1997 HONDA CIVIC Disc

14. Measure the clearance between the clutch end plate
and toD disc with a dial indicator, Zero th€ dial indica-
tor 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 toD disc.
NOTE: Take measurements in at least three places,
and use the average as the actual clearance.
Clutch End Plate-to-Top Disc Clesranc€:
STANDARD: 0.6 - 0.8 mm 10.024 - 0.031 inl
15. It the clearance is out of tolerance, select a new ciutch
end plate from the following table, then recheck.
NOIE: lf ihe thickest clutch end plate is installed but
the clearance is still over the standard, replace the
clutch discs and clutch Plates.
FORWARD CLUTCH END PLATE
After replacing the clutch end plate, make sure thal
the clearance is within tolerance.
16.
PTATE I{UMBEN
Plate No.Part NumberThickn€ss
1or1522561 - P4V - 0033.5 mm (0.138 in)
2or1622562 - P4V -OO33.6 mm (0.142 in)
3or1722563-P4V-0033.7 mm (0.146 in)
4or1822564 - P4V - 0033.8 mm (0.150 in)
5or192256s-P4V-0033.9 mm (0.154 in)
6ot2022566-P4V-0034.0 mm (0.157 in)
7 ot 2122567 -P4V -0034.1 mm (0.161 in)
8ot2222568-P4V-0034.2 mm (0.165 in)
9ot2322569-P4V-0034.3 mm {0.169 in)
10 or 2422570-P4V -OO34.4 mm (0.173 in)
'll or 2522571,P4V-0034.5 mm (0.177 in)
12 ot 2622572-P4V-OO34.6 mm (0.181 in)
13 ot 2722573-P4V -OO34.7 mm {0.185 in)
14-327

Transmission
Reassembly
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat all parts with CVT Fluid.
. Replace the following parts:- O-rings- Sealing rings- Sealing washers- Gaskets- Start clutch assembly and secondary drive gear assembly8 x 1.25 mm37 N.m {3.8 kgf.m,27 lbtftl
MANUAL VALVE
6x1.0mm12 N m 11.2 kgf.m,8.7 lbl.ft)
LINESREVERSE BRAKEEND PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLEBEARING
END COVEB
DOWELPIN
END COVER GASKET
6x1.0mm12 N.m 11.2 kgtm,8.7 lbtft)THRUST SHIM,25 x 31 mmSelective part
RING GEAR
THRUST WASHER
THRUSTBEARING
8 x 1.25 mm29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATEHOUSING ASSEMBLY
ROLI.IR
SNAPRINGeBH^cMANUALVALVEBOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGSTRANSMISSIONHOUSING GASKETSNAP RING
FORWARD CLUTCH
SNAP RING
SHAFTASSEMALY
DOWEL PtN
SPRING RETAINER/RETURN SPRINGASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14-338
SNAP RING RETAINERTRANSMISSION HOUSING

1.
7.
lnstall the ATF feed pipe in the transmission hous-
ing, and install the three ATF feed pipes with new
O-rings in the transmission housing,
Install the two dowel pins and new transmission hous-
ing gasket on the transmission housing.
Push the control shaft assembly toward the outside
of the transmission housing, then install the inter-
mediate housing assembly (four bolts).
lnstall the manual valve body separator plate and
the two dowel pins on the intermediate housing,
then install the rnanual valve body with the detent
spring (five bolts).
Put the control shaft assembly back, then install the
roller in the intermediate housing.
lnstall the reverse brake piston in the intermediate
housing.
Install the spring retainer/return spring assembly on
the reverse brake Piston.
NOTE: Installthe return springs on the spring guides
of the reverse brake piston securely
tnstall the special tool to compress the return spring
as shown.
REVERSE BRAKESPRING COMPRESSOR07TAE - P4V0110
6.
L
1
CAUTION: lf the spring retainer tab is on the reverse
brakc piston, the spring rstainer may be damaged'
Be sure the spring retainer tab is not on the piston'
rp
SPECIALTOOL REVERSEBRAKE
-^
14-339
10.
9.
14.
Compress the return springs, then install the snap
ring in the intermediate housing above the spring
retainer.
Verify that the snap ring end gap is correct'
Mini
/,,- '-t,,,,.
// \i/ ',r
'1 ,
.r' //'/. .-J?RINGSNAP
mum 15 mm 10.59 in)
Soak the reverse brake discs thoroughly in CVT
Fluid for minimum 30 minutes.
Installthe disc spring on the reverse brake piston'
Starting with a reverse brake plate, alternately
install the reverse brake plates and discs lnstall the
reverse brake end plate, and the snap ring'
Measure the clearance between the reverse brake
end plate and the top disc with a dial indicator' Zero
the dial indicator with a reverse brake end plate
lowered, and lift it up to the snap ring The distance
that the reverse brake and plate moves is the clear-
ance between the reverse end plate, and the top
disc.
NOTE: Take measurements in at least three places'
and use the average as the actual clearance'
STANDARD: 0.45 - 0.75 mm (0.018 - 0'030 in)
{cont'd)
11.
12.
13.

