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Honda Civic Service Manual: M/T Mainshaft Thrust Clearance Adjustment (K24Z7)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / M/T Mainshaft Thrust Clearance Adjustment (K24Z7)

Removal

1. M/T Change Lever Assembly


1.

Remove the interlock bolt (A).

2.

Remove any old liquid gasket from the interlock bolt.

3.

Remove the change lever assembly (B).

4.

Remove the 8 x 14 mm dowel pins (C).

2. Back-Up Light Switch


1.

Remove the back-up light switch (A).

2.

Remove any old liquid gasket.

3. Output Shaft (Countershaft) Speed Sensor

1.

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

4. Transmission Housing

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 10 mm flange bolt (A) and the sealing washer (B).

3.

Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them with transmission hanger A, transmission hanger B, and the harness bracket (C).


4.

Remove the 32 mm sealing cap (A).

5.

While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

6.

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

7.

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

5. Reverse Shift Fork

1.

Remove the reverse shift fork (A).

6. Baffle Plate

1.

Remove the baffle plate (A).

7. Reverse Idler Gear

1.

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

8. 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 28 mm washer (E).

4.

Remove the 28 mm spring washer (F).

9. Differential Assembly


1.

Remove the differential assembly (A).

2.

Remove the magnet (B).

Adjustment

1. M/T Mainshaft Thrust Clearance Adjustment


1.

Thoroughly clean the 28 mm spring washer (A) and the 28 mm washer (B) before installing them on the clutch housing side ball bearing (C).

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

2.

Assemble all of the mainshaft components.

NOTE: Refer to the Exploded View as needed during the assembly.

3.

Install the mainshaft assembly into the clutch housing.

4.

Place the transmission housing over the mainshaft and onto the clutch housing.

5.

Tighten the clutch and transmission housings with several 8 mm bolts.

NOTE: It is not necessary to use sealing agent between the housings for this procedure.

6.

Lightly tap on the mainshaft with a soft face hammer.


7.

Attach the mainshaft holder and the mainshaft base to the mainshaft as follows:

Back out the mainshaft holder bolt (A), and loosen the two hex bolts (B).

Fit the mainshaft holder over the mainshaft so its lip is towards the transmission.

Align the mainshaft holder lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.

8.

Fully seat the mainshaft by tapping its end with a soft face hammer.

9.

Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.


10.

Zero a dial gauge (A) on the end of the mainshaft.

11.

Turn the mainshaft holder bolt (B) clockwise; stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft thrust clearance.

NOTE: Do not turn the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving. Applying more pressure with the mainshaft holder bolt could damage the transmission.

12.

If the reading is within the standard, the clearance is correct. If the reading is not within the standard, select the appropriate shim needed from the table, and recheck the thrust clearance.

Standard:

0.11－0.17 mm
(0.0043－0.0067 in)

(Example)

Measure reading:

1.93 mm (0.0760 in)

Subtract the total clearance measurement from the middle of the clearance standard 0.14 mm (0.0055 in).

1.93 － 0.14 mm (0.0760 －0.0055 in) = 1.79 mm (0.0705 in)

Select the shim closest to the amount calculated, for example the 1.80 mm (0.0709 in) shim.

13.

With oil guide plate M and the appropriate size shim installed in the transmission housing, check the thrust clearance again to verify the clearance is within the standard.

