1998 HONDA CIVIC Main bearing

Mainshaft Thrust Shim
Adjustment
Remove the thrust shim and oil
the transmission housing.
1.gu ide plate from
THRUST SHIM
OIL GUIDEPLATE
TBANSMISSIONHOUSING
Install the 3rd/4th synchro hub, spacer collar, 5th
synchro hub, ball bearing, and thrust washer on themainshaft. Install the assembly in the transmission
h ousing.
@ gnol+lx syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measure the distance @ between the end of thetransmission housing and thrust washer.
NOTE:
. Use a straight edge and vernier caliper.. Measure at three locations and average the read-
Ings.
Measure the distance @ between the surfaces ofthe clutch housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and average the read-
Ings.
sTH SYNCHRO IIUB
BALL EEARING
CLUTCH
L
HOUSINGENO OF
13-36
INNER RACE OF BALL AEARING
\
5.Select the proper shim on the basis of the followingcalculations:
NOTE: Use only one thrust shim.
(Basic Formula)(B) + {C). 0.95 = shim thickness
Example of calculation:
Distance @ (2.00 mm) + Distance @= 2.09 mm
subtract the spring washer height (0.95
required thrust shim (1.14 mm)
65 mm THRUST SHIM: D16Y7 engine:
(0.09
mm)
mm)
= tne
r1
Part NumborThickness
23931 - PL3 A100.60 mm (0.0236 in)23932 - PL3 A100.63 mm 10.0284 in)c23933 - PL3 A100.66 mm {0.0260 iniD23934 PL3 - A100.69 mm (0.0272 in)
E23935-PL3-4100.72 mm 10.0283 in)
F23936-PL3-4100.75 mm 10.0295 in)G23937-PL3-A100.78 mm {0.0307 in}
23938 PL3 - A100.81 mm (0.0319 in)I23939 - PL3 At00.84 mm (0.0331 in)J23940-PL3-Ar00.87 mm (0.0343 in)
23941 - PL3 - A100.90 mm (0.0354 in)
L23942 - PL3 A100.93 mm (0.0366 in)
23943-PL3-A100.96 mm (0.0378 in)N23944 PL3 - A100.99 mm 10.0390 in)
o23945-PL3-A101.02 mm {0.0402 in}23946 - PL3 A101.05 mm (0.0413 in)o23947 PL3 - 4101.08 mm (0.0425 in)R23948-PL3-A101.11mm (0.0437 in)s23949 PL3 - A101.14 mm {0.0449 in}T23950-PL3-A101.17 mm (0.0461 in)
U23951 PL3 - A101.20 mm (0.0472 in)
23952-PL3-Ar01.23 mm {0.0484 in)
23953-PL3-A101.26 mm {0.0496 in}X23954 - P13, A101.29 mm (0.0508 in)23955 - PL3 A101.32 mm (0.0520 in)z23956-PL3-Ar01.35 mm {0.0531 in)
23957-PL3-A101.38 mm (0.0543 in)
AB239s8 - PL3 A101.41 mm (0.0555 in)AC23959 PL3 - A101.44 mm (0.0567 in)
AD23960 - PL3 A101.47 mm (0.0579 in)23961 - PL3 4101.50 mm (0.0591 in)23962 PL3 - A101.53 mm (0.0602 in)AG23963-PL3-4101.56 mm (0.0614 in)AH23964 - PL3 A101.59 mm (0.0626 in)AI23965-PL3-A101.62 mm {0.0638 in)
23966 PL3 - A101.65 mm (0.0650 in)AK23967-PL3-A101.68 mm {0.0661 in)
23968 PL3 - A101.71 mm {0.0673 in)23969-PL3-A101.74 mm (0.06a5 iniAN23970- PL3 -A101.77 mm (0.0697 in)AO23971 - PL3 - A101.80 mm 10.0709 in)

Transmission
Reassembly lcont'dl
11. Position the 36 mm spring washer and washer onto
the mainshaft bearing.
MAINSHAFT/COUNTERSHAFTSHIFT FORK ASSEMELIES
Tape the mainshaftsplines.
12.
13.
Install the mainshaft, countershaft, and shift fork
assemblies.
NOTE; Align the finger of the interlock with thegroove in the shift fork shaft,
lnstall the spring washer and shift arm B attaching
bolt.I x 1.0 mm31 N.m (3.2 kgl.m, 23 lbt.ft)
IST/2ND SELECT SPRINGL. 36.26 mm 11.428 in)
54 N.m 15.5 kgf.m,40 tbt.ftl
SPf,INGWASHER
GUIDE BOLT
14.
39 N.m 14.0 kgf.m, 29 lbf.frl
Install the 1sv2nd select spring, 28 mm plug bolt.
and interlock guide bolt,
NOTE: Apply Iiquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads of the 28 mm plug bolt
and interlock guide bolt.
13-40
15. Install the reverse idler gear and reverse idler gear
shaft.
REVERSE IDLERGEAR SHAFT
LJ16. Install the reverse shift holder.
REVERSE SHIFT
l5 N.m (1.5 kgf.m,11 lbt.trl
GEAR
6 x 1.0 mm

