1996 HONDA CIVIC plate

Transmission
Reasembly
NOTE;
. Coat all parts with ATF.. Beplace the following parts:- O-rings- Lock washers- Gaskets- Mainshaft and countershaft locknuts and conical spring washers- Sealing washers
TOROUE: l2 N.m (1.2 ksf'm,8.7 lbf.ft)
6 x 'l.0 mm7 BoltsFEED PIPE: A
LOCK.UP VALVEBODY
LOCK.UP SEPARATORPLATE
REGULATOR VALVEBODY
DOWEL PINS. 2
6xl.0mm1 BoltATF STRAINERATF FEEDPIPES:
a
COOIER RELIEF VALVE
TOROUE CONVENIERCHECK VALVESTATOR SHAFT
O.RING
STOP SHAFT
ATF FEEO PIPE: H
5x1.0mm5 Bolts
DOWEL PINS.
MAIN VALVE BODY
ATF PUMP
SERVO SEPARATORPLAYE
6x1.0mm7 Bolts
SERVO BODY
SECONOARYSEPARATOR PLATE
CONTROL
GEAR SHAFT
ATF PUMP DFIVENGEAR
MAIN SEPARATORPLATE
DOWEL PINS,
/ SHAFI
' -
7r(
t'se - oo ^od"t"t
lli
triTOROUE CONVERTERHOUSING
NOTE: The illustration shows the'96 - 98 modsls, the'99 - 00 models do not have the servo detent base; the servodetent is integralwith the servo bodv.
14-176
L-

1.Install the ATF magnet and suction pipe collar in the
torque converter housing. if necessary.
lnstall the main seDarator plate and the two dowel
pins on the torque converter housang.
Install the ATF pump drive gear, ATF pump driven
gear and ATF pump driven gear shaft on the torque
converter housing.
NOTE; Install the ATF pump driven gear with its
grooved and chamfered side tacing down.
ATF PUMP
ATF PUMP DRIVENGEAR SHAFT
ATF PUMPDRIVEN GEAR
Grooved and chamferedside taces separalorplate.MAIN SEPARATORPLATE
4.Loosely install the main valve body with five bolts.
Make sure the ATF pump drive gear rotates smoothly
in the normal operating direction and the ATF pump
driven gear shaft moves smoothly in the axial and
normal operating directions.
Install the secondary valve body, separator plate
and two dowel pins on the main valve body.
NOTE: Do not installthe bolts.
6. Install the control shaft in the housing with the con-
trol shaft and manual valve together.
7. lnstall the detent arm and arm shaft in the main
valve body, then hook the detent arm spring to the
detent arm,
SERVO SEPARATOR PLATE
DETENT
MANUAL VALVE
DETENT ARM SPRING
15.
14-177
a
10.
11.
Install the servo body and separator plate on the
secondary valve body ('95 - 98 models: seven bolts.'99 - 00 models: eight boltsl.
For '96 - 98 models: Install the servo detent base
and the ATF strainer (two boltsl.
For'99 - 00 models: Install the ATF strainer (one
bolt).
Tighten the five bolts on the main valve body to 12
N.m ('1.2 kgf.m,8.7 lbf.ft).
Make sure the ATF pump drive gear and ATF pump
driven gear shaft move smoothlY'
lf the ATF pump drive gsar and ATF pump driven
gear shaft do not move freely, loosen ths five bolts
on the main valve body, and disassemble the valve
bodies.
Realign the ATF pump driven gear shaft and reassem-
ble the valve bodies, then retighten the bolts to the
specified torque,
CAUTION: Fsilule to align tho ATF pump driven
goar shaft corr.ctly will rscuh in a s€ized ATF pump
drive goar or ATF pump d ven gear shaft.
Install the stator shaft and stop shaft.
Install the bolts and the shaft stop on the secondary
valve body, then tighten the bolts (three boltsl.
Install the torque converter check valve, cooler relief
valve and valve springs in the regulator valve body.
then install the regulator valve body on the main
valve bodv (one bolt).
Install the lock-up valve body on the regulator valve
bodv (seven bolts).
Install the ATF feed pipes in the main valve bodY,
the three ATF feed pipes in the secondary valve and
the four ATF feed pipes in the servo body. (cont'dl
12.
't 3.
14.
PUMP

