2003 HONDA CIVIC ect

Slave Cylinder Replacement
NOTE:. Use fender covers to avoid damaging painted
surfaces.. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake fluid does contact the paint, wash it
off immediately with water.
1. Write down the frequencies for the radio's preset
buttons. Disconnect the negative ( ) cable first,
then the positive (+)cable from the battery.
Remove the battery.
2. Remove the battery tray.
a
Remove the air cleaner housing cover and the air
cleaner housing (see step 6 on page 5-2).
Remove the intake air duct (see step 8 on page 5-3) .
Remove the clutch line bracket (A).
4.
5.
6. Remove the mounting bolts (A) andtheslave
cylinder (B).
Remove the roll pins (C). Disconnect the clutch line(D), and remove the O-ring (E). Plug the end of the
clutch line with a shop towel to prevent brake fluid
f rom coming out.
Installthe slave cylinder in the reverse order of
removal. Install a new O-ring (A).
7.
,,6NJ'
=--#.q!4sEn(P/N 08798-90021
9.
(Brak6 Assembly Lube)
Pullthe boot (B) back, and apply brake assembly
lube to the boot and slave cylinder rod (C). Reinstall
the boot.
Apply super high temp urea grease (P/N 08798-
9002) to the push rod of the slave cylinder. Tighten
the slave cylinder mounting bolts to 22 N m (2.2
kgf m, 16lbf.ft).
(cont'd)
12-7
10.

Clutch
Slave Cylinder Replacement (cont'd)
11. Bleed the clutch hydraulic system.
. Aftach a hose to the bleeder screw (A), and
suspend the hose in a container of brake fluid.. Make sure there is an adequate supply offluid in
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear atthe
bleeder hose.. lt may be necessary to llmit the movement of the
release fork (B) with a block of wood to remove
all the air from the system.. Tighten the bleed screw to I N.m (0.8 kgf.m, 6 lbf
ft); do not ovenighten it,. Refill the clutch master cylinder with fluid when
done.. Always use only Honda DOT 3 brake fluid.
Install the intake air duct (see step 36 on page 5-14).
Installthe air cleaner housing (see step 37 on page
5-15).
Install the battery tray.
Install the battery, connect the positive (+) cable
first, then the negative (- ) cable.
Reset the frequencies for the radio station preset
buttons,
12.
13.
14.
t5.
16.
12-8
L

Clutch Replacement
Spscial Tools Required. Clutch alignment disc 07JAF-PM701 1A. Ring gear holder 07LAB-PV00100 or
07924-PD20003. Clutch alignment shaft 07ZAF-PR8A100. Remover handle 07936-3710100
Pressure Plate and Glutch Disc Removal
1. Check the diaphragm spring fingers for height
using lhe special lool and feeler gauge. lf the height
is more than the service limit, replace the pressure
ptate.
Standard lNewl: 0.6 mm (0.02 in.) max.
Service Limit: 0.8 mm {0.03 in.)
07zAF-PR8A10007936-3710100OTJAF-PM7O11A
2. Installthe special tools.
A
\-
A-.- nl I\ffim9fra-I tP|-
07LAB-PV00100 or07924-PD20003
To prevent warping, unscrew the pressure plate
mounting bolts (A) in a crisscross pattern in several
steps, then remove the pressure plate (B).
Inspect the fingers of the diaphragm spring (A) for
wear at the release bearing contact area.
5. Inspect the pressure plate 1A) surfaceforwear,
cracks. and burning.
(cont'd)
12-9

Clutch
Clutch Replacement (cont'd)
6. Inspecl for warpage using a straight edge (A) and
feeler gauge (B). l\4easure across the pressure plate
(C). lf the warpage is more than the service limit,
replace the pressure plate.
Standard {New): 0.03 mm (0.001 in.) max.
Service Limit: 0.15 mm (0.006 in.)
7. Remove the clutch disc and sDecialtools.
Inspectthe lining ofthe clutch disc for signs of
slipping or oil. lf the clutch disc is burned black or
oil soaked. reolace it.
1d
12-10
9. lvleasu re th e clutch d isc th ickness. lfthethickness
is less than the service limit, replace the clutch disc.
Standard lNew): 8.3 8.9 mm(0.33 0.35 in.)
Service Limit: 6.0 mm {0.24 in.)
Measure the rivet depth from the clutch disc lining
surface (A) to the rivets (B) on both sides. lf the
rivet depth is less than the service limit, replace the
clutch disc.
Standard (New): 1.65 2.25 mm(0.065 0.089 in.)
Service Limit: 0.7 mm (0.03 in.)
10.
L

Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the
flywheel for wear, cracks, and burning.
3. Measure the flywheel (A) runout using a dial
indicator (B) through at least two full turns. Push
against the flywheel each time you turn it to take up
the cra nksh aft th rust washer clea rance. lf the
runout is more than the service limit, replace the
flywheel and recheck the runout. Resurfacing the
flywheel is not recommended.
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.15 mm (0.006 in.)
Flywheel Replacement
1. Installthe special tool.
2.
3.
4.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, then remove the tlywheel.
Installthe flywheel on the crankshaft, and install
the mounting bolts fingertight.
Installthe specialtool, then torque the flywheel
mounting bolts in a crisscross pattern in several
sreps.
12 x 1.0 mm103 N.m(10,s kst.m. 76 lbf ftl
(cont'd)
12-11

Manual Transmission
SpecialTools
Transmission Fluid Inspection
and Reo1acement ...................-.
Back-Up Light Switch Test ..........
Transmission Removal
Transmission Installation ...........
Transmission Disassemblv ........
Reverse Shift Fork Clearance
lnsoection
Change Lever Clearance
lnsoection
Change Lever Assembly
Disassembly/Reassembly .......
Shift Forks Clearance
Inspection
Shift Forks
Disassembly/Reassembly .......
Mainshaft Assemblv
Clearance Inspection
Mainshaft Disassembly
Mainshaft lnsoection
Mainshaft Reassembly
Countershaft Assemblv
Clearance Inspection
Countershaft Disassembly .........
Countershaft Inspection .............
Countershaft Reassembly ..........
Synchro Sleeve and Hub
Inspection and Reassembly ....
Synchro Ring and Gear
Insoection ....... 13-39
Mainshaft Bearing and Oil Seal
Replacement ........................,... 13-41
Cou ntershaft Bearing
ReDlacement .. 13-42
Mainshaft Thrust Clearance
Adiustment ..... 13-43
Transmission Reassemblv ......... 13-46
Gearshift Mechanism
Replacement ............................ 13-51
M/T Differential
Comoonent Location Index ........ 13-52
Backlash Inspection ..................... 13-53
Final Driven Gear/Carrier
Replacement .. 13-53
Carrier Bearings Replacement ... 13-54
Oil Seal Replacement .................. 13-55
Differential Thrust Clearance
Adiustment ..... 13-56
13-2
| 5-J
tJ-5
13-4
I J-at
13-14
13- 19
13- 19
13-20
13-21
13-22
13-23't3-25
13-26
| 5-2.5
13-31
13-32
13-33
13-34
13-39

Manual Transmission
SpecialTools
Inspection Tool Set,
Must be used with commercially available 3/8" '16 Slide Hammer.
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Ref.No.Tool NumberDescription Oty
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vs802c000015
vs802c000018
07GAJ-PG20']10
07GAJ-PG20130
07JAD-P190100
07NAD-P20A100
07736-A01000B
07746-0010300
07746-0030100
07746-0030300
07749-0010000
l,l
l
Engine Hanger Adapter, 2.0 to 2.4 Liter
Engine Hanger
Mainshaft Holder
Mainshaft Base
Oil Seal Driver
Oil Seal Driver Aftachment
Adjustable Bearing Puller, 20-40 mm
Attachment, 42 x 47 mm
Driver, 40 mm LD.
Driver, 30 mm LD.
Driver
on Tool Set. 07GAJ-PG20102.of Mainshaft
\'---''
13-2

Transmission Fluid Inspection and
Replacement
'1. Park the vehicle on level ground, and turn the
engine OFF.
2. Remove the oilfiller plug (A) and washer (B), check
the condition of the fluid, and make sure the fluid is
at the proper level (C).
lf the transmission fluid is diny, remove the drain
plug (D) and drain the fluid.
A44 N.m{4.5 kgt.m,33 rbr.ftl
Reinstall the drain plug with a new washer, and
refill the transmission fluid to the proper level.
Oil Capacity
1.5 0 (1.6 US (F) at tluid change
1.7 0 {1.8 US qt) at overhaul
Always use Honda Manual Transmission Fluid
(MTF). Using motor oil can cause stiffer shifting
and noise because it does not contain the proper
additives.
Reinstall the oil filler plug with a new washer.5.
13-3
Back-Up Light Switch Test
1. Disconnectthe back-up light switch (A) connector.
Check for continuity between the back up light
swilch 2P connector No. 1 and No.2 terminals.
There should be continuity when the shift lever is in
reverse.
lf necessary, replace the back-up light switch.
Apply liquid gasket (P/N 08718-0001), and install it
on the transmission housing.
2.
3.