2003 HONDA CIVIC %27

Manual Transmission
Mainshaft Thrust Clearance Adjustment (cont'dl
72 mm Shim
Part NumberThickness
23931-P21-0000.60 mm {0.0236 in.)
B23932-P21-0000.63 mm (0.0248 in.
c23933-P21-0000.66 mm (0.0260 in.D23934-P21-0000.69 mm (0.0271 in.
E23935-P21-0000.72 mm (0.0283 in.
F23936-P21-0000.75 mm (0.0295 in.
23931-P21-0000.78 mm (0.0307 in.-23938-P2'l-0000.81 mm (0.0319 in
23939-P21-0000.84 mm (0.0331 in
J23940-P21-0000.87 mm {0.0343 in,
23941-P21-0000.90 mm (0.0354 in.
L23942.P21-0000.93 mm (0.0366 in.
M23943-P21-0000.96 mm (0.0378 in.
N239 44-P21 .0000.99 mm (0.0390 in.
o23945-P21-0001.02 mm (0.0402 in.P23946-P21-0001.05 mm (0.0413 in.
o23941-P2't-000'l.08 mm (0.0425 in
R23948-P2'l-000'1 .1 1 mm {0.0437 in
23949-P21-000'1.14 mm (0.0449 inT23950-P21-0001.17 mm {0.0461n.
U23951-P21-0001.20 mm 10.0472n.
23952-P21-0001.23 mm (0.0484n.
23953-P21-0001.26 mm {0.0496n.X23954-P21-0001.29 mm (0.0508n.
23955-P21-0001.32 mm (0.0520n.z23956-P21,0001.35 mm (0.0531 in
23957-P21-0001.38 mm (0.0543 in
AB23958-P21-0001.41 mm (0.0555nAC23959-P21-0001.44 mm (0.0567n.
AD23960-P21-0001.47 mm (0.0579n.
AE23961-P21-0001.50 mm (0.0591n.AF23962-P21-OOO1.53 mm (0.0602n.AG23963-P21-000156 mm (0.0614n.
AH23964-P21-0001.59 mm (0.0626n.
AI23965-P21-0001.62 mm (0.0638 in
AJ23966-P21-0001.65 mm (0.0650 in
AK23967-P21-0001.68 mm (0.0661 in
AL23968-P2r -0001.71 mm (0.0673 in.
AM23969-P21-0001.74 mm (0.0685 in.
AN2397 0-P21-0001.77 mm (0.0697 in.AO23971-P2't-OOO1.80 mm (0.0709 in.
13-44
12.
7. Installthe 72 mm shim (A) selected and oil guideplate M in the transmission housing (B).
,6,,-oV
Thoroughly clean the spring washer (A) and
washer (B) before installing them on the clutchhousing side ball bearing {C). Note the installation
direction of the spring washer.
8.
{
10.
11.
9.lnstallthe mainshaft in the clutch housing.
Place the transmission housing over the mainshaft
and onto the clutch housing.
Tighten the clutch and transmission housings withseveral 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
Tap the mainshaft with a plastic hammer.

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.
(

M/T Differential
Differential Thrust Clearance Adjustment
SpecialTool Required
Driver. 40 mm LD. 07746-0030100
1. Install an 80 mm shim that's the same size as the
one you removeo.
2.Install the differential assembly into the clutch
housing.
13-56
5.
Install the transmission housing onto the clutch
housing, then tighten the 8 mm flange bolts in a
crisscross pattern in several steps (see step 15 on
page 13-48).
8 x 1.25 mm
27 N m (2.8 kgf'm, 20 lbf.ft)
Use the special toolto bottom the differential
assembly in the clutch housing.
00746-0030100
Measure the clearance between the 80 mm shim
and bearing outer race in the transmission housing.
Standard: 0 0.10 mm l0 0.004 in.)
-i.w.t ..1-- -- :,- -=.

EPS COI{IFOI UNITcou{EcToR A (2P)
F-l
A
EPS CONTNOL UNITco|lNEcTofi 8 {2P}
|ll
t2)
Wir. !.le ol l.m.l. t.tman.r.
MOTOFCONNECTOR
riTt
OATA !IN( CONN€CTOA (T6P)
vTTrvaEvnrv
wwzna
T.rmin.l.id. oll.m.l.r.rmin.l.
17-27

EPS Components
{Steering Gearbox Overhaul (cont'dl
22. Apply multipurpose grease to the sliding surfaceand circumference ofthe rackguide (A), and installit onto the gearbox housing. Wipe the grease offthe threaded section ofthe housrno.
...'.
,. ,l
.j
23. Installthe disc washer (B)with its convex sidefacing the rack guide. Installthe spring (C). Appty
sealant to the middle of the threads on the rackguide screw (D), then install and tighten it to 25
N m (2.5 kgf.m, 18 lbf.ft). Loosely instatlrhe tocknut(E).
24. Apply multipurpose grease to the sliding surface ofthe slider guide (A). Keep grease off of the rack-to-slider guide mating surfaces and the boot-to-sliderguide mating surfaces.
Slide the steering rack all the way to left, and place
the slider guide on the steering rack by aligning thebolt holes (B).
'1 - .- =-1, -
17-60
29.
25. Centerthe steering rack within its stroke, and alignthe slider guide (A)with the hotes (B) in the boot (C).
Fit the slider guide to the boot by pressing around
the edges of the holes securely
E25 N.m 12.5 kgt.m, 18 tbt.ft)
26. Before installing the bracket (D), clean the mating
surface ofthe 12 mm flange bolts (E) and thebracket. Coat the new O-rings {F) with multipurposegrease, and installthem on the '12 mm flange bolts.
27. Loosely install the bracket on the steering rack bytightening the 12 mm flange bolts to 25 N.m (2.5
kgf.m, 18lbf.ft).
28. Hold the gearbox housing using a yoke, then install
the specialtool on the lock screw (A). Retighten thelock screw to the specified torque values.
{16.5 kgt.m, 119 lbf.ft}
Remove the special tool.
A