Torque Converter/Drive plate
6x1.0mm12 N.m (1.2 kgt.m, 8.7 lbf.ft)
/
E PLATE
74 N.m 17.5 kgl.m, 54 lbf.ftlTorque in a ctisscaoss oattern.
@
@
L
14-182

Transmission
Installation (cont'dl
9. Attach the torque converter to the drive plate witheight drive plate bolts and torque as follows:Rotate the crankshaft pulley as necessary to tightenthe bolts to 1/2 of the specified torque. then to thefinal torque, in a crisscross pattern.
After tightening the last bolt, check that the crank-shaft rotates freely.
TOROUE: 12 N.m {1.2 kgl.m, 8.7 tbt{r}
10 x 1.25 mm
6x1.0mm12 N.m (1.2 kgt m,8.7 rbt ft)
I 1.25 mm2/t N.m {2.4 kg{.m,17 tbt ftlCONVERTEB
10. Install the torque convener cover and the €nginestiffener.'11. Tighten the crsnkshaft pull€y bolt, if necessary (see
section 61.
12. Connect the ATF cooler hoses to the ATF cooler lines(see page 1,t192).
ATF COOIIRUNE
10 x 1.25 mma,l N.m {4.5 kgl.m,33 rbt.fttRIGHT FRONT 12 x 1.25 mmMOUNT/BRACKET 6.t N.m (6.5 kg{.m,47 tbt ftl
13. Install the right front mounvbracket.
4,r N.m 14.5 kgf.m,33 lbtft)
COVER
L,
14-1A4
SHIFT CABLE
SHIFT CAAE COVER
14. Install the control lever with a new lock washer tothe control shaft, then install the shift cable cover.
CAUION: Taks care not to bend the shift cable.
L(rcK WASHERReplace.
8 x 1,25 r'|m22N-m12.2 tgt m. 16lbnftl
x 1.0 mmtit N.m 11.4 kgt m,10 tbr,ft,
15. lnstall the exhaust pipe A.
NOTE: D16Y8 engine is shown; D16y/ engine is sim_ilar.
Replace.
GASKETReplace.
SELF.LOCKING NUTReplace.10 x 1.25 mm54 N.m (5.5 lgf.m,40 tbt ftl
NUTSELF.LOCKING NUTReplace.8 x 1.25 mm22 N.m {2.2 kgl.m, 16lbtfrl
Replace.8 x 1.25 mm16 N.m {1.6 kgI.m,12 tbf.ft)

Shift Lever
PUSH KNOB SPRING
SILICONE GREASE
SCBEWN.m {0.3 kgtm.2 lbf ft)
Apply non-hardening thread lock sealant
SCREW3 N.m {0.3 kgif m,2 lblft)
GEAR POSITION INDICATOR PANEL
COVER
SHIFT LEVER ASSEMBLY
SHIFT INDICATOR
BUSHING
-61SILICONE GREASELEVERSHIFT LOCK
SCREW3 N.m {0.3
g
6x1.0mm9.8 N.m {1.0 kgf.m,7.2 tbt.ft)
A/T GEAR POSITION
PLATE
SHIFT LEVER BRACKET BASE
SHIFT LEVER
2/""*"
,.@* _.\__r.\
-Rt \ooru.r.,
A/T GEAR POSITION SWITCH
6x1.0mm9.8 N.m 11.0 kgf.m.7.2lbf.ft)
BASE COLLAA
14-191

