2003 HONDA CIVIC Synchro

Manual Transmission
Mainshaft Reassembly
Exploded View
A
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Y7
ANGULAB BALL BEARINGCheck for wear and operation.Note the direction ofinstallation.3RD/4THSYNCHROSLEEVE
3RD/4THSYNCHRO HUB
SYNCHROSPRING
SYNCHRO RING
TAPEBED CONE RING
MBS DISTANCE COLLAR
SYNCHRO SLEEVE
NEEDLE BEARINGCheck for wear and operation.
GEAR
SYNCHRO RING
SYNCHRO SPRING
NEEDLE BEARINGCheck for wear and operation.
MAINSHAFT
4TH/5TH GEAB DISTANCE COLLAR
\(
a
13-28

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

Manual Transmission
Mainshaft Reassembly (cont'dl
10. Installthe synchro ring and the synchro spring.
1 '1. Installthe sth synchro hub (A) by aligning the
synchro cone fingers (B) with sth synchro hub
grooves (C).
Installthe 5th synchro hub (A) using the special
tools.
07746-0030100
07746-0030300
13. Installthe 5th synchro sleeve.
12.
13-30
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14. Installthe synchro spring (A).
Installthe synchro ring (B) by aligning the synchro
cone fingers (C) with sth synchro hub grooves (D).
Installthe MBS distance collar and the tapered
cone ring.
Installthe new ball bearing {A) using the special
tools and a press (B).
t5.
16.
11.
U1
07746-0030100

Countershaft Assembly Clearance lnspection
1.Measure the clearance between the 1st gear (A)
and the distance collar (B)with a feeler gauge (C).
. lf the clearance is more than the service limit, go
to step 2.. lf the clearance is within the service limit. go to
step 4.
Standard: 0.06 0.16 mm 10.002 0.006in.l
Service Limit: 0.25 mm (0.010 in.l
2. fvleasure the thickness of the distance collar.
. lf thethickness is notwithin the standard, replace
the distance collar with a new one.' lf the thickness is within the standard, go to
Standard:23.03 23.08 mm (0.907 0.909 in.l
3. Measu re the thickness of the 1st oear.
. lf thethicknessof lst gearis lessthanthe service
limit, replace lstgearwith a newone.. lf the thickness of '1st gear is within the service
limit, replace the lst/2nd synchro hub with a new
one.
Standard: 22-92 22.97 mm 10.902 0.904 in.l
Service Limit; 22.87 mm {0.900 in.)
Measure the clearance between the 2nd gear (A)
and 3rd gear (B) with a feeler gauge (C). lf the
clearance is more than the service limit, go to
steD 5.
Standard: 0.06 0.16 mm (0.002 0.006in.)
Service Limit: 0.25 mm {0.010 in.l
4.
(cont'd)
13-31

Manual Transmission
Countershaft Assembly Clearance
Inspection (cont'd)
5. Measure the th ickness of the distance collar.
. lf thethickness is notwithin the standard, replace
the distance collar with a new one.. lf thethickness iswithinthe standard, goto
step 6.
Standard: 28.03 28.08 mm {1.104-1.106 in.)
6. Measure the thickness of the 2nd qear.
. lf thethickness of 2nd gearis lessthan the
service limit, replace 2nd gear with a new one.. lf thethicknessof 2nd geariswithintheservice
limit, replace lhe 1sV2nd synchro hub with a new
one.
Standard: 27 -92-21.97 mm|.1.099 1.r01 in.l
Service Limit: 27.87 mm 11.097 in.)
13-32
Countershaft Disassembly
1.Securely clamp the countershaft assembly in a
bench vlse with wood blocks.
Remove the special bolt (left-hand threads).
Support the ball bearing (A) on steel blocks, then
use a press (B) and an attachment (C)to press the
countershaft out of the ball bearing.
4. Remove the 35 mm shim and distance collar.
I

Manual Transmission
(
(
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

Special Tools Required. Driver, 40 mm l.D.07746-0030100. Aftachment.30 mm 07746-0030300
NOTE: Refer to the Exploded View as needed during
lhis procedure.
1. Clean all parts in solvent, dry them, and apply
lubricantto all contact surfaces.
Installthe dislance collar, needle bearing, and 1st
gear onto the countershaft.
Install the triple cone synchro assembly (A) by
aligning the synchro cone fingers (B) with 'lst gear
grooves (C), then install the synchro spring {D).
3.
Installthe '1st/2nd synchro hub (A) by aligning the
synchro cone fingers (B)with 1sV2nd synchro hub
grooves (C).
5. Installthe reverse gear.
13-35
6. Installthe synchro spring (A).
lnstall the triple cone synchro assembly (B) by
aligning the synchro cone fingers (C) with the
1sv2nd synchro hub grooves (D).
Installthe distance collar (A) and friction damper(B) by aligning the friction damper fingers (C) with
the 1sv2nd synchro hub grooves (D).
1.
8.
(cont'd)

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