1997 HONDA CIVIC Face

Transmission
Removal
@Maks sure lifts, iacks and safety stands are placedproperly, and hoist bracket ate aftached to the cor_rec{ position on the engine lsee section 1).Apply parking brake and block rear whoels so vehiclewill not roll off stands and fall on you while workingunder it.
CAUTION: Use tender covers to avoid damaging paint-ed surfaces.
1, Disconnect the battery negative (_) terminal fromthe battery, then remove the positive (+) terminal.
2. Remove the intake air duct.
D16Y7 engins:
Remove the intake air duct and resonator.
D16Y8 engine:
Remove the intake air duct and the air cleaner hous-ing assembly,
3. Remove the starter cables and cable holder fromthe starter motor.
MOTOR CABLE
MOTOR CABLE
14-122
4. Remove the transmission ground cable, and discon_nect the lock-up control solenoid connector.
LOCK.UP CONTROLSOLENOID CONNECTOR
5, Disconnect the vehicle speed sensor (VSS) connec_tor and the countershaft speed sensor connector.
VEHICLE SPEED

Transmission
Removal(cont'd)
'10. Remove the cotter pins and castle nuts, th€n separatethe balljoints from the lower arms (see section 1gl.
DAMPER PINCH BOLT
NUT
FORI(FORK BOLT
11. Remove the right damper fork bolt. th€nright damper fork and dampor.
COTTER PINReplace.
separate
12.
1a
14.
Pry the right and left driveshafts out ofthe differential.
Pull on the inboard joint to remove the right and leftdrivsshafts (see section 16).
Tie plastic bags over the driveshaft onds.
NOTE: Coat all precision finished surfaces with cleanengine oil.
Remove the exhaust pipe A,
NOTE: Dl6YB engine is shown; D16y7 engine issimilar.
t9.
SELF-LOCKING NUTReplace.
L
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EXHAUST PIPE AMOUNT/BRACKET
17.
18.
16. Remove the shift cable cover. then remove the shiftcable by removing the control lever,
CAUTION: Take car6 not to bond the shift cable.
Remove the right front mounvbracket.
Remove the ATF cooler hoses at the ATF coolerlines. Tufn the ends of the ATF cooler hoses uo toprevent ATF from flowing out, then plug the ATFcooler hosgs and lines.
NOTE: Check for any sign of leakage at the hoseioints.
WASHER

Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubricate all parts with ATF during reassembly..Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O_rings.. Locknut has left-hand threads.
LOCKNUT {FLANGE NUTI21 x 1.25 mm78 N.m (8.0 kgl.m,58 lbt.fttReplace.Left-hand threadsSNAP RINGCONICAL SPRING WASHERReolace.
lST CLUTCHASSEMBLYTHRUST WASHER
THRUST NEEOI.EBEARING
4TH GEAN
O-RINGSReplace.
THRUST WASHER
THRUST NEEDLEBEARING
MAINSHAFTCheck splines for excessivewear and oamage.Check bearing surtace for scoring,scratches and excessive wear.
BEARINGBEARINGS
THRUST NEEDLEBEABING
4TH GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST NEEDLEEEARING
2NO GEAB
NEEDLE BEABING
THRUST NEEDLEBEARING
1ST GEAR
1ST GEARCOLLAR
TRANSMISSIONHOUSING BEARING
O-RINGSReplace.
THRUST WASHER, 36.5 x 55 mmSelective part.
SEALING RINGS,35 mm
Install the sealing ringmating faces as shown,
RING,29 mm
NEEDLE BEARING
SET RING
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Countershaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricate all parts with ATF before reassembly'
. tnrp"",,n",t -"t needle bearings and the needle bearings for galling and rough movement'
. Before installing the O-rings. wrap the shaft splines with tape to prevent damaging the O-rings
. Locknut has left-hand threads
LOCKNUT (FLANGE NUT}
23 x 1.25 mm103 N.m
{10.5 kgf'm, 75.9 lbf'tt)
Replace.Left'handlhreads
CONTCAL SPRING
WASHERReplace.
GEAR
CLUTCH
1ST GEAR
BEARING
lST GEAR COLLAR
TRANSMISSIONHOUSING BEARING
REVERSE GEAR
NEEDLEBEARING
SELECTOR
SELECTOR
4TH GEAR
NEEDLE BEARING
DISTANCE COLLAS,
28 mmSelective pa .
COUNYERSHAFTCheck splines lor excesslve
wear and damage
2'{D GEAR
THRUST NEEDLEBEARING
3RD GEAB
NEEDLE BEARING
3RD GEAR COLLAR
THRUST NEEDLE EEARING
SPLINEO WASHER
3RD CLUTCH ASSEMBLY
Check bearing surface for scoring'
scratches and excessive wear'
Replace.
1+151