S4C Model ('99 - 00 2-door Si, SiR)
Manual Transmission
Special Tools ............' 13-46
Maintenance
Transmission Oi1 ...................'.......... 13-47
Back-up Light Switch
Repfacement ...""" 13'47
Transmission Assembly
Removal ......'.......... 13-/tB
lnstallation ............. 13-52
lllustrated lndex ................................... 13-54
Transmission Housing
Removal ................. 13-55
Beverse Shift Holder, Reverse ldler Gear
Clearance lnspection ...................".. 13-57
Removal ................. 13-58
Change Holder Assembly
Clearance lnspection .................".... 13-59
Removal ....,,........... 13-61
Disassembly/Reassembly ............... 1 3-62
Mainshaft, Countershaft, Shift Fork
Removal ................. 13-63
Shift Rod
Removal .........."'.... 13-64
Shift Fork Assembly
lndex ................ ...... 13-65
Clearance lnspection .............'......... 13'66
Mainshaft Assembly
lndex ............"" ...... 13-67
Clearance lnspection ....................... 13-68
Disassembly .......... 13-71
fnspection '."'.......', 13'72
Reassembly .......'... 13-73
Countershaft Assembly
fndex ................ "....13-71
Glearance Inspection'......'...........'... 1 3'75
Disassembly .......... 13-76
fnspection .'............13'77
Reassembly "......... 13'78
Synchro Sleeve, Synchro Hub
Inspection .............. 13'8C
Installation ............. 13-80
Synchro Ring, Gear
Inspection .'............ 13-81
Differential
lndex ................ ...... 13-82
Backlash Inspection ..."..........."'...... 1 3-82
Final Driven Gear Replacement ...... 13-83
Bearing Replacement ....."'.......""'.. 13-83
Thrust Shim Adiustment ......""'..... 13-84
Clutch Housing Bearing
Replacement ..'...... 13-86
Mainshaft Thrust Glearance
Adiustment '.........'. 13-88
Transmission
Reassembly ."'....... 13-91
Oil Seals
Replacement ..'...... 13-96
Gearshift Mechanism
Overhaul ................ 13-97
\

Special Tools
SpecialTools
I
I
I
./
Ref. No. Tool NumberD€scriptionOty I Remark
o
@
o-@
@
o
@
@
@
o
@
07GAJ - PG20110
07GAJ - PG20l30
07JAD - PH80l0'1
07736 - A010004
07746 - 0010300
07746 - 0010400
07746 - 0030100
07746 - 0030300
07746 - 0030400
07746 - 0041100
07749 - 0010000
07947 - SD90200
Mainshaft Holder
Mainshaft Base
Driver Attachment
Adjustable Bearing Puller,25 - 40 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Driver, 40 mm LD.
Attachment, 30 mm LD.
Attachment, 35 mm LD.
Pilot, 28 mm
Hand le
Driver Attachment
I
1
1
1
I
1'l
I
1
1
1'I
13-90
13-90
13-96
13-86, 87
13-86
13-86, 87
13-73,79,83,84
13-73,19
13-73,79
13-86
13-86,87,96
13-96* Must be used with commercially-available 3/8,,-16 Slide Hammer.
o
aol@(t4^

