1999 HONDA CIVIC Counter shaft

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
\

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

Transmission Housing
Removal
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting theworkbench.
'1. Remove the back-up light switch.
2. Remove transmission hanger B.
3. Remove the set screws, the springs, and the steelballs.
BACK.UP UGHTswrTcH
SET SCREW
4. Remove the reverse idler gear shaft bolt.
WASHERReplace.
REVEBSE
13-56
5. Loosen the transmission housing attaching bolts ina crisscross pattern in several steps, then removethem.
TRANSMISSIONHANGER A
R€move the 32 mm sealing bolt.
Expand the snap ring on the countershaft ball bear-ing, and remove it from the groove using a pair ofsnap ring pliers,
32 mm SEALING BOLT
o.
1.
I{
ATTACHING BOLT
SNAP RING

Mainshaft, Countershaft, Shift Fork
Removal
1.Remove the mainshaft and the countershaft assem-
blies with the shift forks from the clutch housing.
NOTE: Tape the mainshaft spline before removing
the mainshaft and the countershaft assemblies.
Remove the spring washer and the washer'
v
MAINSHAFT
COUNTERSHAFT
Remove the differential assembly from the clutch
housing.
Tape the
splrnes.
WASHER
DIFF€RENTIAL ASSEMBLY
4. Remove the chamber Plate.
CLUTCH HOUSING
CHAMEEF PLATE
CLUTCH HOUSING
13-63

Gountershaft Assembly
Index
DAMPER
ST GEARInspection, page 13-75
EALL EEARING
and operation.
NEEDLE BEARINGlnspect for wearano operaton.
5TH GEAR
4TH GEAR
3RD GEAR
NOTE:
3
The 4th and sth gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4thand 5th gears. however, should be installed with a press before lubricating them.
REVERSE GEAR
LOCKNUT Replace108"0-108N.m
i11.0 - 0- l1.0kgtm,180-0-80lbttr
WASHER
DISTANCECOLLAR
COUNTERSHAFTInspection, page 13-77
NEEDLE BEARING
and operatron,
Inspection, page 13-75
NEEDLE BEARING
ano operatron,
SPACER
FRICTION DAMPER
DOUBLE CONE
Inspection, page 13 81
SYNCHRO SPRING
13-74

Gountershaft Assembly
Disassembly
1. Securely clamp the countershaft assemblv in a
bench vise with wood blocks.
2. Raise the locknut tab from the groove in the coun-
tershaft, then remove the locknut and the spring
washer.
Remove the ball bearing using a bearing pulle. asshown.
BEARING PULLER
BALL BEARING
13-76
4, Remove the bearing outer race, then remove theneedle bearing using a bearing puller as shown.
BEARING PULLEF
BEARING
CAUTION: Romove the gears using a pr63 and the
stesl blocks as shown, Use of a ,aw-typo puller can
cause damage lo lhe gear tooth.
Support 4th gear on steel blocks, and press thecountershaft out of sth and 4th gears, as shown.
sTH GEAF
{TH GEAR
.(
a
ItI

t
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage, then measure the counter-
shaft at points A, B, and C. lf any parts of the coun-
tershaft are less than the service limit. reDlace coun-
torshaft with a new one.
Standard:
A: 2/t.980 - 2{.993 mm (0.9835 - 0.9&O in}
B: 35.984 - 37.000 mm {1.4561 - 1.4567 in)
G: 33.fiD - 33.015 mm {1.2992 - 1.2998 in)
Sorvicc Limit:
Ar 2/t.9't0 mm 10.9819 inl
B: 36.930 mm {1.'l5qt in}
C: 32.950 mm {1.2972 in}
Insp€ct for wear
Inspect oil passage for clogging.
13-77
2. Insoect for runout. lf the runout is more than the
service limit, reolace the countershaft with a new
one.
Strndard: 0.02 mm {0.(x)08 in) max.
Servic. Limit 0.05 mm (0.002 in)
NOTE: SuoDort th€ countershaft at both ends as
shown.
Rotate lwo complelerevotutons.

Gountershaft Assembly
Reassembly
CAUTION:
. Pross 4th and sth gears on the countershaft without
lubrication.
. When installing ilth and sth geafs, support the shaft
on steel blocks, and install the gears using a press.
. Install ilth and sth gear with a maximum pressure of
25.5 kN (2,600 ksf, 18,806lbf).
NOTE; Refer to page 13-74 for reassembly sequence.
'1. Install the distance collar and the needle bearinos
on the countershaft.
COUNTERSHAFT
Install the friction damper, the synchro ring, and the
synchro spring on 1st gear.
Install the 1sv2nd synchro hub by aligning the fin-
gers on the friction damper and the grooves in the
1sv2nd synchro hub, as shown.
lST/2NO
13-78
lSI GEAR
insteps2-6onthe
{
4.lnstall the reverse gear.
Install the synchro spring. and the double cone
synchro as shown.
Assemble the friction damper, the needle bearing,
and 2nd gear, then install them by aligning the fin-gers on the friction damper and the grooves in the
1sv2nd synchro hub with the fingers of the double
cone synchro and the grooves on 2nd gear, as
snown.
Installthe spacer.
FRICTION DAMPER
Install the parts assembled
countershaft.
;
2ND GEAR