2003 HONDA CIVIC ERS

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 Disassembly
Exploded View-Clutch Housing
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.!) 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}
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13-14

6.
5. Remove the 8 mm flange bolts in a crisscross
Dattern in several steos.
Remove the transmission hanger A, and
transmission hanger B.
Remove the 32 mm sealing cap (A).
Expand the 72 mm snap ring (B) on the
countershaft ball bearing, and remove it from the
groove using a pair of snap ring pliers.
Remove the transmission housing (C) and
14 x 20 mm dowel pins (D).
7.
L
10. Remove the reverse lock cam.
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11.Remove the reverse idler gear {A) and reverse gear
shaft {B).
(,
^A
(cont'd)
13-17

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.

Reverse Shift Fork Clearance
Inspection
1. Measure the clearance between the reverse idler
gear {A) and the reverse shift fork (B) with a feeler
gauge (C). lf the clearance is more than the service
limit, go to step 2.
Standard: 0.20-0.59 mm (o.oo7 0.024 in.l
Service Limit: r.3 mm {0.051 in.)
Measu re the width of the reverse shift fork.
. lf distance is notwithinthestandard, replacethe
reverse shift fork with a new one.. lf distance is within the standard, replacethe
reverse gear wrln a new one.
Standard: 13.4 13.7 mm (0.527 0.539 in.l
I
Change Lever Clearance Inspection
1.Measure the clearance between change lever (Al
and the select lever (B) with a feeler gauge (Cf. lf
the clearance is more than the service limit, go ro
step 2.
Standard: 0.05 0.25 mm (0.002-0.010 in.)
Service Limit: 0.50 mm {0.020 in.)
2.Measure the groove of the change lever'
. lf distance is not within the standard, replace the
change lever with a new one.
. lf distance iswithinthe standard, replacethe
select lever with a new one.
15.00 15.10 mm (0.591-0.594 in.)Standard:
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13-19

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
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DUST COVEB
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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
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,.* (A)tace. ix#,,l
H\
lV srxSELECT-z:-=:l-': SPRING
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(g)'
' -, OIL SEAL,/ ReDlace./-r,s
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INTERLOCK
SHIFT ARM
SELECT STOPPLATE
REVERSE LOCK CAMSTRIKER
SHIFT ARM COVER
WASHER
9.8Nm{1.0 kgf.m, 7.2 lbf.ft)
13-20

Shift Forks Glearance Inspection
NOTE: The synchro sleeve and synchro hub should be
replaced as a set.
1. Measu re the clearance between each shift fork (A)
and its matching synchro sleeve (B). lf the
clearance exceeds the service limit, go to step 2.
Standard: 0.35 0.65 mm {0.014 0.026in.1
Service Limit: 1.0 mm 10.039 in.l
A
l\4easure the thickness of the shift fork fingers.
. lf thethicknessof theshift forkfinger is not
within the standard, replace the shift fork with a
new one.. lf thethicknessof the shift forkfinger iswithin
the standard, replace the synchro sleeve with a
new one.
Standard: 7.4 7.6 mm (0.29-0.30 in.)
2.
3. Measure the clearance between the shift fork (A)
and the shift arm (B). lf the clearance exceeds the
service limit, go to slep 4.
Standard: 0.2-0.5 mm (0.007 0.020 in.)
Service Limit: 0.62 mm (0.024 in.)
Measure the width of the shift arm.
. lf thewidth of theshiftarm is notwithinthe
standard, replace the shift arm with a new one.. lf thewidth of the shift arm iswithinthe standard,
replace the shift fork and shift piece with a new
one.
Standard: 16.9-17.0 mm (0.665-0.669 in.)
4.
13-21

Special Tools Required. Driver,40 mm 1.D.07746-0030100. Attachment,30 mm l.D. 07746-0030300
NOTE: Refer to the Exploded View as needed during
this procedu re.
2.
4.
'1.Clean all the parts in solvent, dry them, and apply
lubricant to all contact su rfaces except the 3rd/4th
and 5th synchro hubs.
Installthe needle bearing and 3rd gear on the
mainshaft.
Installthe synchro ring and the synchro spring.
Installthe 3rd/4th synchro hub (A) by aligning the
synchro ring fingers (B)with 3rd/4th synchro hub
grooves (C).
-A
lnstallthe 3rd/4th synchro hub {A) using the special
tool.
07746-0030100
6. Installthe 3rd/4th synchro sleeve (A) by aligning
the stops (B)with the 3rd/4th synchro sleeve and
hub. After installing, check the operation of the 3rd/
4th synchro hub set.
@--
7. Installthe synchro spring (A).
Installthe synchro ring (B) by aliging the synchro
cone fingers (C)with 3rd/4th synchro hub grooves
(D).
Installthe 4th gear, needle bearing, distance collar,
needle bearing, and sth gear.
(cont'd)
9.
13-29