1999 HONDA CIVIC Gear

9. Support the countershaft on a steel block, and
install 4th gear using the special tools and a press.
as 5nown.
ATTACHMENT,35 mm LD.07746 - 0030400
Support the countershaft on a steel block, and
install 5th gear using the special tools and a press,
as shown.
ATTACHMENT, 30 mm I,D,07746 - 0030300
10.
\
'1'1. Install the needle bearing, then install the ball bear-
ing using the special tools and a press as shown.
PRESSDRIVER,40 mm LD.07746 - 0030100
ATTACHMENT,30 mm LD.07746 - 0030300
J.-12.Securely clamp the countershaft assembly in a
bench vise with wood blocks.
lnstall the spring washer, tighten the locknut, then
stake the locknut tab into the groove.
LOCKNUT
108- 0- 108N.m 111.0- 0- 11.0kgt.m,
80+ 0* 80 lbf'ftl
WOOD BLOCKS
13-79

Synchro Sleeve, Synchro Hub
Inspection
1,Inspect gear teeth on all synchro hubs and synchro
sleeves for rounded off corners. which indicates
Install each synchro hub in its mating synchro
sleeve and check for freedom of movement.
NOTE: lf replacement is required, always replace
the synchro sleeve and synchro hub as a set.
Installation
When assembling the synchro sleeve and synchro hub,
be sure to match the three sets of longer teeth (120
degrees apart) on the synchro sleeve with the three sets
of deeper grooves in the synchro hub.
CAUTION: Do noi install tho synchro sleeve with its
longer toeth in the synchro hub slots, because it will
damage the spring ring.
SYNCItROSLEEVCLONGER TEETH
13-80

Synchro Ring, Gear
Inspection
'1. Inspect the synchro ring and gear.
A: Inspect the inside of the synchro ring for wear'
B: Inspect the synchro sleeve teeth and matching
teeth on the synchro ring for wear (rounded off).
oo
GOOD WORN
C: Inspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
nn
UUGOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
F: Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks'
2. Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear. Rotate the
ring, making sure that it does not slip
Measure the clearance between the synchro ring
and gear allthe way around.
NOTE: Hold the synchro ring against the gear even-
ly while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.73 - 1.18 mm
(0.029 - 0.0'16 in)
Ssrvice Limit:0.,0 mm {0.02 in}
Double Cone Synchro-to-Geal Clearanc€
Standald:
@: (Outer Synchro Ring to Synchro Con6l
0.5 - 1.0 mm 10.02 - 0.04 in)
@: (Synchro cone to Gearl
0.5 - 1.0 mm (0.02 - 0.04 inl
O: {Outer Synchlo Ring to Gear)
0.95 - 1.68 mm (0.037 - 0.066 in)
Service Limit:
@: 0.3 mm {0.01 in}
@: 0.3 mm {0.01 in)
O: 0.6 mm t0'02 inl
lf the clearance is less than the service limit, replace
the synchro ring and sYnchro cone.
SYNCHRO SPRING
SYNCHRO RING
t
SYNCHRO CONE
13-81

Differential
Index
FINAL DRIVEN GEARInspect tor wear and damage.
80 mm SHIMSelection, page'13,84
101 N.m {10.3 kgtm,74.5 lbf.ft)Left-hand threadsBALL BEAFINGInspect foa wear and ooeration.
13-82
Backlash Inspection
1. Place the differential assembly on V-blocks and installboth axles.
Measure the backlash of both pinion gears. lf thebacklash is not within the standard, replace the dif,ferential carrier.
Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inl
DIAL INDICATOR

rla
Final Driven Gear Replacement
'1. Remove the bolts in a crisscross pattern in several
steps, and remove the final driven gear from the dif-
ferential carrier.
NOTE: The final driven gear bolts have left-hand
threads,
12 x 1.0 mm101 N.m {'10.3 kgf.m,74.5 lbf.ftlLeft hand
FINAL DRIVEN GEARChamfer on inside daameter offinal driven gear faces carrier.
2. Install the final driven gear by tightening the bolts
in a crisscross pattern in several steps.NOTE: Drive the bearings squarely until they bot-
tom against the carrier.
BALL BEARING
13-83
Bearing Replacement
NOTE: Check the ball bearings for wear and rough rota-
tion. lf bearings are OK, removal is not necessary.
1. Remove the ball bearings using a standard bearing
puller and bearing separator as shown.
BEARING PULLER
BEARING SEPARATOR
lCommerciallyavailab16)
BALL BEARING
2. Install new ball bearings using the special tool as
shown.

Transmission
Reassembly (cont'd)
11. Installthe change holder assembly.
6x1.0mm15 N.m {1.5 kgf.m,
12 N.m {1.2 kgf.m,9lbtftlCHANGE HOLDERASSEMBLY
Install the shift piece and the interlock. then installthe shift piece shaft.
12.
13-92
(
13. Measure the distance @ after mounting the shiftpiece shaft. lf it's incorrect. check the installation.
Distance @: 11.9 - 12.3 mm {0./t7 - 0.48 inl
14. Install the .everse idler gear and the reverse idlergear shaft.
REVERSE IDLER GEAR
REVERSEIDLE

25. Install the 32 mm sealing bolt
NOTE: Apply liquid gasket (P/N 08718 - 0001 or
08718 - 0003) to the threads.
26. Tighten the reverse idler gear shaft bolt'
REVERSE IDLER G€AR
SHAFT BOLT10 x 1.25 mm5a N.rn t5.5 kgl m, {0 lbtftl
32 mm SEALING BOLT
25 N.m {2.5 kgl'm,
lnstall the steel balls, the springs, and the set
screws.
Install the back-up light switch and the transmission
hanger B.
BACK.UP LIGHT SWITCH
25 N.m 12.5 kgt m, 18 lblttl
TRANSMISSIONHANGER B
8x2117
1.25 mmN.m (2.4 kgf m,lbf.ftt
II
I
I
EALL
\\
\
\
SET SCREW'12 x 1.0 mm
22 N.m (2.2 kgf'm,16 tbt.trl
13-95

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