1999 HONDA CIVIC ect

Countershaft Assembly
Reassembly (cont'd)
4. Suppon the countershaft on a steel block as shownand install 3rd gear using the special tools and apress.
PRESS
35 mm l.o.07746-0030400
5. Install 4th gear using the special tools and a press.
DRlvER. 40 mm
DRIVER, 40 mm LO.07746 -0030100
ATTACHMENT,
07746- 0030100
ATTACHMENT,
DRIVER, 40 mm l.D.07746-0030100
ATTACHMENT,30 mm l.D.
35 mm LO.07746-0030400
6. Install 5th gear using the special tools and a Dress.
07746-00303005TI{ GEAR
.g
7. Install the bearings in the direction shown using thesDecialtools and a oress.
CAUTION: Install ths bearings with a maximumpressure ot 7.8 kN {800 kgt, 5,786 lbfl.
ATTACHMENT,30 mm l.D.07745 - q'303tl)
*1: 016Y7 engine*2: D16Y5, D16Y8 enginesThin edge of outerrace faces down,
8. Securely clamp the countershaft assemblv in
bench vise with wood blocks.
LOCKNUT
108+0r108N.m(11.0 * 0 - 11.0 kgt m. 79.6 - 0 * 79.6 tbf.ft)
Install the spring washer, tighten the locknut, thenstake the locknut tab into groove.
/rt-\
srySnap ring
lacss up.
\J

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub shouldbe replaced as a set.
l. Measure the clearance between each shift fork andits matching synchro sleeve.
Standard: 0.35 - 0.65 mm {0.014 - 0.026 intService Limit 1.0 mm (0.04 in)
2. lf the clearance is more than the service limit, mea-
sure the thickness of the shift fork fingers.
Standard:
3rd/ilth: 7.il - 7.6 mm {0.291 - 0.299 in}lst/2nd, 5th: 6.2 - 6.il mm (O.2,tt - 0.252 in)
lf the thickness of the shift fork finge.s is 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
SHIFT FORK
13-26
J
3. Measure the clearance between the shift piece orshift fork and the shift arm B.
Standard: 0.2 - 0.5 mm {0.008 - 0.02 in}
Sarvice Limit: 0.62 mm 10.0244 inl
4. lf the clearance is more than the service limit, mea-sure the groove of the shift piece or shift fork,
Standard: 13.2 - 13.4 mm (0.520 - 0.b28 inl
lf the groove of the shift piece or shift fork is notwithin the standard, replace the shift piece orshift fork with a new one.
lf the groove of the shift piece or shift fork iswithin the standard, replace the shift arm B witha new one.
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Synchro Sleeve,
Synchro Hub
MBS Shift Piece InsPection
1. Measure the width of the MBS shift piece.
Standard; 6.9 - 7.1 mm 10 272 - 0.280 inl
Service Limit: 6.8 mm {0.268 inl
lf the width of the MBS shift piece is less than
service limit, replace the MBS shift piece'
t
I nspection/l nstallati on
'1.lnspect gear teeth on all synchro hubs and synchro
sleeves tor rounded off corners, which indicate
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.
SYNCHROSLEEVE
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 not install th€ sYnchro sleeve with
its longsr t€sth in the synchro hub slots bocause ii
will damage ths spring ring.
LONGER TEETH
13-27

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).
r- /-\
oioi *-o*
C: Inspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
,

UtJGOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
Fr 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
synchro ring. making sure that it does not slip.
Measure the clearance between the synchro ring
and gear all the way around.
NOTE: Hold the synchro ring against the gear evenly
while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.73 - 1.18 mm {0.029 - 0.046 in}
Service Limit 0.4 mm {0.02 in)
lf the clearance is less than the service limit, replace
the synchro ring and synchro cone.
SYNCHRO
SYNCHRO
\a
r/
13-28

