2003 HONDA CIVIC Workshop Manual

-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

Manual Transmission
Transmission Reassembly (cont'dl
22. Installthe vehicle speed sensor (VSS) {A)andO-ring (B).
22 N.m (2.2 kgf.m, r6 lbf.ft)
13-50
(
{

Gearshift Mechanism Replacement
SHIFT CABLE CLIPReplace.
8 x 1.25 mm22 N.m (2.2 kgf.m, 16 lbt ftl
--SHIFT LEVER KNOB
/ ,.-,'-' 8 N m {0.8 ksr.m. 5.8lbf.ft}
l'/
SHIFT LEVER HOUSING
{P/N 08798-9002}
r-Ll Rotate the shift cabletoward the opening.
6x1.0mm9.8Nm(1.0 kgf.m,7.2 tbf.fr)
COTTER PINS
qrBemove the shift cablefrom the shift lever bracket.{P/N 08798-9002)
13-51

M/T Differential
Component Location Index
DRIVEN GEARBeplacement, page 13-53
Backlash Insoection. oaoe 13-53Feplacemeni, paoe I 3-5-3
\
\
,<-=- ,/BALL BEARING
/ ,/ Beplacemenl, page 13-54
I \c1 l/
=/
13-52
(
I

\
Backlash lnspection
1.Place the differential assembly on V-blocks (A), and
install both axles.
Measure the backlash of both pinion gears (B) with
a dial indicator (C). lf the backlash is not within the
standard, replace the differential carrier.
Standard (New): 0.05 0.15 mm (0.002 0.006 in.)
Final Driven Gear/Carrier
Replacement
1. Remove the bolts (left-hand threads) in a crisscross
pattern in several steps, then remove the final
driven gear (A)from the differential carrier {B).
t x t.o mm {to)121 Nm(12.3 kgf m,89 rbt.ft)
Install the final driven gear with the chamfer on the
inside diameter facing the carrier. Align the marks
on the final driven gear and the carrier. Tighten the
bolts in a crisscross pattern in several steps.
13-53

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
\{
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