1997 HONDA CIVIC fluid

Transmission Housing Bearings
Driven Pulley Shaft Bearing Replacement
1. To remove the driven pulley shaft b'earing trom the
transmission housing, expand the snap ring with
snap ring pliers, then push the bearing out using
the specialtools and a press as shown.
NOTE: Do not remove the snap ring unless it's nec-
essary to clean the groove in the housing.
07749 - 001(xDo
ATTACHMENT,72x75mm07746 - (x'l05U)
077i() - 001(xrco
14-334
SNAP RING
Expand the snap ring with snap ring pliers, insert
the new bearing part-way into the housing using
the special tools and a press as shown. Install the
bearing with the groove facing outside the housing.
NOTE: Coat all pans with CW Fluid.
Release the pliers, then using the special tools,push the bearing down into the housing until the
snap ring snaps in place.
BEARING
ATTACHMENT,72x75mm07746 - OO1 0600
GROOVE
SNAP RING
After installing the bearing verify the following:
o The snap ring is seated in the bearing and hous-
ing grooves.
. The ring end gap is correct.
END GAP| 0 -9 mm
l0 - 0.35 inl

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.

22. Install the shift cable end on the control lever, and
install the shift cable on the shift cable bracket'
CAUTION: Take care not to bend the shift cable'
23. lnstall the clip in the direction shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLEERACKET
WASHERIPLASTIC)
CONTROL LEVER
24, Connect the solenoid harness connector. the drive
pulley speed sensor connector. and the ground
cable terminals.
6x1.0mm12 N.m {1.2 kgf.m.8,7 rbtft)
GROUND CABLETERMINAL 6x1.0mm
GROUNDTERMINAL
12 N.m {1.2 kgf'm,8.7lbtfrl
DRIVE PULLEYSPEED SENSORCONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cable on the starter motor.
and install the cable holder.
NOTE: When installing the staner motor cable. make
sure that the crimped side of the ring terminal is
facing out (see section 23).
STARTEB
BMOUNTING NUT
9 N.m (0.9 kgf m,7 lbf ft)
26. Install all removed connectors and clamps'
27. Install the distributor.
28. Install the intake air duct and air cleaner housing
29.
assemDly.
Refill the transmission with the recommended
Genuine Honda CVT Fluid (see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
Connect the battery positive (+) terminal first, then
the negative (-l terminal to the battery'
Check the ignition timing (see section 23).
Start the engine. Set the parking brake, and shift the
transmission through all gears three times Check
shift cable adjustment (see page 14-355).
Check the front wheel alignment (see section 18)
Let the engine reach operating temperature (the
radiator fan comes on) with the transmission in lXl
or E position, then turn it off and check fluid level'
Perform the start clutch calibration procedure on
page 14-293.
Road test as described on pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351

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

Driveshafts
Inspection
Driveshaft Boot
Check the boots on the driveshaft for cracks, damage,
leaking grease and loose boot bands. lf any damage is
found, replace the boot and boot bands,
Loose Splines
Turn the driveshaft by hand and make sure the splines
and joint are not excessively loose. lf any damage is
found, replace the inboard joint.
Twisied or Cracked
Make sure the driveshaft is not twisted or cracked.
Reolace it if necessarv.
DRIVESHAFT
BOOT BANDS
1.
Removal
Loosen the wheel nuts slightly.
Raise the front of the vehicle, and support it with
safety stands in the proper locations (see section 'l).
Remove the wheel nuts and front wheels.
Drain the transmission fluid (see section 13 or 14).
Raise the locking tab on the spindle nut, then
remove the nut.
Remove the selJ-locking nut and flange bolts.
FLANGE BOLT10 x 1.25 mm
(cont'd)
16-3
1.

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