Continuously Variable Transmission (CVTI
Special Tools ................ 14-194
Description .................... 14-195
Clutches/Reverse Brake/Planetary
Gear/Pulleys .......... 14-198
power Flow ..............,..... 14-200
Electronic Control SYstem(,96 - 98 Modets) ......14-203
Electronic Control System
('99 - oo Models) " 14-205
Hydraulic Control '....... 14-208
Hydraulic Flow .'..-.....'... '14-212
Park Mechanism .....-...'.' 14-222
Eleqtrical Systom
Component Locations'96 - 98 Models """"""' 14-224,99 - 00 Modets ............. 14-225
TCM Circuit Diagram ('96 - 98 Models) ............. 14-226
TCM Terminal Voltage/Measuring Condiiions ('96 - 98 Models) '.... 14-228
PcM Circuit Oiaqram{A/T Control System: '99 - 00 Models} ...--.... 14-230
PCM Terminal Voltage/Measuring Conditions('99 - 00 Models)
A/4 Control System .'.'...14-232
Troubleshooting Procedures ... . .... .....',........."' '14-234
Symptom-to-ComPonent Chart
Electrical System - '96 - 98 Models ......'..... '14-234
Electrical System -'99 - 00 Models ..'....-..-. '11-210
Electrical Troubleshooting
Troubleshooting Flowcharts('96 - 98 Models) """'11-242
Troubleshooting Flowchart
('99 - 0O Modets) ...... 14-265
Linear Solenoids/lnhibitor Solenoid
Test ......................... . ...... 14-29f
Drive Pulley/Driven Pulley/Secondary Gear
Shaft Speed Sensors
Replacement .........'...... .14-292
Start Clutch Control
Start Clutch Calibration Procedure ....... ....,. 14-293
Hydraulic SYstem
Symptom-to-ComPonent Chart
Hydraulic System '.'.......14-294
Road Test ............................ 14-296
Stall Speed
Test......................... ...... 14-294
Fluid Level
Checking/Changing ....... 14-299
Pressure Testing ................. 14-300
Lower Valve BodY AssemblY
Replacement ..........,... 14-302
ATF Filter
Removal/lnstallation ..... 14-303
Transmission
Transmission
Removal ........... . 14-304
lllustrated Index
Transmission/Lower Valve BodY
Assembly ................. 14-308
Transmission Housing/Flywheel Housing ... 14-310
End Cover/f ntermediate Housing ..........'.'.... 14-312
Transmission Housing/Lower Valve Body Assembly
Removal ..........'.... .. " 14-314
Transmission Housing/Flywhesl Housing
Removal ................. ........ 1+316
End Cover/lntermediate Housing
14-318Removal .........,...............
Manual Valve Body
Disassembly/lnspection/Reassemblv .'.'.'..... 1 4-320
Forward Clutch
lltustrated Index ........................................ 14-321
Disassemblv .................. 14-322
Reassemblv , ,, . ',','......14-324
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection ..'.'....-... 14-324
Differential
lllustrated lndex ...,.....................,.,...-.-.-...'... 14-329
Backlash Inspection .-....14-329
Bearing Replacement ......'........'....'... ....'... 14-330
Differential Carrier Replacement ........'........ 14-330
Oil Seal Removal ........... 14-331
Oil Seal Installation/Side Clearance ....... . . 14-331
Flywheel Housing Input Shaft Oil Seal
Replacement .....,.... ...'.'.. 14-333
Transmission Housing Bearings
Driven Pulley Shaft Bearing
Replacenient ...................'. . ...................'.. 14-334
Secondary Gear Shaft Bearing
Reolacbment ...................... . .......... . ........ 14-335
Flywheel Housing Beating
Secondary Gear Shaft BearingReo1acement..................,........................... 14-335
Ring Gear Bearing
Replacement......... ........ 14-336
Control Shaft Assembly
Removal/lnstallation ....................'........... 14-336
Transmission
Reassembly .................. 14-338
Flywheel/Drive Plate .. . ...... . ...... ... . ....-.....'.'...14-341
Transmission
lnstalation ..................... 14-348
Cooler Flushing .'......... 14-352
shift cable
Removal/lnstallation....'........." """ 14-354
Adjustment .......'........ 14-355
Shift Lever ........................,. 14'356
Shift Indicator Panel
Adjustment ................ 14-357
ATF Cooler/Hoses
lnsta llation ......,,...... .... 14-357

