2002 HONDA CIVIC manual transmission

Manual Transmission
Transmission Removal (cont'd)
15. Remove the transmission mount bracket (A) and
transmission mounting bolt (B).
Remove the air cleaner bracket {C).
Raise the vehicle, and make sure it is securely
supponed.
Drain the transmission fluid. Reinstall the drain bolt
with a new washer (see page 13-3).
Remove the splash shield.
€Ds
to.
17.
18.
19.
db--qF
13-6
20.
21.
22.
23.
Remove the three way catalytic converter (TWC)
assembly (see step 30 on page 5-5)
Remove the driveshafts (see page 16-3).
Remove the intermediate shaft {see page 16-19).
Remove the front engine mount bracket mounting
bolt.
Remove the three bolts securing the transmission
rear mounI.
24.

Manual Transmission
\
12 x 1.25 mm64 N.m{6.5 ksf.m,47 tbf.ft)
30.
Transmission Removal (cont'd)
Pull the transmission away from the engine until
the transmission mainshaft clears the clutchpressure plate, then lower the transmission on the
transmission jack.
Remove the transmission rear mount (A) and the
transmission rear mount bracket {B).
Remove the boot (A), the release fork {B). and the
release bearing (C) from the transmission (D).
32.
13-8
Transmission Installation
Special Tools Required. Engine hanger adapter, 2.0 to 2.4 liter VS802C000015. E ngine hanger VS802C000018. Engine support hanger, A & Reds AAR-T-12566". subframe adaDter EoS02c000011* Available through the Honda Tool and Equipment
Program 888-424-6857
1. Check the two dowel pins are installed in the clutch
housr ng.
Apply super high temp urea grease (P/N 08798-
9002) to the release fork (A) and the release bearing(B). Installthe release fork and the release bearing.
0.4 1.0 g {0.01 0.04 ozl
3. Installthe transmission rear mount bracket (A)and
the transmission rear mount (B).
x 1.25 mmN m {6.5 kgf.m,
Place the transmission on the transmission iack.
and raise it to the engine level.
't2
6447
1.0 '1.6 g{0.04 0.06 oz)

Manual Transmission
Transmission Installation (cont'dl
'10. Installthe three rear mounting bolls for the
transmission rear mount.
59 N.m (6.0 kgf.m,43 tbf.ft)
Loosely tighten the front engine mount bracket
mounting bolt.
11.
12.
t5.
14.
Install the intermediate shaft (see page 16-24).
Installthe drivershafts (see page 16-17).
lnstall the three way catalytic converter (TWC)
assembly (see step 17 on page 5-12).
10 x 1.25 mm
13-10
6x1.0mm12Nm
15.Install the transmission mount bracket (A) and the
transmission mounting bolt {B).
12 x 1.25 mm54 N.m {5.5 ksf.m, 40lbf.ft)
12x 1.25 nn54 N.m(5.5 kgf.m,40 tbt.ft)
16.
17.
/t':::= 12 x 1.25 mm-) 54 N.m(5.5 kgf.m,40 tbf.ftl
Install the air cleaner bracket (C).
Install the two upper transmission mounting bolts.
12 x 1.25 mrn64 N.m (6.5 kgt.m,47 lbf.ftl
18. Remove the engine hanger and special tool from
engrne.

Manual Transmission
Transmission Installation (cont'dl
Apply super high temp urea grease (P/N 08798-
9002) to the end of the slave cylinder rod. Install the
slave cylinder and the clutch line bracket. Take care
not to bend the clutch line.
8 x 1.25 mm22 N.m (2.2 kgf.m, 16 lbf ft)6x1.0mm9.8 N.m(1.0 kgf.m,7.2 tbt.ftla^_#._gEEa9En(P/N 08798-9002)
24. Installthe harness clip.
13-12
25. Installthe cable bracket (A) and cables (B).
BWZ[i:i'u'T!'*n'-'
lPlN 08798-9002)
Apply a light coat of super high temp urea grease(P/N 08798 - 9002)to the cable ends.
Connect the back-up light switch connector (A) and
the vehicle speed sensor {VSS)connector (B).
26.
t1

Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
,.Y
-'- R
,ot/u
,t- v -1A' i6 t3l
\?
q'/V^
.!) DIFFERENTTAL ASSEMBLY
r2l SHIFT FORK ASSEMBLY
a9l 6 mm FLANGE BOLT12 N.m (1.2 kgf m,9lbf ftl
..4] BEARING sET PLATE
G, COUNTERSHAFT ASSEMBLY
O NEEDLE BEARING
3 OIL GUIDE PLATE C
e 14 x 20 mm DOWEL PIN
.9-i MAGNETi.!! MAINSHAFT ASSEMBLY
U 28 mm WASHER
t€4
i[, 28 mm SPRING WASHERiO BALL BEARING(l 28 x 43 x 7 mm OIL SEALReplace.
.D REVERSE GEAR SHAFT
1' REVERSE IDLER GEARf lr 6 mm SPECIAL BOLT15 N.m (1.5 kgt.m, 11 lbf.ft)
(!I REVERSE SHIFT FORK
.4' REVERSE LOCK CAMQ-t 35 x 58 x 8 mm OIL SEALReplace.
n""
?]] BACK-UP LIGHT SWITCH29 N m (3.0 kgf.m,22 lbf ftl.?1 O.RINGReplace.
1!) VEHICLE SPEEo sENsoR (Vss).O 8 mm FLANGE BOLT22 N.m (2.2 kgf m, 16lbf.ftl
.' CLUTCH HOUSINGiI6) TRANSMISSION HANGER
tl 10 mm FLANGE BOLT44 N.m {4.5 kgt.m,33 lbf.ft}
:
r'<__J'.@t / ,, tl
' j=-X ri ,1.-6
'-==-Yh,_-9
13-14

Manual Transmission
Transmission Disassembly (cont'd)
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the detent bolts (A), springs, steel balls,
and back-up light switch (B).
Remove the vehicle speed sensor (VSS) (A) and
O-ring (B).
13-16
3, Remove the interlock bolt (A), the change lever
assembly (B), 8 x 14 mm dowel pins (C), andthe
clutch line clip bracket {D).
€
Remove the drain plug (A), filler plug (B), and
10 mm flange bolt (C).

Manual Transmission
Transmission Disassembly (cont'd)
12. Remove the reverse shift fork.
Apply vinyl tape to the mainshaft splines to protect
the seal, then remove the mainshaft assembly (A)
and countershaft assembly (B) with the shift forks
{C)from the clutch housing (D).
14. Remove the 28 mm spring washer (E) and28mm
washer (F).
t7t1I
13-18
15. Remove the differential assembly (A) and magnet(B ).
Remove the oil gutter plate (A), 72mm shim (B),
and oil guide plate M.
16.

Manual Transmission
Change Lever Assembly Disassembly/Reassembly
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
BREATHER CAPTurn the arrow toward the {ronto{ the vehicle, and install it.
SELECT LEVERBe careful not to damage the dust sealwhen installing it.@).1 IlLrl
rrl
I
DUST COVEB
a^^
7 Fr"irr6-rooa
(P/N 08798-9002)
ROLLER
6x1.0mm12 N.m(1.2 kgl.m,8.7 lbf.ft)
'^ E-='-Fl !-d 1sr/2Noq )-=^l sELEcr
i €2 sPntruc
,.* (A)tace. ix#,,l
H\
lV srxSELECT-z:-=:l-': SPRING
r\
tr7
,/u
/
\op
(g)'
' -, OIL SEAL,/ ReDlace./-r,s
\__/
INTERLOCK
SHIFT ARM
SELECT STOPPLATE
REVERSE LOCK CAMSTRIKER
SHIFT ARM COVER
WASHER
9.8Nm{1.0 kgf.m, 7.2 lbf.ft)
13-20