1997 HONDA CIVIC Disc

Clutch
Disassembly
1.Remove the snap ring. then remove the clutch endplate, clutch discs and plates.
SCREWDRIVER
SNAP RING
2. Remove the disc spring.
NOTE: Except 2nd clutch.
1CLUTCI{ DRUM
DISC SPRING
L
14-160
3. Installthe special tools as shown.
CLUTCHCOMPRESSORAOLT ASSEMBLY07GAE - PG4tt200olO'GAE - FG4O2OA
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE -PX40,t 00
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX()100o107HAE - P150100
CLUTCH SPRINGCOMPRESSORATTACIIMENToTLAE-PX40100
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - Px/Ol00ot07HAE - PLs0100
CLUTCHCOMPRESSORBOLT ASSEMBLY07GAE - PG/O200
OTGAE - PG4O2OA

Glutch
Reassembly (cont'd)
7. Installthe snap ring.
Removs the special tools.
Install the disc spring.
NOTE: Install the disc spring in the direction
shown, except 2nd clutch.
SNAP RING
8.
o
14-164
h
10.
ll.
Soak the clutch discs thoroughly in ATF for a mini-
mum of 30 minutes.
Starting with a clutch plate, alternately install the
clutch plates and discs. Install the clutch end plate
with flat side toward the disc.
NOTE: Before installing the plates and discs, make
sure the inside of the clutch drum is free of din orother foreign mafter.
CLUTCH END PLATEInstall in this direcrion.
12. Installthe snap ring.
SCREWDRIVER
SNAP RING

13. Measure the clearance between the clutch end plate
and top disc with a dial indicator' Zero the dial indi-
cator with the clutch end plate lowered and lift it up
to the snap ring. The distance that the clutch end
plate moves is the clearance between the clutch end
plate and top disc.
NOTE| Take measurements in at least three places,
and use the average as the actual clearance.
Clutch End Plste-to-Top Disc Clearance:
OIAL INDICATOR
CLUTCH ENDPLATEClearance
14.
CLUTCH DISC
lf the clearance is not within the service limits,
select a new clutch end plate from the following
table.
NOTE: lf the thickest clutch end plate is installed,
but the clearance is still over the standard, replace
the clutch discs and clutch plates.
PLATE NUMBERThickn6ss
ClutchSerYice Limit
1st
2nd
3rd
4th
0.65 - 0.85 mm (0.026 - 0.033 in)
0.65 - 0.85 mm (0.026 - 0.033 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
CLUTCH ENO PLATE
14-165
Plate No.Part NumberThickness
,l
2
J
4
5
6
1
8q
22551 - P4R - 003
22552-P4R-003
22553-P4R-003
22554-P4R-003
22555-P4R-003
22556-P4R-003
22557 -P4B-OO3
22558-P4R-003
22559-P4R-003
2.1 mm (0.083 in)
2.2 mm (0.087 in)
2.3 mm (0.091 in)
2.4 mm (0.094 in)
2.5 mm (0.098 in)
2.6 mm (0.102 in)
2.7 mm {0.106 in)
2.8 mm {0.110 in)
2,9 mm (0.1 '14 in)
CLUTCH END PLATE
A4RA, g4RA Transmission:
M,IRA Transmi$ion:
15. After replacing the clutch end plate. make sure that
the clearance is within tolerance.
Plate No.Part NumberThickness
1
3
'l
.'q
10
11't2
13
14
15'16
17
18
22551 - PCg - 000
22552-PCg-000
22553-PCg-000
22554-PCg-000
22555-PCg-000
22555-PCg-000
22557-PCg-000
22558-PCg-000
22559-PCg-000
22560-PCg-000
22561 - PCg - 000
22562-PCg-000
22563-PCg-000
22574 - P4V - 003
22561 - P4V - 003
22562- P4V - 003
22563-P4V-003
22564-P4V-003
2.4 mm (0.094 in)
2.5 mm (0.098 in)
2.6 mm {0.102 in)
2.7 mm (0.106 in)
2.8 mm (0.110 in)
2.9 mm (0.114 in)
3.0 mm {0.118 in)
3.1 mm (0.122 in)
3.2 mm (0.126 in)
3.3 mm (0.130 in)
2.1 mm (0.082 in)
2.2 mm {0.086 in)
2.3 mm (0.090 in)
3.4 mm (0.134 in)
3.5 mm (0.138 in)
3.6 mm (0.142 in)
3.7 mm (0.146 in)
3.8 mm (0.150 in)

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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Transmission
17.
Cooler Flushing (cont'dl
Make sure the transmission is in the E position.
Fill the transmission with ATF, and run the enginefor 30 seconds or until approximately 0.95 f (1.0 USqt.,0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the coolerreturn hose to the transmission (see page l4-192).
Refill the transmission with ATF to the oroDer level(see page 14-118).
18.
19.
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14-18A
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with waterand pressurize the can. Flush the discharge line toensure that the unit is clean.
2. lf discharge liquid does not foam, the orifice may beblocked.
3. To clean, disconnect the plumbing from the tank atthe large coupling nut.
ORIFICE
GRT{G
Remove the in-line filter from the discharge side andclean if necessary.
The fluid orifice is tocated behind the filter.Clean it with the pick stored in the bottom of thetank handle, or blow it clean with air. Securelvreassemble all Darts.
FILLER CAP

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

Description
Hydraulic Flow (cont'd)
lll position, when th€ electronic control system is fauhy.
when the electronic control svstem (linear solenoids and sensors) is faulty, the transmission uses the pitot pipe pressure(PP) to 311o- rh" u"hicle to drive.
when all linear solenoids and sensors are off because of a faulty electronrc control system, clutch reducing pressure (cR)flows to the start clutch control valve, the manual valve, the PH-PL control valve, and the shift control valve. clutch reduc-ing pressure (cR) becomes shift varve pressure (sV) at the shift contror varve, and shift varve pressure {sv) is appried tothe left end of the shift valve and the right end of the shift inhibitor valve. The shift valve moves to the right side. anduncovers the pon that leads high pressure (PH) to the drive pulley and uncovers the po.t tlr"t r""1" ro,,"-pressure (pL) tothe driven pulley At this time, the pulley ratio is high, The shift inhibitor valve moves to the left side, and uncovers theport that leads shift inhibitor pressure (Sll to the pitot lubrication pipe and the pitot regulator valve. tne prtot lubricationpipe discharges fluid inside of the pitot flange, and discharged fluid enters into the pitot pipe and it is applied to the leftend of the pitot regulator valve. The pitot regulator valve moves lo the right side, and uncovers the port that leads pitotregulator pressure (PR) to the shift inhibitor valve. Pitot regulator pressure {pR) becomes start clutch pressure {sc1 at theshift inhibitor valve, and is applied to the stan clutch. The stan clutch rs engaged. The forward clutch pressure (FWD) isapplied to the forward crutch, and the forward crutch is engaged. This alows the vehicre to drive.
NOTE: When used. "|eft" or ,,right', indicates direction on the hydraulic circuit.
14-220
I.