2003 HONDA CIVIC Synchro

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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
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 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|

SuspensionAdjustment................-............................184 VComponent Location Index................. 20-17
Windshield GlessReplacement............-..............-............. 20 19
Synchro Ring, Triple-coneInspection...............-..........................1339 ValveGuides
Synchro SleeveInspectaon/Reassemb1y ....................... 13 39
Inspection ............-.-................................ 6 32Beplacement ..........-................................ 6 33 Wiper Intermittent Control Unit,Rear WindowInput Test
T
Valve SeatsRepair ...................................................... 6 35.....22-134
WiDer Motor, Rear WindowRep1acement....................................... 22-1 46Adjustment .-.-.......Removal ...-...-......................................-... 6-31 WiDer Motor, windshield6-9
.....6-32 Test.......-..........-.....-.............................22-143Taillight
ThermostaiTest ........................
Inspec!on
Vehicle Speed Signal Circuit
VTC System
Wiper/WasheI
Wi.ing System
10 4 Troubleshooting .....-... ..........................22-65 Component Location In dex ..............22-134Replacement.....-...-....... ...................... 10 IvssThrottle BodyTest ..................Removal/lnstallation .. . . . . . .. ... 11-'165 VTC ActuatorDisassembly/Feassemb|y................-11-166 Inspection
Circuit Diagram .......................... 22-136, 131
Replacement -.............. ............ .............22 61 Wiper/Washor SwitchTesVReplacement .............................. 22-1 40
.................68 WireHarnesses
11-160
Replacement ........................................... 6 24 (Seefirstpageofthislndex)Throttle CableAdjustment ...... ...-.................... 11163 VTC Oil ConlrolSolenoid ValveRemoval/1nsta11ation..........................11164 Removal....-...-... |1-127 HowtoIn{ormation ...............................223Belay and Control UnitLocations .-....-.............. -.-.-....- 22-7, 4, 1 1, 12Beplacement.........-............................... 1767 ComponentLocationlndex.............. 11-117Tie-rod Ball Joint Boots
lnstallation
Replacement
Turn Signal/Hazard Relay
tsTiming/Cam ChainVTEC Solenoid Valve...612 Femoval/lnspection....-......................11-128................ 6 15
Timing/Cam Chain Auto-tensionelRemoval/1nsta11ation..............................6-19 W
Troubleshooting{See first page ot this Index)
Turn Signal Light
Timing/Cam Chain CaseOil SealInstallation......................-......................6,21 Washer Fluid Level SwitchTesVReplacement .............................. 22 1 44Trailing ArmsRemoval/lnstallation .............. . . . . ..... 18 33 Washer Fluid ReservoirReplacement ....................................... 22-1 46tnmComponent Location lndex ................- 20 49 Washer Motor, WindshieldRemoval/lnstallation ..-.......20 50,51,52,53 Test -..............-.............. ........................22 144
Washer Tube, WindshieldReplacement......-...-............................ 22 1 47
W.ter Outlet.........22 A4 Installation ..................-........................... '10-9
InputTest........22-87 lnstallation................ 10IWeter Passage
Wheels andTires
Turn Signal/Hazard Warning Lights Water PumpComponent Location In dex .................22 85 Inspection ........................... .. . . . ....... 10 5Circu it Diagram ................-................... 22-86 Replacement .-......................................... 10 5
U
WheelBearingsInspec|ion ....................................... ....... 18 8
Wheel Speed SensorsInspection ..-..,.,.,,.,,,,,.,.,,,...................... 19-59Replac€ment ........-....... . . . . . . .. -.... 19-59UndeFdash Fuse/R€lay BoxRemoval/lnstaf lation ............................ 22-49
Upper ArmsRemoval/|nsta11ation................. ... 18-32
],sInspect|on