2002 HONDA CIVIC trans

Manual Transmission
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Countershaft Reassembly
Exploded View
SPECIAL BOLTEeplace.118 N.m (12 kgf m, 87 lbf ft)
BALL BEARINGCheck for wear andoperation.Note the direction of installation.
35 mm SHIM
REVERSE GEAR
1ST/2ND SYNCHRO HUB
SPRING
TRIPLE CONE SYNCHRO
1ST GEAR
NEEDLE BEARINGCheck for wearano opera!on.
DISTANCE COLLAR
ANCE COLLAR
GEAR
4TH GEAR
Check for wear andoperation.
DISTANCE COLLAR
FRICTION DAMPERCheck for wear and damage.
TRIPLE CONE SYNCHRO
SYNCHRO SPRING
COUNTERSHAFT
13-34

Manual Transmission
10.
Countershaft Reassembly (cont'dl
9.Install the needle bearing.
Installthe 2nd gear (A) by aligning the synchro
cone fingers (B) with znd gear grooves (C).
'l 1.Supoort the countershaft (A) on the steel blocks,
then install the 3rd gear (B) using the special tool
and a press (C). Do not exceed the maximum
Dressure.
14,700 N (1,500 kgf,3,307 lbflmax.
07746-0030100
13-36
L,
12. Install the 4th gear (A) using the specialtool and a
press (B). Do not exceed the maximum pressure.
B14,700 N {1,500 kgt,3,307 lbf) max.
07746-0030100
Installthe 5th gear (A) using the special tool and a
press (B). Do not exceed the maximum pressure.
14,700 N (1.500 kgl,3.307 lbf) max.
07746-0030100
I

Manual Transmission
Countershaft Reassembly (cont'd)
11.Support ball bearing (A) on steel blocks (B), then
use a press (C) and an attachment (D) to press the
countershaft (E) out of the ball bearing.
lf necessary, installthe 35 mm shim selected in
step 16, then recheck the clearance,
Install the distance collar (A).35 mm shim, and new
ball bearing (B) using the specialtools and a press
(c).
46-0030r00
18.
19.
13-38
20. Tighten the new special bolt (A) (left-hand threads).
'l18 N.m (12 kgf.m,87 tbf.ftl

Manual Transmission
Synchro Ring and Gear Inspection (cont'dl
3. Inspect the thrust surface {D) on each gear hub for
wear.
Inspect the cone surface (E) on each gear hub for
wear ano rougnness.
Inspect the teeth on all gears (F) for uneven wear,
scoring, galling, and cracks.
Coat the cone surface of each gear (E) with oil, andplace its synchro ring on it. Rotate the synchro ring,
making sure that it does not slip.
13-40
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7. Measure the clearance between each gear (A) and
its synchro ring (B) allthe way around. Hold the
synchro ring against the gear evenly while
measuring the clearance. lf the clearance is less
than the service limit, replace the synchro ring andgear.
Synchro Ring.to.Gear Clearance
Standard: 0.70 1.49 mm 10.028 0.059 in.)
Service Limit: 0.4 mm {0.016 in.)
Triple Cone Synchro-to-Gear Clearance
Slandard:
O: Outer Synchro Ring {B}to Synchro Cone (Cl
0-70 1.19 mm (0.028-0.047 in.)
@: Synchro Cone lC) to cear (A)
0.50- 1.04 mm (0.020-0.041 in.)
O: Outer Synchro Ring (B) to Gear (Al
0.95 1.68 mm 10.037 0.066 in.)
Service Limit:
O: 0.3 mm (0.012 in.)
: 0.3 mm (0.012 in.)
O; 0.6 mm 10.024 in.l
\
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Mainshaft Bearing and Oil Seal Replacement
Special Tools Required. Oil seal driver 07JAD-P190100. Adjustable bearing puller,20 40 mm
07736-4010008. Driver 07749-0010000. Attachment,42 x 47 mm 07746-0010300. Slide hammer, commercially available
1. Remove the differential assembly,
2. Remove the ball bearing (A)from the clutch
housing (B) using the specialtool and a
commercially available 3/8" - l6 slide hammer (C).
Remove the oil seal (A) from the clutch side. Be
careful when removing the seal so the clutch
housing is not damaged.
4.Drive the new oil seal in from the transmission side
using the special tools.
07749-0010000
07746-0010300
Drive the new ball bearing (A) in from the
transmission side using the specialtool.
13-41

Manual Transmission
Countershaft Bearing Replacement
Special Tools Required. Adiustable bearing puller,20-40 mm 07736-A0tOOOB. Oil seal driver 07JAD-AP190100. Slide hammer, commercially available
1. Remove the bearing set plate (A)from the clutchhousing (B).
Remove the needle bearing (A) using the special
tool and a commercially available 3/8" - 16 slidehammer (B), then remove the oil guide plate C.
07736-A010008
13-42
3. Position the oil guide plate C and new needle
bearing (A) in the bore of the clutch housing (B).
Installthe needle bearing using the specialtool.
Installthe bearing set plate (A) wirh bolts (B).
B6x 1.0 nn12N.m {1.2 kgt m,8.7 tbf.ft)
(

