1997 HONDA CIVIC Gear

Mainshaft Assembly
Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Measure the clearance between 2nd and 3rd gears,
Standard: 0.06 - 0.21 mm 10.002 - 0.008 in)
Service Limit: 0.33 mm (0.013 inl
2ND GEAR
3RO GEAR
lf the clearance is more than the service limit. mea-
sure the thickness of 3rd gear,
Standard: 3O.22 - 3O.27 mm
{1.190 - 1.192 in}
Servica Limit: 30.15 mm (1.187 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 service
limit, replace the 3rdl4th synchro hub with a new
one.
/ -J-il -)frl"-
TI
Hl I
3RD GEAR
13-16
3. Measure the clearance between 4th gear and thespacer collar.
Standard: 0.06 - 0.19 mm 10.002 - 0.007 in)
Service Limit: 0.31 mm 10.012 in)
+
4TH GEAR
INDICATOR
If
-r ''==f{'
5TH GEAR
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer collar.
Standard: ?2.V. - 22.86 mm
10.8!t8 - 0.900 in)
Sorvica Limii: 22.81 mm {0.8t8 inl
4TH GEARSIDE
SPACERCOLLAR
lf distanc€ @ is less than the service limit, replace
the spacer collar with a new one,
lf distance @ is within the service limit, measure
the thickness of 4th gear.
Standard: 30.12 - 30.17 mm(1.186 - 1.188 inl
Servic6 Limh: 30.05 mm (1.1&l inl
4TH GEAR
lf the thickness of 4th gear is less than the ser-vice limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rdl4th svnchro hub with a newone,
di

T
6. Measure the clearance between the spacer collar
and sth gear.
Standard: 0.06 - 0.19 mm 10.002 - 0.007 inl
Service Limit: 0.31 mm (0.012 inl
4TH GEAR
DIALINDICATOR
I
-<=q,
7.
5TH GEAR
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer coilar
Standard: 23.53 - 23.56 mm
10.926 - 0.928 in)
Sowice Limit 23.51 mm {0.926 in}
SPACERCOLLAR
sTH GEARSIDE
lf distance @ is less than the service limit, replace
the spacer collar with a new one,
lf distance @ is within the service limit, measure
thickness of 5th gear.
Siandatd:28.1:2 - 28.17 mm
11.119 - 1.121 in)
Servica Limit: 28.35 mm (1.116 inl
sTH GEAR
lf the thickness of 5th gear is less than the ser-
vice limit, replace sth Oear with a new one.
lf the thickness of sth gear is within the service
limit, replace the 5th synchro hub with a new
one.
Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEARING PULLER(Commercially
availablel
CAUTION: Remov€ ths synchro hubs using a press
and steel blocks as shown. Us€ of a iaw-type pullel
can caus€ damage lo the gear teeih.
Support 4th gear on steel blocks. and press the
mainshaft out of the sth svnchro hub as shown.
{cont'd)
13-17

Mainshaft Assembly
Disassembly (cont'd)
3. Support the 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th synchro hub as shown.
13-18
Inspection
'1. Inspect the gear surface and bearing surface for
wear and damage. then measure the mainshaft atpoints A, B, C, and D.
Siandard: A: 21.987 - 22.000 mm
10.8656 - 0.8661 inl
B: 26.980 - 26.993 mm
11.0622 - 1.0627 inl
C: 33.98,1- 34.000 mm(1.3380 - 1.3385 in)
D: 25.977 - 25.990 mm
|.1.0227 - 1.0232 inl
Service Limit: A: 21.930 mm 10.8634 inl
B: 26.930 mm {1.0602 in}
C: 33.930 mm (1.3358 in)
D: 25.920 mm (1.0205 in)
Check for wear and damage
lf any part of the mainshaft is less than the service
limit, replace it with a new one.
2. Inspect for runout.
Standardi 0.02 mm (o.(Xtl in) max.
S€rvice Limii: 0.05 mm (0.002 in)
NOTE: Support the mainshaft at both ends as
snown.
lf the runout is more than the service lirnit, reolace
the mainshaft with a new one.
Y