Description
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clulches/Reverse Brake
The CVT uses the hydraulically-actuated clutches and brake to engage or disengage the transmission gears. When
hydraulic pressure is introduced into the clutch drum and the reverse brake piston cavity, the clutch piston and the reverse
brake piston move. This presses the friction djscs and the steel plates together, locking them so they don't slip. Power is
then transmitted through the engaged clutch pack to its hub-mounted gear. and through engaged ring gear to pinion
gears.
Likewise, when the hydraulic pressure is bled from the clutch pack and the reverse brake piston cavity, the piston releases
the friction discs and the steel plates, and they are free to slide past each. This allows the gear to spin independently on its
shaft, transmitting no power.
Start Clutch
The start clutch, which is located at the end of the driven pulley shaft, engages/disengages the secondary drive gear.
The start clutch is supplied hydraulic pressure by its ATF feed pipes within the driven pulley shaft.
Forward Clutch
The forward clutch, which is located at the end of the drive pulley shaft, engages/disengages the sun gear.
The forward clutch is supplied hydraulic pressure by its ATF feed pipe within the drive pulley shaft.
Reverse Brake
The reverse brake, which is located inside the inte.mediate housing around the ring gear, locks the ring gear in E posi-
tion. The reverse brake discs are mounted to the ring gear and the reverse brake plates are mounted to the intermediate
housing. The reverse brake is supplied hydraulic pressure by a circuit connected to the internal hydraulic circuit.
Planetary Gear
The planetary gear consists of a sun gear, a carrier assembly, and a ring gear. The sun gear is connected to the input shaft
with splines. The pinion gears are mounted to the carrier which is mounted to the fo.ward clutch drum. The sun gear
inputs the engine power via the input shaft to the planetary gear, and the carrier outputs the engine power. The ring gear
is only used for switching the rotation direction of the pullev shafts,
In E. E, and E positions (forward range), the pinion gears don't rotate and revolve with the sun gear, so the carrier
rotates. In E] positjon {reverse range), the reverse brake locks the ring gear and the sun gear drives the pinion gears to
rotate. The pinion gears rotate and revolve in the opposite direction from the rotation direction of the sun gear, and the
carrier rotates with pinion gear revolution.
Pulleys
Each pulley consists of a movable face and a fixed face, and the effective pulley .atio changes with engine speed. The
drive pulley and the driven pulley are linked by the steel belt.
To achieve a low pulley ratio, high hydraulic pressure works on the movable face of the driven pulley and reduces the
effective diameter of the drive pulley. and a lower hydraulic pressure works on the movable face of the drive pulley to
eliminate the steel belt slippage. To achieve a high pulley ratio, high hydraulic pressure works on the movable face of the
drive pulley and reduces the eifective diameter of the driven pulley, and a lower hydraulic pressure works on the movable
face of the driven pulley to eliminate the steel belt slippage.
b
14-198

ATF PUMPDRIVEN SPROCKET
RING GEAR
FLYWHEEL
DRIVE PLATE
ATF PUMP
DRIVE PULLEYREVERSE BRAKEPISTON
FORWARD CLUTCH
BEVERSE BRAKE
CARRIER
RING GEAR
PLANETARYPINION GEARS
INPUT SHAFT
ATF PUMPDRIVE CHAIN
ATF PUMPDRIVE SPROCKET
START CLUTCH
DRIVEN PULLEY
STEEL BELT
SECONDARY DRIVE GEAR
PARK GEAR
DRIVEN PULLEYSHAFT
FINAL DRIVE GEAR
SECONDARY GEARSHAFT
a--
i___
il
14-199