1997 HONDA CIVIC parts

Gountershaft Assembly
Index
DAMPER
ST GEARInspection, page 13-75
EALL EEARING
and operation.
NEEDLE BEARINGlnspect for wearano operaton.
5TH GEAR
4TH GEAR
3RD GEAR
NOTE:
3
The 4th and sth gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4thand 5th gears. however, should be installed with a press before lubricating them.
REVERSE GEAR
LOCKNUT Replace108"0-108N.m
i11.0 - 0- l1.0kgtm,180-0-80lbttr
WASHER
DISTANCECOLLAR
COUNTERSHAFTInspection, page 13-77
NEEDLE BEARING
and operatron,
Inspection, page 13-75
NEEDLE BEARING
ano operatron,
SPACER
FRICTION DAMPER
DOUBLE CONE
Inspection, page 13 81
SYNCHRO SPRING
13-74

t
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage, then measure the counter-
shaft at points A, B, and C. lf any parts of the coun-
tershaft are less than the service limit. reDlace coun-
torshaft with a new one.
Standard:
A: 2/t.980 - 2{.993 mm (0.9835 - 0.9&O in}
B: 35.984 - 37.000 mm {1.4561 - 1.4567 in)
G: 33.fiD - 33.015 mm {1.2992 - 1.2998 in)
Sorvicc Limit:
Ar 2/t.9't0 mm 10.9819 inl
B: 36.930 mm {1.'l5qt in}
C: 32.950 mm {1.2972 in}
Insp€ct for wear
Inspect oil passage for clogging.
13-77
2. Insoect for runout. lf the runout is more than the
service limit, reolace the countershaft with a new
one.
Strndard: 0.02 mm {0.(x)08 in) max.
Servic. Limit 0.05 mm (0.002 in)
NOTE: SuoDort th€ countershaft at both ends as
shown.
Rotate lwo complelerevotutons.

Gountershaft Assembly
Reassembly
CAUTION:
. Pross 4th and sth gears on the countershaft without
lubrication.
. When installing ilth and sth geafs, support the shaft
on steel blocks, and install the gears using a press.
. Install ilth and sth gear with a maximum pressure of
25.5 kN (2,600 ksf, 18,806lbf).
NOTE; Refer to page 13-74 for reassembly sequence.
'1. Install the distance collar and the needle bearinos
on the countershaft.
COUNTERSHAFT
Install the friction damper, the synchro ring, and the
synchro spring on 1st gear.
Install the 1sv2nd synchro hub by aligning the fin-
gers on the friction damper and the grooves in the
1sv2nd synchro hub, as shown.
lST/2NO
13-78
lSI GEAR
insteps2-6onthe
{
4.lnstall the reverse gear.
Install the synchro spring. and the double cone
synchro as shown.
Assemble the friction damper, the needle bearing,
and 2nd gear, then install them by aligning the fin-gers on the friction damper and the grooves in the
1sv2nd synchro hub with the fingers of the double
cone synchro and the grooves on 2nd gear, as
snown.
Installthe spacer.
FRICTION DAMPER
Install the parts assembled
countershaft.
;
2ND GEAR

Gearshift Mechanism
Overhaul
NOTE:
. Inspect rubber parts for wear and damage when disassembling;
. Install the spring pin and the clip on the change joint as shown'
. Turn the shift rod boot so the hole is facing down as shown'
. Make sure the shift rod boot is installed on the shift rod'
reDlace any worn or damaged Parts.
I x 1.25 mm22 N.m 12.2 kgf.m, 16 lbf.ft)
ffi-:t't:il1ii51i?"'*,
TU
/g3i'51!Exii
V ExrENsroN
EXTENSfON ilr'eol.T
EXTENSION ENDBUSHING
hV\
EXTENSIONWASI{ER B
MOUNT -_.--_-_---
@2'
--1'>=2 -:liT.i'ff"
.o,-.o*&--ffi{---*,
v/,,/ BALL SEAT
8 x 1.25 mm22 N.m 12.2 kgf'm, 16lblftl
,@
EXTENSION ROD
SHIFT ROD
SPRING
END
BOOT
N: g sHrFr LEvER
.*rr"r,o"-tf V-oiliiSi[a
MOUNTING I --::=t SHIFT I"EVERBRAcxEr / €9-l--enr xoloen
8 x 1.2s mm :-,rro""a,ii-ri- ri.z rsr.-, -.Q u
16 tbf.ft) ,,,.
,rar-aoa*,"o "u, / E ,",t.ruaa
Replace.6x1.0mm9.8 N.m ('1.0 kgt'm,7 tbr.ftt
8x22mmSPRING PINReplace.
IIt
@CLIP
9.a-"t't
PIN SHIFT ROD/
ZW
€lt#-,\
HOLE
13-97

