2003 HONDA CIVIC ect

Manual Transmission
Mainshaft Assembly Clearance Inspection (cont'd)
6. Measure the thlckness of 4th gear.
. lf thethickness of 4th gear is lessthantheservice
limit, replace 4th gear with a new one.. lf thethicknessof 4th geariswithin the service
limit. replace the 3rd/4th synchro hub with a new
one.
Standard: 23.92 23.97 mm
(0.941 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
7. l\4easure the clearance between the distance collar
(A) and sth gear (B) with a dial indicator (C). lfthe
clearance is more than the service limit. go to step
8. lf the clearance is with in the service limit, go to
steD 10.
Standard: 0.06 0.16 mm(0.002-0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
13-24
Standard:
Standard:
Service Limit:
8. Measure distance O on the distance collar.
. lf distance O is notwithinthestandard, replace
the distance collar with a new one.' lf distanceO iswithinthe standard, gotostep9.
24.03 24.08 mm
(0.946 0.947 in.)
9. Measure the thickness of 5th gear.
. lf thethicknessof 5th gearis lessthantheservice
limit, replace 5th gear with a new one.. lf the thickness of sth gear iswithin the service
limit. replace the 5th synchro hub with a new one.
23-92 23.97 mm
10.941 0.944 in.l
23.80 mm (0.937 in.l

Manual Transmission
Mainshaft Disassembly (cont'dl
3. Supportthe 3rd gear (A) on steel blocks, and press
the mainshaft out of the 3rd/4th synchro hub (B).
Use of a jaw-type puller can damage the gear teeth.
13-26
Mainshaft Inspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, C, D, and E. lf any part of the mainshaft
is less than the service limit, reDlace it with a new
o ne.
Standard:
A Ball bearing surface (transmission housing side):
27.987 28.000 mm (1.1019 1.1024in.)
B Distance collar surtace:
31.984 32.000 mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000 mm (1.53/t8 1.5354 in.)
D Ball bearing surface (clutch housing side):
27 .977 -27 .990 mm (1.1015 1.1020in.)
E Bushing surface:
20.80 20.85 mm (0.819 0.821 in.)
Service Limit;
A: 27.93 mm 11.100 in.l
B: 31.93 mm |.1.257 in.l
C: 38.93 mm 11.533 in.l
Di 27.92 mm {1.099 in.l
E: 20.75 mm 10.817 in.l
{

2. Inspect the runout by supponing both ends of the
mainshaft. Rotate the mainshaft two complete
revolutions when measuring the runout. lf the
runout is more than the service limit. reolace the
mainshaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-27

Manual Transmission
Mainshaft Reassembly
Exploded View
A
QJ'
frfl
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

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

5. Support 4th gear (A) on steel blocks, then use apress and an attachment (B) to press the
countershaft (C) out ofthe 5th gear.
6.Support 2nd gear (A) on steel blocks, then use a
Dress and an attachment {B} to press the
countershaft (C) out of the 3rd gear.
Cou ntershaft lnspection
1. Inspect the gear surface and bearing surface for
wear and damage, then measure the countershaft
at points A, B, and C. lf any part of the countershaft
is less than the service limit, replace it with a new
one.
Standard:
A Ballbearing surface ltransmission housing sidel:
30.020 -30.033 mm {1.1819 1.1824in.)
B Distance collar surface;
39.937- 39.950 mm 11.5723 1.572A in.l
C Needle bearing surface (clutch housing side):
35.000 35.015 mm {r.3780-1.3785 in.)
Service Limit:
A: 29.97 mm {1.180 in.)
B: 39.88 mm {1.570 in.l
C: 34.95 mm {1.376 in.)
lnspect the runout by supporting both ends of lhe
countershaft. Rotate the countershaft two complete
revolutions when measuring the runout. lf the
runout exceeds the service Iimit, replace the
countershaft with a new one.
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
2.
13-33

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