Shift Rod
Removal
NOTE: The steel batlsareall of the same size (5/16 in)'
1. Remove the differential assembly'
2. Remove the 28 mm plug bolt and lst/2nd select
spring.
3. Remove the shift arm C attaching bolt'
4. Remove the shift arm shaft'
NOTE: Be careful notto lose the steel ball'
5. Remove the steel ball, spring, and collar'
SHIFT ARM C
SHIFT ARM B
INTERLOCK
6. Remove shift arms C and B, and the interlock, then
remove the reverse select spring and retainer'
7. Remove the shift arm A attaching bolt, the set ball
spring bolt, set spring, and steel ball'
8. Remove the shift rod' then remove the shift arm A'
9. Remove the reverse lock cam'
10. Remove the magnet.
CAM
REVERSE SELECT RETAINER
REVERSE SELECT SPRING
L. 63.4 mm {2.50 inl
REVERSE LOCK
lIV/
' lJ
\s
SPRING L. 21.4 mm(0.843 in)
SI{IFT ARM A
14x20OOWEL PIN
COLLAR
,*(S* \
6S* srtrr ran,t srarr
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',)r,r"o r..."r "rr,*n

t. 36.26 mm {1.428 in,
28 mm PI-UG BOLT
OIL SEALReplace.
&-"onn"
BALLSPRING EOLT
SPRINGL. 25.6 mm 11.01 inl
DIFFERENTIAL ASSEMBLY
SHIFT ROD

Differential
Check lor cracks.
BALL BEARINGCheck for wear and damage.
DIFFERENTIAL
THRUST SHIMSelective part
SPEEDOMETERDRIVE GEAR
10 x 1.0 mm101 N.m (10.3 ksf.m. 74.5 lbt.ftlLeft-hand threads
ffi
FrNAL DRTvEN o*^r'@c'ec'owea'-Zl
BALL BEARINGCheck for wear and damage.
13-30
Backlash Inspection
'1. Place differential assembly on V-blocks, and installboth driveshafts.
OIAL
Measure backlash of both pinion gears.
Standard {New); 0.05 - 0.15 mm {0.002 - 0.006 in)
lf the backlash is not within the standard, reDlacethe differential carrier.
SI

7. lf the clearance is more than the standard, select a
new thrust shim from the following table
NOTE: It the clearance measured in step 6 is within
the standard. go to step 10.
Standard: 0 - 0.10 mm l0 - 0.00/t inl
72 mm THRUST SHIM: D16Y7 engin€
\
Part NumberThickness
41441 - PL3 - A001.0 mm (0.0394 in)
41442-PL3-A00'1 .1 mm {0.0433 in)
41443-PL3-A001.2 mm {0.0472 in)
41444-PL3-A001.3 mm (0.0512 in)
41445-PL3-A001.4 mm (0.0551 in)
41446-PL3-A001.5 mm (0.0591 in)
41447-PL3-A001.6 mm (0.0630 in)
41448-PL3-A001.7 mm (0.0669 in)
4r449-PL3-A001.8 mm (0.0709 in)
41450-PL3-A001.05 mm {0.0413 in)
41451-PL3-A001.15 mm (0.0453 in)
41452-PL3-A001.25 mm (0.0492 in)
41453-PL3-A001.35 mm (0.0532 in)
41454-PL3-A00'1.45 mm (0.057'l in)
41455-PL3-A001.55 mm (0.0610 in)
41456-PL3-A001.65 mm (0.0650 in)
41457-PL3-A001.75 mm (0.0689 in)
80 mm THBUST SHIM: D16Y5. D16Y8 engines
Remove the bolts and transmission housing.
Replace the thrust shim selected in step 7, then
recheck the clearance.
Remove the bolts and transmission housing. Apply
liquid gasket to the surface of the transmission
housing and reassemble
8.
9.
10.
Part NumbelThickness
41441 - PL3 - B001.0 mm (0.0394 in)
41442-PL3-8001.1 mm (0.0433 in)
41443-PL3-8001.2 mm (0.0472 in)
41444-PL3-8001.3 mm (0.0512 inl
41445-PL3-8001.4 mm (0.0551 in)
41446-PL3-8001.5 mm (0.0591In)
41447-PL3-8001.6 mm (0.0630 in)
4r 448 - PL3 - 8001.7 mm (0.0669 in)
4 t449 - PL3 - 8001.8 mm (0.0709 in)
41450-PL3-800'1.05 mm (0.0413 in)
41451 - PL3 - 800'1.15 mm (0.0453 in)
41452-PL3-8001.25 mm (0.0492 in)
41453-PL3-B001.35 mm (0.0532 in)
41454-PL3-B001.45 mm (0.0571 in)
41455-PL3-B001.55 mm (0.0610 in)
41456-PL3-8001.65 mm (0.0650 in)
41457-PL3-8001.75 mm {0.0689 in)

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
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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)