1999 HONDA CIVIC service

Change Holder Assembly
Clearance Inspection (cont'd)
7. Measure the clearance between the select arm andthe 10 mm shim.
Standard: 0.01 - 0.2 mm (0.0004 - 0.008 in)
lf the clearance is not within the standard, selectand install the appropriate l0 mm shim for the cor-rect clearance from the chart below.
mm Shim
8.
SELECT ARM
l0 mm SHIM
Part NumberThickness
24435-689-0000.8 mm (0.031 in)
B24436-589-0001.0 mm (0.039 in)
c24437-689-0001.2 mm (0.047 in)
D24438-689-0001.4 mm (0.055 in)
E24439-689-0001.6 mm {0.063 in)
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9. Measure the clearance between the shift arm holderand the change piece.
Standard; 0.05 - 0.35 (0.fi)2 - 0.014 inlService Limit: 0.8 mm (0.03 in)
lf the clearance is more than the service limit. mea_sure the groove of the change piece.
Standard: 12.05 - 12.15 mm {0.i[7it4 - 0.47txt inl
lf the groove is not within the standard, replacethe change piece with a new one.lf the groove is within the standard, replace theshift arm holder with a new one.
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SHIFT ARM HOLOER
CHANGE PIECE

UO
11. Measure the clearance between the select arm and
the change Piece.
Standard: 0.05 - O'25 mm 10'002 - 0'010 in)
Servica Limii: 0.5 mm {0.02 in)
lf the clearance is more than the service limit, mea-
sure the width of the change Plece.
Standard: 12.05 - 12.15 mm {0.47'|{ - 0 47tI| inl
CHANGE PIECE
lf the width is not within the standard, replace
the change Piece with a new one'
lf the width is within the standard, replace the
select arm with a new one.
't2.
a
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SELECT ARM
Removal
1. Bemove the shift piece shaft. then remove the shift
piece and the interlock.
SHIFT PIECE SHAFT
INTERLOCK
2. Remove the change holder assembly'
13-61

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub shouldbe replaced as a set.
1. Measure the clearance between each shift fork andits matching synchro sleeve.
Standard: 0.35 - 0.65 mm {O.Olit - 0.026 inlService Limit: 1.0 mm t0.04 inl
SHIFT FOBK
lf the clearance is more than the service limit. mea_sure the thickness of the shitt fork finoers.
Standard: 7.4 - 7.6 mm (0.291 - 0.299 in)
lf the thickness of the shift fork frngers rs notwithin the standard, replace the shift fork with anew one.
lf the thickness of the shift fork fingers is withinthe standard, replace the synchro sleeve with a
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3. Measure the clearance between the shift piece andthe shift fork shafts.
Standard: 0.2 - 0.5 mm (0.008 - 0.02 inlService Limit: 0.8 mm {0.03 in)
lf the clearance is more than the service limit. mea-sure the width of the shift Diece.
Standard: 11.9 - 12.0 mm (0.469 - 0.it72 in)
lf the width of the shift piece is not within thestandard, replace the shift piece with a new one.lf the width of the shift piece is within the stan_dard, replace the shift fork with a new one.
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SHIFT PIECE

Mainshaft Assembly
Clearance Inspection
NOTE: lf replacement is required, always reDlace thesynchro sleeve and the synchro hub as a set.
1. Measure the clearance between 2nd and 3rd oears,
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inlService Limit: 0.3 mm (0.01 inl
2. lf the clearance is more than the service limit, mea-sure the thickness of 3rd gear.
Standard: 34.92 - 3it.97 mm t1.375 - 1.377 intService Limit: 3,1.3 mm (1.350 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 servicelimit, replace the 3rd/4th synchro hub with a newone.
Id

3. Measure the clearance between 4th gear and the
spacer collar.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inl
Servic€ Limit: 0.3 mm (0.01 inl
It the clearance is more than the service limit, mea-
sure distance @ on the spacer collar
Standard: 26.03 - 26.08 mm {1.025 - 1.027 in}
4TH GEARSIDE
SPACER COLLAE
5. lf distance @ is not within the standard. replace the
spacer collar with a new one. lf distance O is within
the standard. measure the thickness of 4th gear'
Standard: 31.12-31'17 mm {1.237 - 1.239 inl
Service Limh:31.3 mm (1.232 in)
lf the thickness of 4th gear is less than the ser-
vice llmit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one,
(cont'd)
13-69

Mainshaft Assembly
Clearance Inspection (cont'dl
6. Measure the clearance between sth gear and
spacer collar.
Standard: 0.05 - 0.21 mm (0.002 - 0.008 inl
Service limit: 0.3 mm 10.012 inl
lf the clearance is more than the service limit, mea-
sure distance €) on the spacer collar.
Standard: 26.03 - 26.08 mm {1.025 - 1.027 inl
the
1.
5TH GEAB
\
8. lf distance (E is not within the standard, replace the
spacer collar with a new one.
lf distance @ is within the standard, measure the
thickness of 5th gear.
Standard: 31.12-31.47 mm {1.237 - 1.239 in}
Service Limit:31.3 mm {1.232 in)
lf the thickness of 5th gear is less than the ser-
vice limit, replace sth gear with a new one.
lf the thickness of 5th gear is within the servace
limit, replace the 5th synchro hub with a new
one.
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5TH GEAR
3-70
SPACER COLLAB

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.
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Inspect for wearano oamage.
Inspect oil passages tor clogging.
13-72

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Clearance Inspection
1. Measure the clearance between the 1st gear and
distance collar.
Standard: 0,045 - 0.205 mm
10.002 - 0.008 in)
Service Limit: 0.25 mm (0.01 inl
2. lf the clearance exceeds the service limit. measure
the thicknesses of 1st gear.
lST GEAR
Standard: 29.45 - 29.50 mm {1.159 - 1.161 in}
DISTANCE COLLAR
Standard:@ 36.5 mm (1.4i1in)
@ ,12.0 mm (1.65 in)
@ 30.0 mm (1.18 in)
lf the thicknesses of 1st gear and distance collar
are less than the standard, replace with a new
one.
lf the thicknesses of 1st gear and distance collar
are within the standard, replace the lsv2nd syn-
chro hub with a new one.
3. Measure the clearance between
gears.
Standard: 0.07 - 0.14 mm
(0.003 - 0.006 inl
Servico Limii: 0.24 mm (0.009 in)
the 2nd and 3rd
3RD GEAR
2ND GEAR
4. lf the clearance exceeds the service limit, measure
the thicknesses of znd gear and spacer.
2ND GEAR
Standard: 28.92 - 28.97 mm (1.139 - 1.1't1 inl
'-.
ll-=Jl
71 il
SPACER COLLAR
Standard: 29.07 - 29.09 mm {1.1it4 - 1.1,15 inl
lf the thicknesses of 2nd gear and spacer are less
than the standard, replace with a new one.
lf the thicknesses of 2nd gear and spacer are
within the standard, replace the lsv2nd synchro
hub with a new one.
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