I
)r'
Reassembly
CAUTION: When installing the 3rd/4th and 5th synchro
hubs, support th€ shaft on steel blocks, and insiall the
synchro hubs using a press.
NOTE: Refer to page 13-15 for reassembly sequence.
1. Support 2nd gear on steel blocks' then install the
3rd/4th synchro hub using the special tools and a
oress.
ATTACHMENT,35 mm LO.07746-OO3O/+OO
' ,2I{D GEAR
Install the 3rd/4th synchro sleeve by aligning the
stops of the 3rdl4th synchro sleeve and hub.
NOTE; After installing, check the operation of the
3rd/4th svnchro hub set
SYf{CHRO SLEEVE
3. Install the sth
ano a press.
synchro hub using the special tools
DRIV€R, 40 mm I O.
07746 -0030'100
ATTACHMENT,30 mm l.D.07746 -O030300
sTH SYNCHRO HU8
Install the ball bearing in the direction shown using
the special tools and a Press.
DRIVER, iO mm l.D.
07746 - lxxlollx'
ATTAGHMENT, 30 mm l.D.
077i16 - 00303qt
BAI-L BEARING
Ball cage faces uP
*1: D16Yt engane*2: Dl6Y5, D16Y8 6ngines
13-19

Countershaft Assembly
Index
I.r
NOTE:
-re
The 3rd, 4th, and sth gears are installed with a press.
Prior_to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the3rd, 4th, and 5th gears.
Snap ring groove faces up.
LOCKNUT Replace.108-O- 108 N.m
I 11.0-O-11.0 kst.ml
I 79.6-0- 79.6 lbt.ft I
SYNCHRO SPRING
SYNCHRO RINGInspectaon, page 13-28
FRICTION DAMPER
Thin edge ol outerrace faces down.
Check for wear andoperatron,
/ BALL EEAR|NG t*1)
t NEEDLE BEARTNG (.2)
Check for wearand operatron,
WASHERBEARING
GEAR
4TH GEAR
3RD GEAR2ND GEAR
FRICTION DAMPER
SYNCHRO SPRING
SYNCHRO RINGInspection, page 13-2836 x 41 x 25.5 mmNEEDLE BEARINGCheck for wear and operataon.
Inspection, page 13-23
1ST GEARlnspection, page 13 21, 28lnspection, page 13-21, 2839x44x27mmNEEDLE BEARIfI'GCheck for wear andoperation.
SPACER COLLARInspection, page 13-21
REVERSE GEARlnspection, page 13 27
1ST/2ND SYNCHRO HUB
*1: D'16Y7 engine*2: D16Y5, D16Y8 engines
13-20

I)t
Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Measure the clearance between the countershaft
and lst gear.
Standard: 0.03 - 0.10 mm (0'(X)l - 0'qt4 in)
Sorvic. Limit: 0.22 mm (0.009 inl
2. lf the clearance is more than the service limit, mea-
sure the thickness of 1st gear.
Standard: 30./tl - 30.'l'l mm
11.197 - 1.198 in)
Servics Limit 30.36 mm (1.195 in)
lf the thickness of 1st gear is less than the service
limit, replace lst gear with a new one.
lf the thickness of 1st gear is within the service
limit, replace the lsv2nd synchro hub with a new
one.
GAUGE
1ST GEAB
3. Measure the clearance between 2nd and 3rd gears.
Standard: 0.04 - 0.12 mm (0.002 - 0.005 in)
Servico Limit: 0.2,1 mm 10.009 in)
4. lf the clearance is more than the service limit, mea-
sure th€ thickness of the spacer collar'
stlndard: 32.G1 - 32'06 mm
{1.261 - 1.262 in}
S6rvica Limh: 32'01 mm (1'260 in)
SPACERCOLLAR
lf the thickness is less than lhe service limit, replace
the sDacer collar with a new one.
lf ths thickness is within the service limit, measure
the thickness of 2nd gear.
Standard: 31.91 - 31.96 mm
11.256 - 1.258 inl
Soryice Limit 31.85 mm (1.25,1inl
z4:_- 2I{D GEAF
/l\\/j'T - "b/
P-
1^'.-1r.--l--f
lf the thickness of 2nd gear is less than the ser-
vice limit, replace 2nd gear with a new one.
lf the thickness of 2nd gear is within the servace
limit, replace the lsv2nd synchro hub with a new
one,
13-21

Countershaft Assembly
Disassembly
CAUTION: Remove the gears using a press and steelblocks as shown. Use of a iaw-type puller can damagethe gear teeth.
1. Securely clamp the countershaft assembly in a
bench vise with wood blocks.
2. Raise the locknut tab from the groove of the coun-
tershaft, then remove the locknut and the springwasher.
3.Remove the bearings using a bearing puller as
shown.
EEARING PULLER
\
4. Support 4th gear on steel blocks, and press the coun-tershaft out of 5th and 4th gears as shown.
Support 1st gear on steel blocks, and press the coun-
tershaft out of 3rd gear as shown.
5.
I./
3RD GEAR
1ST GEAR

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