End Cover
Removal
NOTE:
. Cleanall parts thoroughly in solvent or carburetor cleaner, and drywith compressed air,. Blow out all passages,
. When removing the right side cover, replace the following:- O-rings- Mainshaft and countershaft locknuts- Conical spring washgrs- End cover gasket
- Lock washer- Sealing washers
END COVER6 x 1.0 mm BOLT13 Bolts
PARK PAWL
PARK ITVER
LOCK WASHER
COUI{TERSI{AFTLINE AOLT
tST GEAF COLLAR
I
14-132
SEALING WASHERS

NOTE;
. Clean all parts thoroughly in solvent or carburetor
cleaner, and dry with compressed air.
. Blow out all passages.
. When removing the valve body, replace the O-ring.
l, Remove the ATF feed pipes from the servo body,
secondary valve body and main valve body.
For'96 - 98 models: Remove the ATF strainer and
servo detent base (two bolts).
For'99 - 00 models: Remove the ATF strainer (one
bolt).
Remove the servo body and servo separator plate
{'96 - 98 models: seven bolts,'99 - 00 models: eight
bolts).
Remove the secondary valve body, shaft stop and
secondary separator plate (three bolts).
Remove the lock-up valve body and separator plate
{seven bolts).
Remove the regulator valve body (one boltl.
Remove the stator shaft and stop shaft.
Remove the detent spring from the detent arm. then
remove the control shaft from the to.que converter
housing.
Remove the detent arm and detent arm shaft from
the main valve body.
Remove the main valve body (five bolts).
NOTE: Do not let the eight check balls fall outofthe
main valve body when removing the main valve
body.
Remove the ATF pump driven gear shaft, then remove
the ATF pump gears.
Remove the main separator plate and two dowel
pins.
7.
't'1.
10.
12.
14.
13. CIean the inlet opening of the ATF strainer thor-
oughly with compressed air. then check that it is in
good condition, and the inlet opening is not clogged.
INLET OPENING
Test the filter by pouring clean ATF fluid through
the inlet opening. Beplace the ATF strainer if it is
clogged or damaged.
NOTE: The ATF str8iner can be reused if it is not
clogged.
14-137

Valve Body
2.
Repair
NOTE: This repair is only necessary if one or more of
the valves in a valve body do not slide smoothly in their
bores. You may use this procedure to free the valves in
the valve bodies.
1. Soak a sheet of #600 abrasive paper in ATF for
about 30 minutes.
Carefully tap the valve body so the sticking valve
drops out of its bore.
CAUTION: lt may b€ necessary to use a small
screwdriver to pry the valve free. Be careful not to
scratch the bore whh the screwdriver.
Inspect the valve for any scuff marks. Use the ATF-
soaked #600 paper to polish off any burrs that are
on the valve, then wash the valve in solvent and dry
it with compressed a ir.
Roll up half a sheet of ATF-soaked paper, and insert
it in the valve bore of the sticking valve.
Twist the paper slightly, so that it unrolls and fits the
bore tightly, then polish the bore by twisting the
paper as you push it in and out.
CAUTION: The valve body is aluminum and doesn't
require much polishing to remove any burrs,
3.
4.
ATF-soaked#600 abrasive Paper
5.
7.
Remove the #600 paper and thoroughly wash the
entire valve body in solvent. then dry it with com-
pressed air.
Coat the valve with ATF, then drop ir into its bore.
It should drop to the bonom of the bore under its
own weight. lf not, repeat step 4, then retest.
VALVE BODY
Remove the valve. then thoroughly clean it and the
valve body with solvent. Dry all parts with com-
pressed air. then reassemble using ATF as a lubri
cant.
W
-M
14-139

Valve
Assembly
NOTE:
Coat all parts with ATF before assembly.
. Install the valve, valve spring and cap in the valve
body and secure with the roller.
5-'--------P/-_^?=w_
=/ /- ( ,. )l_/1 -,.1)
VALVE BODY
VALVE AODY
VALVE
h
14-140
SPRING
. Set the spring in the valve and install it in the valve
body. Push the spring in with a screwdriver, theninstall the spring seat.
SPRIITG SEAT
VALVE BODY
Install the valve, spring and cap in the valve body.
Push the cap, then installthe clip.