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Honda Civic Service Manual: M/T Countershaft Assembly Clearance Inspection (R18Z1 M/T)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / M/T Countershaft Assembly Clearance Inspection (R18Z1 M/T)

Removal

1. M/T Change Lever Assembly


1.

Remove the change lever assembly (A).

2.

Remove the 8 x 10 mm dowel pins (B).

2. Back Up Light Switch

1.

Remove the back-up light switch (A) and the 18 mm sealing washer (B).

3. M/T Output Shaft Speed Sensor

1.

Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).

4. M/T Transmission Housing Assembly

1.

Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (C), and the steel balls (D).

2.

Remove the 8 mm flange bolts in a crisscross pattern in several steps.


3.

Remove the 32 mm sealing cap (A).

4.

While expanding the 69 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

5.

Release the snap ring pliers, and remove the transmission housing.

6.

Remove the 14 x 20 mm dowel pins (D).

5. M/T Reverse Shift Fork

1.

Remove the reverse shift fork (A).

6. Reverse Idler Gear

1.

Remove the reverse idler gear (A) and the reverse idler gear shaft (B).

7. M/T Mainshaft and Countershaft and Shift Fork Assembly


1.

Apply a thin layer of tape to the mainshaft splines to protect the seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

2.

Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

3.

Remove the 26 mm washer (E).

4.

Remove the 36 mm spring washer (F).

Inspection

NOTE: Before inspection, make sure the special bolt is tightened to the specified torque.

1. Countershaft Assembly Clearance Inspection

1.

Measure the clearance between 1st gear (A) and the 1st gear distance collar (B) with a feeler gauge (C).

If the clearance exceeds the service limit, go to step 2.

If the clearance is within the service limit, go to step 4.

Standard:

0.06－0.21 mm
(0.003－0.008 in)

Service Limit:

0.21 mm
(0.008 in)

2.

Measure the length of the 1st gear distance collar as shown.

If the length is not within the standard, replace the 1st gear distance collar.

If the length is within the standard, go to step 3.

Standard:

26.53－26.58 mm
(1.0445－1.0465 in)

3.

Measure the thickness of 1st gear.

If the thickness is less than the service limit, replace 1st gear.

If the thickness is within the service limit, replace the 1st/2nd synchro hub and the reverse gear as a set.

Standard:

27.42－27.47 mm
(1.0795－1.0815 in)

Service Limit:

27.42 mm
(1.0795 in)

4.

Measure the clearance between 2nd gear (A) and 3rd gear (B) with the feeler gauge (C). If the clearance exceeds the service limit, go to step 5.

Standard:

0.06－0.14 mm
(0.003－0.005 in)

Service Limit:

0.14 mm
(0.005 in)

5.

Measure the length of the 2nd gear distance collar.

If the length is not within the standard, replace the 2nd gear distance collar.

If the length is within the standard, go to step 6.

Standard:

26.53－26.56 mm
(1.0445－1.0457 in)

6.

Measure the thickness of 2nd gear.

If the thickness is less than the service limit, replace 2nd gear.

If the thickness is within the service limit, replace the 1st/2nd synchro hub and the reverse gear as a set.

Standard:

26.42－26.47 mm
(1.0402－1.0421 in)

Service Limit:

26.42 mm
(1.0402 in)

Installation

1. M/T Mainshaft and Countershaft and Shift Fork Assembly


1.

Install the 36 mm spring washer (A).

NOTE: Be sure to install the spring washer in the direction shown.

2.

Install the 26 mm washer (B).

3.

Apply a thin layer of tape to the mainshaft splines (C) to protect the seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

4.

Install the mainshaft assembly (D) and the countershaft assembly (E) with the shift fork assembly (F), as an assembly.

2. Reverse Idler Gear

1.

Install the reverse idler gear (A) and the reverse idler gear shaft (B).

3. M/T Reverse Shift Fork

1.

Install the reverse shift fork (A).

4. M/T Transmission Housing Assembly


1.

Clean any dirt or oil from the mating surface of the transmission housing and the clutch housing.

2.

Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

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3.

Install the 14 x 20 mm dowel pins (A).

4.

Set the tapered cone ring pawl (B) faces the 5th shift fork (C).

5.

Place the transmission housing on the clutch housing, making sure to line up the shafts.

6.

While expanding the 69 mm snap ring (D) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring.

7.

Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.

NOTE: Install the 32 mm sealing cap (E) after setting in the 69 mm snap ring.


8.

Make sure the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension as installed: 3.3－6.5 mm (0.130－0.256 in)

9.

Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the threads of the 32 mm sealing cap. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

10.

Install the 8 mm flange bolts finger-tight.

11.

Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

Specified Torque:

8 x 1.25 mm
27 N·m (2.8 kgf·m, 20 lbf·ft)

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12.

Install the steel balls, the detent ball springs, and the detent bolts (A) with new 12 mm sealing washers (B).

5. M/T Output Shaft Speed Sensor

1.

Install the output shaft (countershaft) speed sensor (A) with a new O-ring (B) and the plain washer (C).

6. Back Up Light Switch

1.

Install the back-up light switch (A) with a new 18 mm sealing washer (B).

7. M/T Change Lever Assembly

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1.

Clean any dirt or oil from the mating surface of the change lever assembly and the transmission housing.

2.

Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

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3.

Install the 8 x 10 mm dowel pins (A).

4.

Install the change lever assembly (B).

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