72 mm Shim

Type

Thickness

A

0.60 mm (0.0236 in)

B

0.63 mm (0.0248 in)

C

0.66 mm (0.0260 in)

D

0.69 mm (0.0272 in)

E

0.72 mm (0.0283 in)

F

0.75 mm (0.0295 in)

G

0.78 mm (0.0307 in)

H

0.81 mm (0.0319 in)

I

0.84 mm (0.0331 in)

J

0.87 mm (0.0343 in)

K

0.90 mm (0.0354 in)

L

0.93 mm (0.0366 in)

M

0.96 mm (0.0378 in)

N

0.99 mm (0.0390 in)

O

1.02 mm (0.0402 in)

P

1.05 mm (0.0413 in)

Q

1.08 mm (0.0425 in)

R

1.11 mm (0.0437 in)

S

1.14 mm (0.0449 in)

T

1.17 mm (0.0461 in)

U

1.20 mm (0.0472 in)

V

1.23 mm (0.0484 in)

W

1.26 mm (0.0496 in)

X

1.29 mm (0.0508 in)

Y

1.32 mm (0.0520 in)

Z

1.35 mm (0.0531 in)

AA

1.38 mm (0.0543 in)

AB

1.41 mm (0.0555 in)

AC

1.44 mm (0.0567 in)

AD

1.47 mm (0.0579 in)

AE

1.50 mm (0.0591 in)

AF

1.53 mm (0.0602 in)

AG

1.56 mm (0.0614 in)

AH

1.59 mm (0.0626 in)

AI

1.62 mm (0.0638 in)

AJ

1.65 mm (0.0650 in)

AK

1.68 mm (0.0661 in)

AL

1.71 mm (0.0673 in)

AM

1.74 mm (0.0685 in)

AN

1.77 mm (0.0697 in)

AO

1.80 mm (0.0709 in)

AP

1.83 mm (0.0720 in)

AQ

1.86 mm (0.0732 in)

AR

1.89 mm (0.0744 in)

AS

1.92 mm (0.0756 in)

AT

1.95 mm (0.0768 in)

AV

1.98 mm (0.0780 in)

AW

2.01 mm (0.0791 in)

AX

2.04 mm (0.0803 in)

AY

2.07 mm (0.0815 in)

AZ

2.10 mm (0.0827 in)

BA

2.13 mm (0.0839 in)

BB

2.16 mm (0.0850 in)

BC

2.19 mm (0.0862 in)

BD

2.22 mm (0.0874 in)

BE

2.25 mm (0.0886 in)

Installation

1. Differential Assembly


1.

Install the magnet (A).

NOTE: Clean the magnet any time the transmission is disassembled.

2.

Install the differential assembly (B).

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


1.

Install the 28 mm spring washer (A).

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

2.

Install the 28 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.

3. Reverse Idler Gear

1.

Install the reverse idler gear (A) and reverse idler gear shaft (B) by aligning the mark (C) on the clutch housing with the reverse idler gear shaft hole (D).

4. Baffle Plate

1.

Install the baffle plate (A).

5. Reverse Shift Fork

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1.

Install the reverse shift fork (A).

6. Transmission Housing


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.


3.

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

4.

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

5.

While expanding the 72 mm snap ring (B) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring.

6.

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 (C) after setting in the 72 mm snap ring.


7.

Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension as installed: 3.3－6.0 mm (0.130－0.236 in)

8.

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.

9.

Install the 8 mm flange bolts finger-tight with transmission hanger A, transmission hanger B, and the harness bracket (C).

10.

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)


11.

Install the 10 mm flange bolt (A) with new sealing washer (B).

12.

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

7. Output Shaft (Countershaft) Speed Sensor


1.

Apply MTF to a new O-ring (A).

2.

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

8. Back-Up Light Switch


1.

Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the threads of the back-up light switch (A).

2.

Install the back-up light switch.

9. 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.


3.

Install the 8 x 14 mm dowel pins (A).

4.

Install the change lever assembly (B).

5.

Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the threads of the interlock bolt (C).

6.

Install the interlock bolt.

M/T Mainshaft Disassembly, Reassembly, and Inspection (R18Z1 M/T)
Disassembly NOTE: Refer to the Exploded View as needed during this procedure. 1. M/T Change Lever Assembly ...

M/T Reverse Shift Fork Clearance Inspection (K24Z7)
Removal 1. M/T Change Lever Assembly 1. Remove the interlock bolt (A). ...

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