1.Raise the rear of the vehicle, and support it with
safety stands in the proper location (see page 'l-8).
Remove the wheel cap. wheel nuts, and rear wheel.
108 N.m (11.0 kgf.m,80 lbf ftl
Remove the hub cap (A), raise the stake (B), and
remove the spindle nut (C).
O
\A
22 x 1,5 mm181 N.m(18.5 kgf.m, 134lbf.ftl
5.
7.
Release the parking brake lever.
Remove the brake hose mounting bolt (A).
B10 x 1.25 mm55NmC {5.6 kgf m.41 lbf.ft}
(2.2 kgt m, 16lbt.ftl
Remove the caliper bracket mounting bolts (B), and
hang the caliper (C) to one side. To prevent damage
to the caliper or brake hose, use a short piece of
wire to hang the caliper from the undercarriage.
Remove the brake disc retaining screws (A).
Screw two 8 x 1.25 mm bolts (B) into the disc {C) to
oush it awav from the hub. Turn each bolt two turns
at a time to prevent cocking the disc excessively.
Remove the brake disc.
(cont'd)
ap
t
\
IA6x1.0mm9.8 N.m(1.0 kgf.m, ?.2lbf.ftl
18-27

Rear Suspension
Hub Bearing Unit Replacement
(cont'd)
9. Remove the hub bearing unit (A) from the spindle.
Install the hub bearing unit in the reverse order of
removal, and note these items:
. Tighten all mounting hardware to the specified
torque values,. Before installing the brake disc, clean the mating
surface ot the hub and the inside of the brake
disc.. Use a new spindle nut on reassembly.. After tightening, use a drift to stake the spindle
nut shoulder against the spindle.. Use a new hub cap on reassembly.. Before installing the wheel, clean the mating
surface of the brake disc and the inside of the
wneel.
10.
,=,,,
18-28
Raise the rear of the vehicle, and suppon it with
safety stands in the proper location (see page 1-8).
Remove the rear wheels.
Remove the brake disc and hub bearing unit (see
step 1 on page 18-27).
Remove the flange bolts (A) and splash guard (B)
from the knuckle.
11.0 kgf.m, 7.2 lbf ft)
4. Remove the wheel sensor(A), braKe nose
mounting bracket (B), and parking cable mounting
bracket (C) from the knuckle. Do not disconnect the
wheel sensor connector.
8 x 1.25 mm22 N.m{2.2 kgf m, 16 lbf ftl
Knuckle Replacement
1.
6x1.0mm9.8 N,m{I.0 kgt.m,7.2 lbf ft)
tt

Rear Brake Caliper Overhaul
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
' Avoid breathing dust particles.
. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner'
Remove, disassemble, inspect, reassemble, and installthe caliper, and note these items:
. Donotspill brake fluid on the vehicle; it may damage the paint; if brake f luid gets on the paint, wash it off
immediately with water.. To prevent dripping. cover disconnected hose joints with rags or shop towels.
. Cleanall partsinbrakefluidandairdry;blowoutall passageswith compressed air'
. Before reassembling, check that all parts are free of dust and other foreign particles
. Replace pans with new ones as specified in the illustration.. Make sure no dirt or other foreign matter contaminates the brake fluid.
. When reusing pads, always reinstallthem in their original positions to prevent loss of b ra king efficie ncy.
. Do not reuse drained brake fluid.
. Use only clean Honda DOT 3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the
system.. Do not mix different brands ot brake fluid as they may not be compatible.
. Coatthe piston, piston seal groove, and caliper bore with clean brake fluid.
. Make sure no grease or oil gets on the brake discs or pads.
. Replaceall rubber parts with new ones whenever disassembled.
. After installing the caliper, check the brake hose and line for leaks, interference. and twisting.
oG , nonau."rip6r qreas€ lP/N 08c30-aoa4Ml34 N.m (3.5 kgf m,25lbtft)BOLT
WASHERS
BRAKE HOSE
a
l,i,,'IltE" / !!;,ff
olT-J,.o"c.O.RING CUPBeplace. Beplace.
.ARKING NUr lii.'i rz.r rgr.. Gd ffi27Nm{2.8kgtm,
\-"o, V((rA ",1 ;[.,.JF /;;;;---
t H\a \l / t,i*t'*"
?,,.t/*"^.,,.:,"", /"V4#
ADJUSTING BOLT
,/
27Nm{2.8kgf.m,20 tbf.ftr PAD SPRING
A,n Na 7lfl,lif,loffi ',,0,n, ,,:,o" \
--t)(*ff l^7k ''"'t!1'ry#'
INNEBPA'SHIM
/ .r.:._U i*E'( ":;*" *dF ,.2>a>-
fr.x{_>@ fftt **-->**^'"
,,.-"iV ,/q &'"o.,"."""o"^.,
: 10 MM FLANGE BOLTS.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)
19-23