Transmission
16.
Reassembly (cont'dl
21.
17.
lf the clearance is not within the standard, remove thereverse brake end plate and measure its thickness.Select and install a new reverse brake end Dlate.then recheck.
NOTE: lf the thickest reverse brake end olate isinstalled, but the clearance is still over the standard,replace the reverse brake discs and plates.
REVERSE BRAKE END PLATE
After replacing the reverse brake end plate, makesure that the clearance is within the standard.Remove the snap ring, reverse brake end plate,
discs, plates. and disc spring.
Install the snap ring retainer on the drive pulley
shaft.
Wrap the drive pulley shaft splines with tape to pre-
vent damage to the O-rings, then install new O-n ngs.
Install the forward clutch assembly on the drive pul-
ley shaft, then installthe snap ring.
SITAP
O-RINGS
18.
19.
20.
SI{AP RIM;BETA EB
DRIVE PUI.IEYSHAFT
Plat6 No.Part NumberThickness
122551 - P4V - 0033.6 mm (0.142 in)
22552-P4V-0033.8 mm (0.150 in)
22553-P4V-0034.0 mm (0.157 in)
422554-P4V-0034.2 mm (0.165 in)
522555-P4V-0034.4 mm (0.173 in)
622556-P4V-0034.6 mm (0.181 in)
722557 -P4V -OO34.8 mm (0.189 in)
822558-P4V-0035.0 mm (0.200 in)
14-340
25. Installthe carrier assembly on the forward clutch.
22. Verity that the outside diameter ol the snap ring iscorrect.
SI{AP RIiIG
Install the input shaft and the sun gear as a subassemDry.
Install the th.ust needle bearing and the thrustwasher on the sun gear.
CARRIER ASSEMBLY
THFUST I'IEEDI!EEARIT{G
Msximum 41.4 mm 11.63 in)
IHruST

26. Install the thrust washer, the thrust needle bearing'
and the thrust washer on the carrier assembly'
SNAP RING
THRUST SHIM,
25x31 mm
Selective Pan
21.
24.
RING GEAR
THRUST NEEDLETHRUST WASHERS
EEARING
CARRIERASSEMBLY
lnstallthe ring gear and the 25 x 31 mm thrust shim,
then installthe snaP rrng.
Verify that the outside diameter of the snap ring is
correct,
Maximum 30.7 mm (1.21 in)
SNAP RING
Measure the clearance between the 25 x 31 mm
thrust shim and the snaP rlng.
STANDARD: O.O5 - 0.11 mm (0.0020 - 0.00'8 in)
NOTE: Take measurements in at least three places'
and use the average as the actual clearance
29.
,**r#*,".
'- t )
RING GEAR
14-341
30.
31.
lf the clearance is out of tolerance, remove the 25 x
31 mm thrust shim and measure its thickness'
Select and install a new 25 x 31 mm thrust shim.
then recheck.
THRUST SHIM, 25 x 31 mm
snap nng.RING
After replacing the 25 x 31 mm thrust shim, make
sure that the clearance is within tolerance and the
snap ring outside diameter is correct'
Install the disc spring in the direction shown'
Starting with a reverse brake plate, alternately
install the reverse brake plates and discs lnstall
selected reverse brake end plate, then install the
32.
33.
34.
REVERSEEND PLATE
BRAKE
Dtscs
SPRINGlnstall in this direction.
(cont'd)
REVERSEPI-ATES
No.Part Numb.lThickne*3
90451 - P4V - 0001.05 mm (0.041 in)
B90452-P4V-0001.12 mm (0.044 in)
c90453-P4V-000'1.19 mm (0.047 in)
D90454 - P4V - 000'l.26 mm (0.050 in)
90455-P4V-0001.33 mm (0.052 in)
F90456-P4V-0001.40 mm (0.055 in)
904s7-P4V-0001.47 mm (0.058 in)
90458-P4V-0001.54 mm (0.06'l in)
90459-P4V-000'1.61 mm (0.063 in)
J90460-P4V-0001.68 mm (0.066 inl
K90461-P4V-0001.75 mm (0.069 in)
90462-P4V-0001.82 mm (0.072 in)
M904a0-P4V-0001.085 mm (0.0427 in)
N90481-P4V-0001.155 mm (0.0454 in)
o901a2-P4V-0001.225 mm (0.0482 in)
90483-P4V-0001.295 mm (0.0510 in)
o90484-P4V-0001.365 mm (0.0537 in)
R904a5-P4V-0001.435 mm (0.0565 in)
90486-P4V-0001.5O5 mm (0,0593 in)
T90487-P4V-0001.575 mm (0.0620 in)
90488-P4V-00{)1.645 mm {0.0648 in)
90489-P4V-0001.715 mm (0.0675 in)
90490-P4V-0001.785 mm (0.0703 in)

