2000 HONDA CIVIC Gauge

Pressure Plate
\Removal/lnsPection
1.Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard {New}: 0.6 mm (0.02 inl max.
Seruice Limit: 1.0 mm {0.04 in}
FEELER GAUGE
CLUTCH ALIGNMENT DISCOTJAF_PM7O1 1ACLUTCH ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-37tOtOO
lf the height exceeds the service limit, replace the
pressure Plate.
3. Installthe special tools
PRESSURE PLATE
MOUNTINGBOLT
ALIGNMENT SHAFTOTJAF-PM7012AHANDLE07936-371010Oo7924-PD20003GEAR HOLDER
07LA8-PVOOIOOot
ENGINEBLOCKADJUSTER BOLT
BOLT
4. To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
f
12-7
lnspect the pressure plate surface for wear' cracks,
and burning.
Inspect for warpage using a straight edge and leeler
ga uge.
NOTEr Measure across the pressure plate at three
pornrs.
Standard (Newl: 0.03 mm (0.001 inl max.
Service Limit: 0.15 mm (0.006 inl
lf the warpage exceeds the service limit, replace the
pressure plate.
STBAIGHT EDGE

I)t
Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Measure the clearance between the countershaft
and lst gear.
Standard: 0.03 - 0.10 mm (0'(X)l - 0'qt4 in)
Sorvic. Limit: 0.22 mm (0.009 inl
2. lf the clearance is more than the service limit, mea-
sure the thickness of 1st gear.
Standard: 30./tl - 30.'l'l mm
11.197 - 1.198 in)
Servics Limit 30.36 mm (1.195 in)
lf the thickness of 1st gear is less than the service
limit, replace lst gear with a new one.
lf the thickness of 1st gear is within the service
limit, replace the lsv2nd synchro hub with a new
one.
GAUGE
1ST GEAB
3. Measure the clearance between 2nd and 3rd gears.
Standard: 0.04 - 0.12 mm (0.002 - 0.005 in)
Servico Limit: 0.2,1 mm 10.009 in)
4. lf the clearance is more than the service limit, mea-
sure th€ thickness of the spacer collar'
stlndard: 32.G1 - 32'06 mm
{1.261 - 1.262 in}
S6rvica Limh: 32'01 mm (1'260 in)
SPACERCOLLAR
lf the thickness is less than lhe service limit, replace
the sDacer collar with a new one.
lf ths thickness is within the service limit, measure
the thickness of 2nd gear.
Standard: 31.91 - 31.96 mm
11.256 - 1.258 inl
Soryice Limit 31.85 mm (1.25,1inl
z4:_- 2I{D GEAF
/l\\/j'T - "b/
P-
1^'.-1r.--l--f
lf the thickness of 2nd gear is less than the ser-
vice limit, replace 2nd gear with a new one.
lf the thickness of 2nd gear is within the servace
limit, replace the lsv2nd synchro hub with a new
one,
13-21

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)

Mainshaft Thrust ShimI
I
Adjustment (cont'dl
b.Attach the mainshaft holder to the mainshaft asfollows:
NOTEI
. Back-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip istoward the transmission.
. Align the mainshaft holder's lip around thegroove at the inside of the mainshaft splines,then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
MAINSIIAFTHOLDER07GAJ-PG20110
d.
Seat the mainshaft fully by tapping on the end witha plastic hammer.
Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft base.
u
e. Zero a dial gauge on the end ofthe mainshaft.
MAINSHAFT HOLDER07cAJ_PG20110
Turn the mainshaft holder bolt clockwise: stop turn,ing when the dial gange has reached its maximummovement. The reading on the dial gauge is theamount of mainshaft end olav.
CAUTION: Turning the mainshaft holder bolt morethan 60 degre€s after the needle ot the dial gauge
stops moving may damage the iransmission.
lf the reading is within the standard. the clearance iscorrecl.
lf the reading is not within the standard, recheck theshim thickness.
Standard: 0.11 - 0.18 mm {0.00it - 0.007 in}
t.
\,J

Mainshaft Thrust Clearance
Adjustment
1. Remove the 72 mm thrust shim and oil guide platefrom the transmission housing.
4.
TFANSMISSIONHOUSING
72 mm THRUST SH|M
TRAt{SMtSStONHOUSINGOIL GUIOE PLATE
lnstall the 3rd/4th synchro hub. spacer collar,5thsynchro hub. spacer, and ball bearing on the main_shaft, then install the above assembly in the trans_mission housing.
lnstall the washe[ on the mainshaft,
Measure distance @ between the end of the trans-mission housing and washer.
NOTE;
. Use a straight edge and vernier caliper.. Measure at three locations and average the read_ing.ENO otlnA sMtsstoNHOUSINGMAINSHAFT
3RD/irTH SYNCHRO HUB
SPACCR COLLAR
5TH SYNCHRO HUB
o
B
13-88
AALL BEARING
V.
5. Measure distance @ between the end of the clutchhousing and bearing inner race.
NOTE;
. Use a straight edge and depth gauge.. Measure at three locations and average the read-ings.
Select the prcpet 72 mm thrust shim from the chartby using the formula below.
NOTE: Us€ only one 72 mm thrust sntm.
Shim Selection Formula:
From the measurements you made in steps 4 and 5:. Add distance O lstep 5) to distance @ (step 4).
. From this number, subtract 0.93 (which is themidpoint of the flex range of the clutch housingbearing spring washer).
. Take this number and compare it to the availableshim sizes in the chart.
{For example)
B;2.39
+ C: 0.22- 0.93
2.61 = 1.68
Try the 1.68 mm (0.0661 in) shim.
INNER RACE ot EALL BEARING