Cooler Flushing
!!!@ To prevent iniury to. face and eyas, always
-ea. safetv glasses ot a face shield when using the
transmission flusher.
NOTE: This procedure should be performed before rein-
stalling the transmission.
1. Check the tool and hoses for wear and cracks before
using. lf wear or cracks are found, replace the hoses
before using.
Using the measuring cup, fill the tank with 2'l ounces
(approximately 2/3 full) of biodegradable flushing
fluid (J35944 - 20). Do not substitute with any other
fluid. Follow the handling procedure on the fluid
contarner.
Secure the flusher filler cap, and pressurize the tank
with compressed air to between 550 - 829 kpa (5 6 -
8.45 kgflcm'. 80 - 120Psi).
NOTE: The air line should be equipped with a water
trap to ensure a dry air system.
Hang the tool under the vehicle.
Attach the tank's discharge hose to the return line
of the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-
mission cooler using a clamP
IMPORTANT:
Securely clamp the opposite end oJ the drain hose to a
bucket or floor drain.
TRAMtssroN
TRANSMISSION COOLERFLUSHER{Commcrci.llY avail.blel
Kent-Moore J384O5'Aor equivelent
NS
I
{r Water
7. With the water and air valves off, attach the water and
air suDolies to the flusher' lHot water if available.)
8, Turn on the flusher water valve so water will flow
through the cooler for 10 seconds.
NOTE; lf water does not tlow through the cooler, it
is completely plugged. cannot be flushed, and must
be replaced.
9. Depress the trigger to mix the flushing fluid into the
water flow. Use the wire clip to hold the trigger down'
While flushing with the water and flushing fluid for
two minutes, turn the air valve on for five seconds
everv 15 - 20 seconds to create a surging action'
AIR PRESSURE: MAX 845 kpa {8.45 kgf/cm', 120 psi)
Turn the water valve off. Release the trigger, then
reverse the hoses to the cooler so you can flush in
the opposite direction. Repeat steps 8 through 10'
12, Release the trigger, and rinse the cooler with water
onlv for one minute
13. Turn the water valve off, and turn off the water supply
14. Turn the air valve on to dry the system out with air
for two full minutes or until no moisture is visible
leaving the drain hose.
CAUTION: Residual mobturo in tho cooler or pipas
can damage the transmksion'
15. Remove the flusher from the cooler line. Attach the
drain hose to a contalner.
16. Install the transmission, and leave the drain hose
attached to the cooler line
{cont'd)
10.
'11.
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Description
The Continuously Variable Transmission (CVT) is an electronically controlled automatic transmission with drive and driv
en Oullevs, and a steel belt. The CVT provides non stage speeds forward and one reverse. The entire unit is positioned in
line with the engine.
Transmission
Around the outside of the flywheel is a ring gear which meshes with the starter pinion when the engine is being staned.
The transmission has four parallel shafts: the input shaft, the drive pulley shaft. the driven pulley shaft, and the secondary
gear shaft. The input shaft is in line with the engine crankshaft. The drive pulley shaft and the driven pulley shaft consist of
movable and fixed face pulleys. Both pulleys are linked by the steel belt.
The input shaft includes the sun gear. The drive pulley shaft includes the forward clutch which mounts the carrier assem-
bly on the forward clutch drum. The carrier assembly includes the pinion gears which mesh with the sun gear and the ring
gear. The ring gear has a hub-mounted reverse brake disc.
The driven pulley shaft includes the start clutch and the secondary drive gear which is integral with the park gear' The sec-
ondary gear shaft is positioned between the secondary drive gear and the final driven gear. The secondary gear shaft
includes the secondary driven gear which serves to change the rotation direction. because the drive pulley shaft and the