Transmission
Gooler Flushing
@ To prevent iniury to face and eyes, alwayswear safety glasses or a tace shield when using thetransmission flusher.
NOTE: This procedure should be performed before rein-stalling the transmission.
'1. Check the tools and hoses for wear and cracks before
using. lf wear or cracks are found, reDlace the hoses
before using.
4.
Using the measuring cup. fill the tank with 2,1 ounces(approximately 2/3 full) of biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontatner.
Secure the flusher filler cap, and pressurize the tankwith compressed air to between 5S0 - 829 kpa (5.6 -
8.45 kgf/cm', 80 - 120 psi).
NOTE: The air line should be equipped with a watertrap to ensure a dry air system,
Hang the tool under the vehicle.
Attach the tank's discharge hose to the return lineoi 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 ofthe drain hose to abucket or floor drain,
t
TRANSMISSION COOLERFLUSHER{Commercially available)Kent-Moore J384O5-Aor oouivalent
TRANSMISSION
14-352
7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)
8. Turn on the flusher water valve so water will flowthrough the cooler for 10 seconds.
NOTE: lf water does not flow through the cooler, itis completely plugged, cannot be flushed, and mustbe replsced.
9. Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.
'10. While flushing with the water and flushing fluid fortwo minutes. turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgflcmr, 120 psi)
11. Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.
12. Release the trigger. and rinse the cooler with wateronly 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 airfor two full minutes or until no moisture is visibleleaving the drain hose.
CAUTION: Rosidual mobturo in the qooler or linescln damage the transmission,
15. Remove the flusher from the cooler line. Attach thedrain hose to a container.
16. Install the transmission. and leave the drain hoseattached to the cooler line.

l.
17.Make sure the transmission is in the E] position.
Fill the transmission with cvT Fluid, and run the
engine for 30 seconds or until approximately 0 95 {
(1.0 US qt.,0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the cooler
return hose to the transmission (see page 14-355)
Refill the transmission with CVT Fluid to the proper
level (see page 14-299).
18.
'19.
.l ,
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with water
and pressurize the can. Flush the discharge line to
ensure that the unit is clean.
2, lf discharge liquid does not foam, the orifice may be
blocked.
3. To clean, disconnect the plumbing from the tank at
the large couPling nut.
FILTER
\
\- 0--D
i
I
O.RING
Remove the in-line tilter from the discharge side and
clean if necessary'
The fluid orifice is located behind the filter. Clean it
with the pick stored in the bottom of the tank han-
dle. or blow it clean with air. Securely reassemble
all parts.
COUPLINGNUT
II
-@q
\ORIFICE
FILLER CAP
14-353

3. lnsert the inboard end of the driveshaft into the dif-
terential or intermediate shaft until the set ring
locks in the groove
NOTE: Clean the areas where the driveshaft contact
the transmission (differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINTReplace.
GROOVE
an
DIFFERENTIAL
lnstall the knuckie on the lower arm. then trghten
the castle nut and install a new cotter pin
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damago the ball ioint boot'
. Torque the castle nut to the lower torque sp€ci-
fication, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
CASTLE NUT12 x 1 .25 mm
COTTER PINReplace.On reassemblY,bend the cotter pinJi$ - 59 N.m 15.0 - 6.0 kgl m,35 - 43 lbf ftl
16-19
5. lnstall the damper tork over the driveshaft and onto
the lower arm. Install the damper in the damper
fork so the aligning tab is aligned with the slot in
the damPer fork.
FLANGE BOLTl0 r 1.25 mmrit N.m t4.a kgf.m, 32 lbf.ft) AIIGN|NG TAB
1.
SELF-LOGKING NUT12 x 1.25 mm6,1N.m 16.5 kgi.m, a7 lbfftl
Replace.
Loosely install the flange bolts and the new self-
locking nut.
Apply oil to the seating surface of the new spindle
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Install a new spindle nut, then tighten the nut'
9. Clean the mating surfaces ot the brake disc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
11. Refill the transmission with recommended fluid (see
section 13 or 14).'t2. Check the front wheel alignment and adjust if nec-
essary (see section 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgl'm, g) lbl ftl