1997 HONDA CIVIC For

Forward Clutch
Disassembly
1. Remove the snap ring, then remove the clutch endplate, clutch discs, and plates.
SNAP RING
2. Remove the disc spring.
tCLUTCH DRUM
OISC SPRING
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SPRING RETAINES
3. Install the specialtools as shown.
CLUTCH SPRINGCOMPRESSORBOLT ASSEMBLYo7R{E-PG402OO
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100
CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PXa0100 or07HAE - P150100
CAUTION: lf €ither ond of the sp€cial tool is sst overan aroa of the spring retainer which is unsupportedby th€ retum spring, the rotainer may be damaged.
Be sure the spccial tool is adiusted to hava tull con-taqt with the sp.ing retainer.
SPECIAL TOOL
Do not B€t here.

Forward Glutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleaner, and dry them with compressed air.
. Blow out all passages.
. Lubricate all parts with CW Fluid before reassembly.
1. Inspect the check valve; if it's loose, replace the pis-
ton.
CHECK VALVE
Install new O-rings on the clutch pision.
PISTON
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3. Install the piston in the clutch drum. Apply pressure
and rotate to ensure proper seatang,
NOTE: Lubricate the piston O-ring with CVT Fluid
before installing.
CAUTION: Do not pinch thc O-ring by installing the
pistoo with too much torqo.
CLUTCH DRUM
Install the return spring and spring retainer, and
position the snap ring on the retainer.
CLUTCH DRUM

Forward Clutch
Reassembly {cont'd)
9. Install the disc spring.
NOTE: Installthe disc spring in the direction shown.
- "arr"" o"u*
11.
Soak the clutch discs thoroughly in CW Fluid for a
minimum 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 dirt or
other toreign matter.
CLUTCH END PLATEInstall in this dir€ction.
10.
DISC SPRING
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12. Installthe snap ring.
13. Verify that the snap ring end gap is correct.
SNAP RING
CLUTCH
Minimum 7.9 mm (0.31 ini

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

Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection
1. Measure the distance between the flywheel housing
surface and the ball bearing as shown, then note
the measurement (Measurement A).
FLYWHEELHOUSING
>dt?'
BALL BEARING
EALL FLYWHEELBEARING HOUSTNG
Install the secondary gear shatt in the transmission
housing.
Measure the distance between the transmission
housing surface and the thrust washer mounting
surface of the secondary gear shaft as shown, then
note the measurement (Measurement B).
O
Measuring Distance A
BALL
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Calculate 25 x 35 mm thrust shim thickness bv fol-
lowing formula.
FORMULA;
25 x 35 mm Thrust Shim Thicknoss
= Measurement A - Measurement B + Flywheel
Housing Gasket Thickness: 0.5 mm {0.020 in}
Example:
Measurement A: 32.7 mm (1.287 in)
Moasurem.nt B: 30.! mm {1.185 in}
25 x 35 mm Thrust Shim Thickness
= 32.7 mm (1.287 in) - 30.1 mm (1.185 in)
+ 0.5 mm {0.020 in)
= 3.1 mm (0.122 inl
Select 25 x 35 mm Thrust Shim D.
Select the 25 x 35 mm thrust shim from the follow-
ing the table.
THRUST SHIM, 25 x 35 mm
No.Part NumberThickne3s
90551 - P4V - 0002.8 mm (0.110 in)
B90552-P4V-0002.9 mm (0.114 in)
c90553-P4V-0003.0 mm (0.118 in)
D90554-P4V-0003.1 mm (0.122 in)
E90555-P4V-0003.2 mm (0.126 in)
90556-P4V-0003.3 mm (0.130 in)
G90557-P4V-0003.4 mm (0.134 in)
H90558-P4V-0003.5 mm (0.138 in)
90559-P4V-0003.6 mm {0.142 in)
90560-P4V-0003.7 mm (0.146 in)
K90561 - P4V - 0003.8 mm (0.'150 in)

Differential
Bearing Replacement
NOTE: Check the bearings for wear and rough rotation.
lf the bearings are OK, removal is not necessary.
'1. Remove the ball bearings using a bearing puller.
Install the new ball bearings
with a press as shown.
BAI-L BEARING
using the special tool
ORIVER 10 mm l.O.
07746 - 0030100
14-330
BALL BEARING
Differential Carrier Replacement
1. Remove the final driven gear from the differential
carner.
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS10 x 1,0 mm98 N'm 110,0 kgf.m,72 tbl.ttlLeft-hand threads
DIFFERENTIALCARRIER
Install the final driven gear with its chamfered side
on the inner bore facing the differential carrier.
Tighten the bolts to the specified torque in a crisscross
Paftern.
TOROUE: 98 N.m (10.0 kgt.m, 72 lbf.ft)

Differential
Oil Seal Installation/Side Clearance (cont'dl
3. Installthe flywheel housing, and tighten the bolts.
DOWEL PIN
1 .25 mmN m (3.0 kgt m,22 lbf.ttl8x29
uigE
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4. Measure the clea.ance between the 80 mm set ring
and outer race of the ball bearing in the transmis-
sion housing.
STANDARD: 0 - 0.15 mm (0 - 0.006 in)
lf the clearance is more than the standard, select a
new set ring from the table, and install it.
SET RING, 80 mm
NOTE: lf the clearance measured in steD 4 is stan-
dard, it is not necessary to perform steps 7 and 8.
Remove the flywheel housing.
Replace ttle 2.50 mm (0.098 in) set ring, 80 mm with
the one ot the correct thickness selected in steD 5.
6.
7.
Part NumberThickness
904'r4-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
2.50 mm (0.098 in)
2.60 mm (0.102 in)
2.70 mm (0.106 in)
2.80 mm (0.110 in)
2.90 mm (0.114 in)
3.00 mm (0.118 in)

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