Bolt SizeTorque Value
cn
E
F
6x1.0mm
6x1.0mm
8 x 1.0 mm
8 x '1.25 mm
8 x 1.25 mm
8 x 1,0 mm
12 N.m (1.2 kgnm, 8 lbf'ft)
15 N.m (1.5 kgf'm, 11 lbf ft)
15 N.m (l.5 kgf.m, 11 lbift)
24 N'm (2.4 kgim, 17 lbift)
27 N.m (2.8 kgf.m,20 lbf'ft)
30 N.m (3.1 ksf m. 22 lbift)
5i WASHER Replace.6 TRANSMrssioN HouslNG!9 80 mm SHIM@ SHIFT PIECE SHAFT(6' INTERLOCK@ sHrFr PECE6} SHIFT ARM HOLDER@ seucr nnrvtI9 SELECT RETURN SPRING
@ 10 mm SHIM6, 10 mm WASHER@ LOCK COLLARi6sl 3 x l5 mm SPRING PIN Replace.t0 8 mm SPRING WASHERA) CHANGE PIECEll SPRING L.25.6 mm (1.01 in)'' MAGNET?4) CLUTCH HOUSINGta. 14 x 25 x 16 mm OIL SEAL Replace.A sHrFT BooO D|FFERENT|aL ASSEMBLYSee section 15iIO SHIFT ROD BOOT6 OIL GUIDE PLATE@ 33 x 60 x 20 mm NEEDLE BEASINGO BEARING RETAINER PLATElD LocK WASHER Replace..0 couNTERSHAFIA DISTANCE COLLAR6 & x 4I x 22 mm NEEDLE BEARING6. 1sr GEAR@ FRICTION DAMPERO SYNCHRO RING.d SYNCHRO SPRING@ 1ST/2ND SYNCHRO HUB..9i. REVERSE GEARC) DOUBLE CONE SYNCHROO FRICTION DAMPERS SPACER6 T2 x TI x 24 mm NEEDLE BEARING(!' 2ND GEAR61 3RD GEARiD 4TH GEAR@ 5TH GEAR(O NEEDLE BEARING(10 BALL BEARING@ SPRING WASHERf,o LoCKNUT Replace.108 - 0- 108 N'm111.0- 0* 11.0 kgf m,80* 0- 80lbI.ft)IO CLUTCH LINE BRACKET.d BACK.UP LTGHT SWITCH HARNESS BRACKET
:!, ANGULAR BALL BEABING:2, STOP RING:3] TAPER RING..-I NEEOLE BEARINGl!-- SPACERO SYNCHRO RING? SYNCHRO SPRINGE 5TH/REVERSE SYNCHRO SLEEVE...] sTH/REVERSE SYNCHRO HUB
O SYNCHBO EING.11-r sTH GEAR1A 38 x 43 x 26 mm NEEDLE BEARINGI13) SPACER COLLAR[!] /ITH GEAR.T5) SYNCHRO RING
O SYNCHRO SPRING17 3RD/4TH SYNCHRO HUB
O 3RD/4TH sYNcHRo SLEEVE
ii9 38D GEAR8I MAINSHAFT2i WASHERA SPRING WASH€R?I BALL BEARING.a4, 28 x 41 x 7 mm OIL SEAL Replace..2i 35 x 56 x 8 mm OIL SEAL Replace.t-t 14 x 20 mm DowEL PIN
.'] OIL CHAMBER PLATE
O REVERSE IDLER GEAR SHAFT.iI.., REVERSE IDLER GEAR'd REVERSE SHIFI HOLDERait srH/REVERSE sHIFT PIECE'34 5 x 22 mm SPRING PIN Replace.3' 1ST/2ND SHIFT FORK,34' 3RD/4TH SHIFT FORKi9t) srH/nevense sstrr ronx33 OIL GUTTER PLATE!' SNAP RING3d 72 mm THRUST SHIM
@ OIL GUIDE PLATE4t 10 mm WASHER Replaceti REVERSE TDLER GEAR SHAFT BoLT54 N.m {5.5 kgf m, 40lbIft)4N TBANSMISSION HANGER B43] BREATHER CAPA,J TRANSMISSION HANGER AIT' BACK-UP LIGHT SWITCH
I
25 N.m {2.5 kgl.m, 18lblftl14 mm WASHER RePlaceaO 14 mmtt 16 mm16 mm SEALING BOLT29 N.m (3.0 kgf m,22 lbf ft):4s) 32 mm SEALING BoLT25 N m 12.5 kgl m, 18 lbl'ft)40 x 62 x I mm OIL SEAL ReplaceSTEEL BALL D.5/15 iNSPRING L. 30 mm {1.2 in)12 mm WASHER Replace.SET SCREW22 N.m {2.2 kg{ m, 16 lbl ftlOIL DRAIN PLUG39 N.m {4.0 kgf m, 29lbtftlWASHER Replace.OIL FILLER PLUG4,t N.m {4.5 kgl m, 33 lblftl
.!rl00
@l
13-55

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

Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEABING PULLER
BALL BEARING
CAUTION: Remove the synchro hubs using a ptess
and the sts€l blocks as shown. Use of a i8w'type
puller can cause damage to th€ gear teeth.
Support sth gear on steel blocks, and press the
mainshaft out of the sth synchro hub, as shown.
3. Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th svnchro hub, as shown.
13-71

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