1997 HONDA CIVIC Shaft

Reverse Shift Holder, Reverse ldler Gear
Clearance Inspection (cont'dl
3. Measure the clearance between the reverse
gear and the reverse shift holder.
Standard: 0.5 - 1.0 mm 10.02 - 0.04 inl
Service Limit: 1.8 mm (0.07 inl
id ler
lf the clearance is more than the service limit. mea,
sure the width of the reverse shift holder.
Standard: 13.0 - 13.3 mm (0.512 - 0.524 in)
lf the width is not within the standard, replace
the reverse shift holder with a new one.
lf the width is within the standard, replace the
reverse idler gear with a new one.
REVERSE SHIFT HOLDER
13-58
Removal
1. Remove the reverse shift holder.
Remove the reverse idler gear and the reverse idlergear shaft.
REVERSE SHIFT HOLDEB
REVERSEIDLER

UO
11. Measure the clearance between the select arm and
the change Piece.
Standard: 0.05 - O'25 mm 10'002 - 0'010 in)
Servica Limii: 0.5 mm {0.02 in)
lf the clearance is more than the service limit, mea-
sure the width of the change Plece.
Standard: 12.05 - 12.15 mm {0.47'|{ - 0 47tI| inl
CHANGE PIECE
lf the width is not within the standard, replace
the change Piece with a new one'
lf the width is within the standard, replace the
select arm with a new one.
't2.
a
a
SELECT ARM
Removal
1. Bemove the shift piece shaft. then remove the shift
piece and the interlock.
SHIFT PIECE SHAFT
INTERLOCK
2. Remove the change holder assembly'
13-61

Mainshaft, Countershaft, Shift Fork
Removal
1.Remove the mainshaft and the countershaft assem-
blies with the shift forks from the clutch housing.
NOTE: Tape the mainshaft spline before removing
the mainshaft and the countershaft assemblies.
Remove the spring washer and the washer'
v
MAINSHAFT
COUNTERSHAFT
Remove the differential assembly from the clutch
housing.
Tape the
splrnes.
WASHER
DIFF€RENTIAL ASSEMBLY
4. Remove the chamber Plate.
CLUTCH HOUSING
CHAMEEF PLATE
CLUTCH HOUSING
13-63

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub shouldbe replaced as a set.
1. Measure the clearance between each shift fork andits matching synchro sleeve.
Standard: 0.35 - 0.65 mm {O.Olit - 0.026 inlService Limit: 1.0 mm t0.04 inl
SHIFT FOBK
lf the clearance is more than the service limit. mea_sure the thickness of the shitt fork finoers.
Standard: 7.4 - 7.6 mm (0.291 - 0.299 in)
lf the thickness of the shift fork frngers rs notwithin the standard, replace the shift fork with anew one.
lf the thickness of the shift fork fingers is withinthe standard, replace the synchro sleeve with a
13-66
3. Measure the clearance between the shift piece andthe shift fork shafts.
Standard: 0.2 - 0.5 mm (0.008 - 0.02 inlService Limit: 0.8 mm {0.03 in)
lf the clearance is more than the service limit. mea-sure the width of the shift Diece.
Standard: 11.9 - 12.0 mm (0.469 - 0.it72 in)
lf the width of the shift piece is not within thestandard, replace the shift piece with a new one.lf the width of the shift piece is within the stan_dard, replace the shift fork with a new one.
t,
SHIFT PIECE

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
Clearance Inspection
NOTE: lf replacement is required, always reDlace thesynchro sleeve and the synchro hub as a set.
1. Measure the clearance between 2nd and 3rd oears,
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inlService Limit: 0.3 mm (0.01 inl
2. lf the clearance is more than the service limit, mea-sure the thickness of 3rd gear.
Standard: 34.92 - 3it.97 mm t1.375 - 1.377 intService Limit: 3,1.3 mm (1.350 inl
lf the thickness of 3rd gear is less than the ser-vice limit. replace 3rd gear with a new one.lf the thickness of 3rd gear is within the servicelimit, replace the 3rd/4th synchro hub with a newone.
Id

Mainshaft Assembly
Clearance Inspection (cont'dl
6. Measure the clearance between sth gear and
spacer collar.
Standard: 0.05 - 0.21 mm (0.002 - 0.008 inl
Service limit: 0.3 mm 10.012 inl
lf the clearance is more than the service limit, mea-
sure distance €) on the spacer collar.
Standard: 26.03 - 26.08 mm {1.025 - 1.027 inl
the
1.
5TH GEAB
\
8. lf distance (E is not within the standard, replace the
spacer collar with a new one.
lf distance @ is within the standard, measure the
thickness of 5th gear.
Standard: 31.12-31.47 mm {1.237 - 1.239 in}
Service Limit:31.3 mm {1.232 in)
lf the thickness of 5th gear is less than the ser-
vice limit, replace sth gear with a new one.
lf the thickness of 5th gear is within the servace
limit, replace the 5th synchro hub with a new
one.
u,a
5TH GEAR
3-70
SPACER COLLAB

Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEABING PULLER
BALL BEARING
CAUTION: Remove the synchro hubs using a ptess
and the sts€l blocks as shown. Use of a i8w'type
puller can cause damage to th€ gear teeth.
Support sth gear on steel blocks, and press the
mainshaft out of the sth synchro hub, as shown.
3. Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th svnchro hub, as shown.
13-71