1997 HONDA CIVIC Face

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.
l0 mm SH|M
I
,o mm wAsHEF
t/
@@d.
r]7| 3 x 16 mm SpRtNGI Replace.
R€TURN SPRING
SELECT ARM
13-62

Mainshaft AssemblY
lndex
Note the follow
. The 3rd/4th and the 5th synchro hubs are installed with a press
. Install the angular ballbearing with the thin-edged cuter race facing the stop rrng'
Priorto reassembling. clean all the parts in solvent,drythem, and apply lu brica nt to any contact su rfaces The
3rd/4th and the sth synchro hubs, however, should be installed with a press before lubricating them'
ANGULAR BALL BEARING
Inspect lor wear
and operation.Note the drrectlonoI installatton.
v
SYNCHROSPRING
3RO/4TH SYNCHRO HUB
3RD GEARInspection,page 13-68,81
3RO/4TH SYNCHRO SLEEVE
SYNCHROSPRING
STOP RING
TAPER RING
NEEOLE EEARINGInspect for wearand operation.
SPACER
SYNCHRO RINGInspection.page 13-81
SYNCHROSPRING
SYNCHRO HUB
5TH/REVERSESYNCHRO SLE€VE
SYNCHEOSPRING
Inspection,page 13-81
NEEDLE BEARING
and operation.
SYNCHRO RINGInspection,page 13 8'1
GEARInspeclron,page 13-70,81
NEEDLE BEARINGInspect Ior wear
and operation.COLLAB
4TH GEARInspection,page 13'69,81
13-67

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.
t
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

t
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage, then measure the counter-
shaft at points A, B, and C. lf any parts of the coun-
tershaft are less than the service limit. reDlace coun-
torshaft with a new one.
Standard:
A: 2/t.980 - 2{.993 mm (0.9835 - 0.9&O in}
B: 35.984 - 37.000 mm {1.4561 - 1.4567 in)
G: 33.fiD - 33.015 mm {1.2992 - 1.2998 in)
Sorvicc Limit:
Ar 2/t.9't0 mm 10.9819 inl
B: 36.930 mm {1.'l5qt in}
C: 32.950 mm {1.2972 in}
Insp€ct for wear
Inspect oil passage for clogging.
13-77
2. Insoect for runout. lf the runout is more than the
service limit, reolace the countershaft with a new
one.
Strndard: 0.02 mm {0.(x)08 in) max.
Servic. Limit 0.05 mm (0.002 in)
NOTE: SuoDort th€ countershaft at both ends as
shown.
Rotate lwo complelerevotutons.

Synchro Ring, Gear
Inspection
'1. Inspect the synchro ring and gear.
A: Inspect the inside of the synchro ring for wear'
B: Inspect the synchro sleeve teeth and matching
teeth on the synchro ring for wear (rounded off).
oo
GOOD WORN
C: Inspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
nn
UUGOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
F: Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks'
2. Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear. Rotate the
ring, making sure that it does not slip
Measure the clearance between the synchro ring
and gear allthe way around.
NOTE: Hold the synchro ring against the gear even-
ly while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.73 - 1.18 mm
(0.029 - 0.0'16 in)
Ssrvice Limit:0.,0 mm {0.02 in}
Double Cone Synchro-to-Geal Clearanc€
Standald:
@: (Outer Synchro Ring to Synchro Con6l
0.5 - 1.0 mm 10.02 - 0.04 in)
@: (Synchro cone to Gearl
0.5 - 1.0 mm (0.02 - 0.04 inl
O: {Outer Synchlo Ring to Gear)
0.95 - 1.68 mm (0.037 - 0.066 in)
Service Limit:
@: 0.3 mm {0.01 in}
@: 0.3 mm {0.01 in)
O: 0.6 mm t0'02 inl
lf the clearance is less than the service limit, replace
the synchro ring and sYnchro cone.
SYNCHRO SPRING
SYNCHRO RING
t
SYNCHRO CONE
13-81

rla
Final Driven Gear Replacement
'1. Remove the bolts in a crisscross pattern in several
steps, and remove the final driven gear from the dif-
ferential carrier.
NOTE: The final driven gear bolts have left-hand
threads,
12 x 1.0 mm101 N.m {'10.3 kgf.m,74.5 lbf.ftlLeft hand
FINAL DRIVEN GEARChamfer on inside daameter offinal driven gear faces carrier.
2. Install the final driven gear by tightening the bolts
in a crisscross pattern in several steps.NOTE: Drive the bearings squarely until they bot-
tom against the carrier.
BALL BEARING
13-83
Bearing Replacement
NOTE: Check the ball bearings for wear and rough rota-
tion. lf bearings are OK, removal is not necessary.
1. Remove the ball bearings using a standard bearing
puller and bearing separator as shown.
BEARING PULLER
BEARING SEPARATOR
lCommerciallyavailab16)
BALL BEARING
2. Install new ball bearings using the special tool as
shown.

Differential
Thrust Shim Adjustment
1. Install the differential assembly, making sure it bot
toms in the clutch housing, using the special tool as
shown.
ORIVER, 40 mm LO.o7746-0030100
lnstall the 80 mm shim.
NOTE: lnstall the 80 mm shim that was removed.
mm SHIM
13-84
(
4.
Install the transmission housing (see page 13-94).
NOTE: Do not apply liquid gasket to the mating sur-
face of the clutch housing.
Tighten the transmission housing attaching bolts(see page 13-94).
I x 1.25 mm
27 N'm (2.8 kgf.m, 20 lbf.ftl
Use the special tool to bottom the differential assem.
bly in the clutch housing.
Measure clearance between the 80 mm shim and
bearing outer race in the transmission housing.