4. Screw in the brake switch until its plunger is fully
depressed (threaded end touching the pad on the
pedal arm). Then back off the switch 1/4 turn to
make 0.3 mm (0.01 in) of clearance between the
threaded end and pad. Tighten the locknut firmly.
Connect the brake switch connector.
CAUTION: Make sure that the brake lights go off
when the pedal is released.
LOCKNUT
5. Check the brake pedal free play as described below.
Pedal Free Plsy
1. With the engine off, inspect the play on the pedal
pad by pushing the pedal by hand.
Free Play: 1 - 5 mm (1/16 - 3/16 inl
2. lf the pedal free play is out of specitication, adjust
the brake switch.
CAUTION: lf the pedal free play is insufficient, it
may result in brake drag.
BRAKE PEDAL PAO
)
19-5
*0.3 mm(0.01 in)