2003 HONDA CIVIC ERS

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Synchro Sleeve and Hub Inspection
and Reassembly
1. lnspectthe gearteeth on ali synchro hubs and
synchro sleeves for rounded off corners, which
indicate wear.
2. Install each synchro hub (A) in its mating synchro
sleeve (B), and check for freedom of movement. Be
sure to match the three sets of longer teeth (C) (120
degrees apart) on the synchro sleeve with the three
sets of deeper grooves (D) in the synchro hub. Do
not install the synchro sleeve with its longer teeth
in the 1sv2nd synchro hub slots (E) because it will
damage the spring ring.
NOTE; lf replacement is required, always replace
the svnchro sleeve and svnchro hub as a set.
Synchro Ring and Gear Inspection
1.Inspect the inside of each synchro ring (A) for wear.
Inspect the teeth (Bi on each synchro ring for wear
(rounded off).
Example of synchro ring teeth
Inspect the teeth (C) on each synchro sleeve and
matching teeth on each gear for wear (rounded off).
Example ofteeth and gear teeth
(cont'd)
I
Il
GOOD
synchro sleeve
GOOD
/\
I
WORN
tl
WORN
13-39

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)
(

Manual Transmission
Transmission Reassembly
NOTE: Priorto reassembling, clean allthe parts in
solvent, dry them, and apply lubricant to any contact
surfaces.
1. Install the magnet (A) and differential assembly (B).
n-",-o
l;-D
Install the 28 mm spring washer (A) and 28 mm
washer (B) over the ball bearing (C). Note the
installation direction of the spring washer {A).
Apply vinyl tape to the mainshaft splines (D) toprotectthe seal. Installthe mainshaft and
countershaft (E) into the shift forks {F}. and install
them as an assembly.
13-46
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4. Install the reverse shift fork.
6x1.0mm15 N.m (1.5 kgf.m,11 lbf.ft)
f.)
Installthe reverse idler gear (A) and reverse gear
shaft (B) by aligning the mark {C)with the reversegear shaft hole (D).
(

-26 x 1,0 mmz/ / 15 N.m--' / {1 5 kgf m,€t I 11 tbf.ft)
Fl g
E
6, lnstallthe reverse lock cam.
Select the proper size 72 mm shim (A) according to
the measurements made during the Mainshaft
Thrust Clearance Adjustment (see page '13-43),
Installthe oil gutter plate (B), oilguide plate l\4, and
72 mm shim into the transmission housing (C).
7.
8. Remove the dirt and oil f rom the tramsmission
housing sealing surface. Apply liquid gasket (P/N
08718-0001) to the sealing surface. Be sure to seai
the entire circumference of the bolt holes to
prevent oil leakage.
NOTE: lf 5 minutes have passed after applying
liquid gasket, reapply it and assemble the housings.
Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
- - -Liquid gasket
{cont'd)
13-47

Manual Transmission
Transmission Reassembly (cont'dl
9. Install the 14 x 20 mm dowel pins (A).
34 N.m(3.5 kgf.m,25 rbf.ft)
Set the tapered cone ring (B) as shown. Place the
transmission housing over the clutch housing,
being careful to line up the shafts.
10.
13-48
11. Lower the transmission housing the rest of the wayas you expand the 72 mm snap ring {C). Release
the snap ring so it seats in the groove of the
countershaft bearing.
12. Check that the 52 mm snap ring is securely seatedin the groove of the countershaft bearing.
Dimension O as instalted: 3.3 6.0 mm
{0.13 0.24 in.l
Apply liquid gasket (P/N 08718-0001) to the threads
of the 32 mm sealing cap {D), and install it on thetransmission housing,
Install the transmission hangers A. and B, and the
8 mm flange bolts finger-tight.
13.
't4.
15.
8 x 1.25 mm27 N.m(2.8 kgf.m.20 rbf.ft)
(t
\A
e././
Tighten the 8 mm flange bolts in a crisscross
Pattern In several steDs.
(

16. Remove the dirt and oil from the shift iever cover
sealing surface. Apply liquid gasket (P/N 08718-
0001) to the sealing surface.
NOTE: lf 5 minutes have passed after applylng
liquid gasket. reapply it and assemble the housings.
Allow it to cure at least 20 minutes after assembly
before filling the transmission with oil.
- - -Liquid gasket
17. Installthe 8 x 14 mm dowel pins (A). clutch line clip
bracket (B), and change lever assembly (C).
12 N.m (1.2 kgf.m,9lbt ft)
18. Apply liquid gasket (Pi N 08718-0001) to the threads
of the interlock bolt (D), and install it on the
transmission housing.
6x1.0mm
19. Installthe drain plug (A), filler plug (B), and 10 mm
flange bolt (C) with new washers.
A39Nm(4.0 kgf m,33 tbl.ft)
20.
/..l-.=,'-Bg ^ 44N.m
@ Ut !?iJl'.'l,''
R\-: \
-.-t ?0, ,.ru ^44 N m {4.5 kgt m,33lbf.ft}
Installthe detent bolts (A), spring, and steel balls
with new washers.
{3.0 kgf.m.22lbf.ft)
Apply liquid gasket {P/N 08718-0001}to the threads
oithe back-up light switch (B), and install it in the
transmission housing.
(cont'd)
21.
13-49

M/T Differential
Carrier Bearings Replacement
Special Tool Bequired
Driver, 40 mm l.D. 07746-0030100
1. Check the carrier bearings for wear and rough
rotation. lf they rotate smoothly and their rollers
show no signs of wear, the bearings are OK,
2. Remove the carrier bearing (A) with a
commercially-available bearing puller (B).
13-54
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3. Install the new bearings (A)with the special tool
and a press. Press each bearing on until it bottoms.
There should be no clearance between the bearinos
and the carrier.
NOTE: Turn the sealed (B) side of the bearing away
from the differentialto install it.
077i16-0030100
07746-0030100
6

Driveshafts Disassembly
Special Tools Required. Threaded adaDter.22 x 1.5 mm 07XAC-001010A. Slide hammer, commercially available. Boot band pincers, commercially available
Inboard Joint Side:
1. Remove the set rlng from the inboard joint.
Remove the boot bands. Be careful not to damage
the boot and dynamic damper.. lf the boot band is a welded type (A), cut the boot
band (B).
. lf the boot band is a double loop type (C), lift up
the band bend (D), and push it into the clip (E).
. lf the boot band is a low profile type (F), pinch the
boot band using a commercially available boot
band pincers (G).
Welded Type
Low Profile Type
(cont'd)
16-5