2003 HONDA CIVIC service

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

Reverse Shift Fork Clearance
Inspection
1. Measure the clearance between the reverse idler
gear {A) and the reverse shift fork (B) with a feeler
gauge (C). lf the clearance is more than the service
limit, go to step 2.
Standard: 0.20-0.59 mm (o.oo7 0.024 in.l
Service Limit: r.3 mm {0.051 in.)
Measu re the width of the reverse shift fork.
. lf distance is notwithinthestandard, replacethe
reverse shift fork with a new one.. lf distance is within the standard, replacethe
reverse gear wrln a new one.
Standard: 13.4 13.7 mm (0.527 0.539 in.l
I
Change Lever Clearance Inspection
1.Measure the clearance between change lever (Al
and the select lever (B) with a feeler gauge (Cf. lf
the clearance is more than the service limit, go ro
step 2.
Standard: 0.05 0.25 mm (0.002-0.010 in.)
Service Limit: 0.50 mm {0.020 in.)
2.Measure the groove of the change lever'
. lf distance is not within the standard, replace the
change lever with a new one.
. lf distance iswithinthe standard, replacethe
select lever with a new one.
15.00 15.10 mm (0.591-0.594 in.)Standard:
,tl
I
qI
13-19

Shift Forks Glearance Inspection
NOTE: The synchro sleeve and synchro hub should be
replaced as a set.
1. Measu re the clearance between each shift fork (A)
and its matching synchro sleeve (B). lf the
clearance exceeds the service limit, go to step 2.
Standard: 0.35 0.65 mm {0.014 0.026in.1
Service Limit: 1.0 mm 10.039 in.l
A
l\4easure the thickness of the shift fork fingers.
. lf thethicknessof theshift forkfinger is not
within the standard, replace the shift fork with a
new one.. lf thethicknessof the shift forkfinger iswithin
the standard, replace the synchro sleeve with a
new one.
Standard: 7.4 7.6 mm (0.29-0.30 in.)
2.
3. Measure the clearance between the shift fork (A)
and the shift arm (B). lf the clearance exceeds the
service limit, go to slep 4.
Standard: 0.2-0.5 mm (0.007 0.020 in.)
Service Limit: 0.62 mm (0.024 in.)
Measure the width of the shift arm.
. lf thewidth of theshiftarm is notwithinthe
standard, replace the shift arm with a new one.. lf thewidth of the shift arm iswithinthe standard,
replace the shift fork and shift piece with a new
one.
Standard: 16.9-17.0 mm (0.665-0.669 in.)
4.
13-21

Mainshaft Assembly Clearance Inspection
NOTE: lf replacement is required, always replace the
synchro sleeve and hub as a set.
1. Support the bearing inner race with an appropriate
sized socket (A). and push down on the mainshaft(B).
Measure the clearance bet\iveen 2nd (C) and 3rd (D)
gears with a feeler gauge {E).
. lf the clearance is more than the service limit. go
to step 3.. lf the clearance is within the service limit, go to
step 4.
Standard:0.06 0.16 mm
{0.002 0.006 in.l
Service Limit: 0.25 mm (0.010 in.l
Measure the thickness of 3rd gear.
. lf thethickness of 3rd gearis lessthanthe service
limit, replace 3rd gearwith a new one.. lf thethickness of 3rd geariswithintheservice
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.)
4. Measure the clearance between 4th gear (A) and
the distance collar (B) with a dial indicator (C).
. lf the clearance is more than the service limit, go
to step 5.. lf the clearance is within the service limit, go to
step 7.
Standard: 0.06 0.16 mnl(0.002 0.006 in.)
Service Limit: 0.25 mm {0.010 in.)
Measure distance O on the distance co[ar.
. lf distance't is notwithin the standard, replace
the distance collar with a new one.. lf distance e is within the standard, go to step 6.
Standard:24.03 24.08 mm
{0.946-0.9/u in.}
(cont'd)
13-23

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
{