Mainshaft Thrust Clearance
Adjustment (cont'd)
13. Check the thrust clearance in the manner describedoetow.
CAUTION: Measuremenl should be made at roomtempetature.
a. Slide the mainshaft base over the mainshaft.
MAINSHAFT EASE07GAJ - PG20.130
b. Attach the mainshaft holder to the mainshaft asfollows:
NOTE:
. Back-out the mainshaft holder bolt and loosenthe two hex bolts.. Fit the holder over the mainshaft so its lip istowards the transmission.. AIign the mainshaft holder.s Iip around thegroove at the inside of the mainshaft splines,then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
MAINSHAFT
[--F-e
l6fffi l
rx| - \-/ I/ Borrs
ff
MAINSHAFTHOLDER07GAJ - PG20110
MAINSHAFT BASE07GAJ - PG20130
13-90
c. Seat the mainshaft fully by tapping its end with aplastic hammer.
d. Thread the mainshaft holder bolt in untjl it justcontacts the wide surface of the mainshaft base.
e. Zero a dial gauge on the end ofthe mainshaft.
f. Turn the mainshaft holder bolt clockwise; stooturning when the dial gauge has reached itsmaxtmum movement. The reading on the dialgauge rs the amount of mainshaft end Dlav.
CAUTION: Turning tho mainshaft holder boltmore than 60 degrees after the needle of the dialg€uge stops moving may damage the transmis_ston.
07cAJ _ PG20110
g. lf the reading is within the standard, the clear-ance is correct.
lf the reading is not within the standard. recheckthe shim thickness.
Standard: 0.11 - O.18 mm {0.004 - 0.007 in}
DIAL GAUGE

Special Tools
l.- a
Ref. No. Tool Number
o,6'\
€)
@)
@-
@
@
o
@
@
@
@..
@
@
@
@
@
07GAB - PF50101
07GAE - PG40200 or
OTGAE - PG4O2OA
07HAC - PK4010A
07JAD - PH80101
07JAD - PH80200
07LAE - PX40100
07PM - 0010100
07sM - 0010004
OTMAJ - PY4O1 1A
07MAJ - PY40120
07406 - 0020400
07406 - 0070300
07736 - A010004
07746 - 0010500
07746 - 0010600
07746 - 0030100
07749 - 0010000
07947 - 611501
Mainshaft Holder
Clutch Spring Compressor Bolt Assembly
Housing Puller
Driver Attachment
Pilot, 26 x 30 mm
Clutch Spring Compresso. Attachmenr
SCS Service Connector
Backprobe Set
IVT Oil Pressure Hose, 2210 mmAy'T Oil Pressure Hose, Adapter
Ay'T Oil Pressure Gauge Set dpanelA,/T Low Pressure Gauge WpanelAdjustable Bearing Pulter, 25 - 40 mmAftachment, 62 x 68 mm
Aftachment, 72 x 75 mmDriver 40 mm l.D.
Driver
Driver Attachment, 68 mm
I
1
1
1
I
1,l
'l
1
I
1
1
14-133, 180
14-160, 163
14-135
14-171
14-'t7'l
14-160, 163
14-49
14-50, 113
r4-119
14- 1 19
14-119'14-1 19
14-172,173
14-172,'t73,114
14-172,174
14-153, 167. 169, 170
1+17 1 , 17 2, 173, 17
14-'t7'l
4
w
@o
*07HAE - P150101 can be used as a substitute.**Must be used with commercially-available 3/8,, _ 16 slide
E-E
@
@@
hammer.
=k
lalg
€)
ry
o
e
@
o
----a\\<-t-'- /\26
@@
@@@
aL
14-2

PGM Gircuit Diagram (A/T Control System: '96 - 98 Modelsl
UNDEfl -HOOD FUSE/RELAY BOX
No.41 (80A1 N0.42 l40A)
No.47 {7.5 A)
No.l3 (15A)
Arp Np lon,^o l r,, lotrr l 6lt l 3]t lot*
UNDER DASHFUSE/REIAY 8OX
/8LU
c10
YEUBLKBtK
424
Btx
At0423
'96:BLU/BED'97, '98r GFN/BLK
TTTYEL GRN BLULT GRN
BLK/BTU
RED
GRNiELK
F- BTK/BI.U
F_wHr
F- GRN
f- GRN
F- Bru
GRN
BLU
NorE: t :ro5v
T :ro 12v
GAUGE ASSEMBTY
A,T GEAR POSITIONINDICATOR
824 t88 tB17'96: GRN 8LU
'96: BLU/RED al'97,'98: GRN/8LK --