1997 HONDA CIVIC parts

Inspection
1.surfaces lor
countershaftInspect the gear surfaces and bearang
wear and damage, then measure tne
at points A, B, and C.
Standard: A: 30.000 - 30.015 mm
(1.1811- 1.1817 inl
B: 35.984 - 36.000 mm
(1.i1167 - 1.4173 inl
C: 24.980 - 2i1.993 mm
{0.9835 - 0.9840 in)
Seryice Limit: A: 29.950 mm (1.1791 inl
B: 35.930 mm (1 '1146 in)
C: 24.930 mm 10.9815 in)
Check oil passages
for cloggrng-
ICheck for wearano oamage.
. lf any part of the countershaft is less than
service limit, replace it with a new one.
Inspect for runout.
Standard: 0.02 mm (0.001 inl max.
Seryice Limit: 0.05 mm {0'002 in)
. lf the runout is more than the service limit. replace
the countershaft with a new one.
the
2.
t,3. Install the parts on the countershait
Reassembly
CAUTION:
. Press the 3rd,4th, and sth gears on the countershaft
without lubrication.
. When installing the 3rd. 4th, and 5th geals, support
the shaft on steel blocks and installthe gears using a
pless.
NOTE: Reler to page 13-20 for reassembly sequence'
1. lnstall the needle bearing on the countershaft'
, 36x41 x 25.5mmNEEDLE BEARING
COUNTERSHAFT
2. Assemble the pans below as shown.
NOTE: Check that the fingers of the friction damper
are securely set in the grooves of the 1sv2nd syn-
chro hub.
2ND GEAR
39x/+4x27mmNEEDLE BEARING
SPACER COLLAR
FRICTION DAMPER
SYNCHRO RING
SYNCHRO SPRING
REVERSE GEAR
lST/2NOSYNCHRO HUB
SYNCHRO SPRING
SYNCHRO RING
FRICTION DAMPER
1ST GEAR
(cont'd)
13-23

Shift Fork AssemblY
lndex
I
I erio, ,o reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts'
3RD/4TH SHIFT FORK
5THi REVERSESHIFT FORK
5TH/REVERSESHIFT PIECE
M8S SHIFTPIECE
3RD/4THSHIFT PIECE
1ST/2ND SHIFT FORK
\a
13-25

Gearshift Mechanism
Overhaul
NOTE:
.Inspectrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts.
. Install the clip as shown.
. Turn the boot so the hole is facing down as shown.. Make sure the boot is installed on the shift rod.
SHIFT LEVER KNOE7.8 N.m {0.8 kgf.m,5.8 lbt.tt)
EXTENSIONBOLT
)
searr'p)) p f*** \-ii,,l?'"
SHIFT -Vvvvvvvvvvvvvvvvl tlourur Replace. | 1 22 N'm 12.2 ksf'm, 16 lbt.ftl
ii,".i'----....-.9 / g-ia',rf,',,"' sELF-LocKrNG Nur
sEAr '6 .rrr*(,o"" o-","o, ;":'i:;u --
CLIP
dul/
/,1: MOUNT
l': I cusHroN ,€\/\/-sSHIFT l / /-LEVER \, et- ffi
PY:,'\1^l lW -"or.o*Dusr .- \5".o.o)@1 -o-E "ot'o'
sHlFr \:/ Q,gD 22 N.m
IiUei__-.....p anecxer ,-/n I I I
?!il, e* ^.-.-n{wl\^fr J"r^r"
7****r
""'%ilf
t@
t1
t\sHrFT LEVER IBALL HOLDER
\
REAR JorN*lr,""17E@
_6,
L\
EXTENSION
SELF-LOCKING NUTReplace.6 x '1.0 mm9.8 N.m {1.0 kgf.m, 7.2 lbf.lr}
tJSPRING PINReplace.
-6r
16 tbf.trl
13-44

Transmission Assembly
lnstallation
Install the transmission assembly in the reverse order of
removal.
. Before installing, check that the two dowel pins are
installed in the clutch housing.
. When installing the starter cable. make sure that the
crimped side of the ring terminal is facing out (see
section 23).
. Apply grease to the parts as shown, then install the
release fork and release bearing.
NOTE; Use only Super High Temp Urea Grease(P/N 08798 -9002).
RELEASE FORK BOLT29 N.m 13.0 kgf.m,22 tbllrl
(P/N 08798 - 9rD2l
-R1
tP/N 08798 -
13-52
CLIP
L f ;
Torque the mounting bolt and nuts in the sequence
shown.
Check that the busings are not twisted or offset.
@ t2 x 1.25 mm6,t N.m 16.5 kgtm,47 lbf.ft)O t2 x 1.25 mm6,r N.m (6.s kg{.m,17 tbf.ft)
O 12 x 1.25 mm7ilNm17.5kgf.m,5it lbt ft)
I
Install the alip and the spring pin on the change joint
as snown.
Turn the shift rod boot so the hole is facing down as
snown.
Make sure the shift rod boot is installed on the changerod.
CHANGE ROO
FL.- SPRING PINll heptace,
8 mm PINPUNCH
/ "*,*
lo,iD(
CHANGE ./EXTENSfoN ( ^ st
l?rffi
l\K

lllustrated Index
t
Refer to the drawing below for transmission disassembly/reassembly.
Clean all the parts thoroughly in solvent and dry with compressed air.
I Luoricate att the pans with oil before reassembly.
NOTE:
. This transmission uses no gaskets between the majorhousings; use liquid gasket (P/N 08718-0001 or08718-0003)
(see page '13-93).
. Always clean the magnet @ whenever the transmission housing is disassembled.
. Inspect all the bearings for wear and operation.
?-c
\I
ir 6d
a h Plt tia.fl
) K1T\A
l,l 1r
@rt? u
L6q
i"\^Br 'u
t@)
E,M A
#&f
o-*ffiX,
@
I
R
h"ii
'F@
,
€D
13-54

Shift Fork AssemblY
lndex
-A erior ro reassemblinq. clean all the parts in solvent, dry them and apply lubricant to any contact pans
I
mm PIN PUNCH
sTH/REVERSESI{IFT FORK
3RD/4TH SHIFT FORK

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