driven oullev shaft rotate the same direction. When certain combinations of planetary gears in the transmission are
engaged by the clutches and the reverse brake, power is transmitted from the drive pulley shaft to the driven pulley shaft
to provide E, E, E, and El.
Electronic Control'96 - 98 Models:
The electronic control system consists of the Transmission Control Module (TCM), sensors, three linear solenoids, and a
inhibitor solenoid. Shifting is electronically controlled under all conditions'
The TCM is located below the dashboard, behind the kick panel on the driver's side.'99 - 00 Models:
The electronic control svstem consists of a Powertrain Control Module (PCM), sensors, three linear solenoids and an
inhibitor solenoid. Shifting is electronically controlled under all conditions. A Grade Logic Control System to control shift-
ing in E position while the vehicle is ascending or descending a slope.
The PCM is located below the dashboard, under the kick panel on the passenger's side.
Hydraulic Control
The lower valve body assembly includes the main valve body, the Pressure Low (PL) reguiator valve body, the shift valve
body, the start clutch control valve body, and the secondary valve body. They are positioned on the lower part of the
transmission housing.
The main valve body contains the Pressure High (PH) control valve, the lubrication valve, and the pitot regulator valve.
The secondary valve body contains the PH regulator valve, the clutch reducing valve, the start clutch valve accumulator,
and the shift inhibitor valve. The PL regulator valve body contains the PL regulator valve and the PH-PL control valve
which is ioined to the PH,PL control linear solenoid. The inhibitor solenoid valve is bolted on the PL regulator valve body.
The shift valve body contains the shift valve and the shift control valve. which is joined to the shift control linear solenoid.
The start clutch control valve body contains the start clutch control valve, which is joined to the start clutch control linear
solenoid. The linear solenoids and the inhibitor solenoid are controlled by the TCM or PCM. The manual valve body which
contains the manual valve and the reverse inhibitor valve, is bolted on the intermediate housing.
The ATF pump assembly is located on the transmission housing, and is linked with the input shaft by the sprockets and
the sprocket chain. The pulleys and the clutch receive fluid from their respective feed pipes, and the reverse brake receives
fluid from internal hydraulic circuit.
Shift Control Mechanism
Input from various sensors located throughout the vehicle determines which linear solenoid the TCM or PCM will activate.
Activating the shift control linear solenoid changes the shift control valve pressure, causing the shift valve to move. This
pressurizes the drive pulley pressure to the drive pulley and the driven pulley pressure to the driven pulley and changes
their effective pulley ratio. Activating the start clutch control linear solenoid moves the start clutch control valve. The start
clutch control valve uncovers the port, providing pressure to the start clutch to engage it(cont'd)
14-195
,!

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

E, E, and E Positions {Forward Rangel
. Sta rt Clutch: engaged
. Forward Clutch: engaged
o Reverse Brake: released
1, The hydraulic pressure is applied to the forward clutch and the start clutch, and the sun gear drives the torward
clutch.
2. The torward clutch drives the drive pulleV shaft. which drives the driven pulley shaft linked by the steel belt.
3, The driven pulley shaft drives the secondary drive gear, via the start clutch.
4. Power is transmitted to the secondary driven gear, which drives the final driven gear.
NOTE: The working hydraulic pressure on the movable face of each shaft depends on the throttle opening position.
DRIVE PULI.f YFLYWHEELSTEEL AELT
CLUTCH
INPUT SHAFT
START CLUTCH
SECONDARY DRIVENGEAR
(cont'd)
FINAL DRIVEN GEAR
14-201