Mainshaft Thrust Clearance Adiustment
Special Tools Required. Mainshaft base 07GAJ-PG20130. Mainshaft holder 07GAJ-PG20110
1. Remove the 72 mm shim (A) and oilguide plate M
from the transmission housing (B).
,5---ov/
Installthe 3rd/4th synchro hub (A), the distance
collar (B), the 5th synchro hub {C). distance collar
(D), and ball bearing (E) on the mainshaft (F), then
installthe assembled mainshaft in the transmission
housing (G).
lnstall the washer (H) on the mainshaft.
Measure distance O between the end of the
transmission housing and washer with a straight
edge and vernier caliper. Measure at three
locations and average the reading.
5.Measure distance @ between the end of the clutch
housing (A) and the bearing inner race (B)with a
straight edge and depth gauge. Measure at three
locations and average the readings.
A
Shim Selection Formula:
6, Select the proper 72 mm shim from the chan.
Follow the example below, and use the
measurements you made in steps 4 and 5:
(Basic Formula)
O+@ (0.8 * 0.11) = shim thickness (maximum)
O + O (0.8 + 0.17) = shim thickness (minimum)
. Add distance O (step 5) to distance O (step 4)
. 0.8 mm (0.031 in): Spring washer, a dimension in
the installation.. 0.11 mm (0.004 in): lvlinimum thrust clearance
. 0.17 mm (0.007 in): Maximum thrust clearance.
(For example)
2.32 + 0.15 - (0.8 + 0.11)= 1.56 mm (0.061 in.)
2.32 + 0.15 - (0.8 + 0.17)= 1.50 mm (0.059 in.)
Take the middle value of the minimum value and
the maximum value, and select the 1.53 mm
(0.060 in.) shim.
{cont'd)
13-/li|

Manual Transmission
Mainshaft Thrust Clearance Adjustment (cont'dl
72 mm Shim
Part NumberThickness
23931-P21-0000.60 mm {0.0236 in.)
B23932-P21-0000.63 mm (0.0248 in.
c23933-P21-0000.66 mm (0.0260 in.D23934-P21-0000.69 mm (0.0271 in.
E23935-P21-0000.72 mm (0.0283 in.
F23936-P21-0000.75 mm (0.0295 in.
23931-P21-0000.78 mm (0.0307 in.-23938-P2'l-0000.81 mm (0.0319 in
23939-P21-0000.84 mm (0.0331 in
J23940-P21-0000.87 mm {0.0343 in,
23941-P21-0000.90 mm (0.0354 in.
L23942.P21-0000.93 mm (0.0366 in.
M23943-P21-0000.96 mm (0.0378 in.
N239 44-P21 .0000.99 mm (0.0390 in.
o23945-P21-0001.02 mm (0.0402 in.P23946-P21-0001.05 mm (0.0413 in.
o23941-P2't-000'l.08 mm (0.0425 in
R23948-P2'l-000'1 .1 1 mm {0.0437 in
23949-P21-000'1.14 mm (0.0449 inT23950-P21-0001.17 mm {0.0461n.
U23951-P21-0001.20 mm 10.0472n.
23952-P21-0001.23 mm (0.0484n.
23953-P21-0001.26 mm {0.0496n.X23954-P21-0001.29 mm (0.0508n.
23955-P21-0001.32 mm (0.0520n.z23956-P21,0001.35 mm (0.0531 in
23957-P21-0001.38 mm (0.0543 in
AB23958-P21-0001.41 mm (0.0555nAC23959-P21-0001.44 mm (0.0567n.
AD23960-P21-0001.47 mm (0.0579n.
AE23961-P21-0001.50 mm (0.0591n.AF23962-P21-OOO1.53 mm (0.0602n.AG23963-P21-000156 mm (0.0614n.
AH23964-P21-0001.59 mm (0.0626n.
AI23965-P21-0001.62 mm (0.0638 in
AJ23966-P21-0001.65 mm (0.0650 in
AK23967-P21-0001.68 mm (0.0661 in
AL23968-P2r -0001.71 mm (0.0673 in.
AM23969-P21-0001.74 mm (0.0685 in.
AN2397 0-P21-0001.77 mm (0.0697 in.AO23971-P2't-OOO1.80 mm (0.0709 in.
13-44
12.
7. Installthe 72 mm shim (A) selected and oil guideplate M in the transmission housing (B).
,6,,-oV
Thoroughly clean the spring washer (A) and
washer (B) before installing them on the clutchhousing side ball bearing {C). Note the installation
direction of the spring washer.
8.
{
10.
11.
9.lnstallthe mainshaft in the clutch housing.
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings withseveral 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
Tap the mainshaft with a plastic hammer.