Honda Civic Service Manual: Manual Transmission Disassembly and Reassembly (R18Z1 M/T)

1.

Remove the change lever assembly (A).

2.

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

1.

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

1.

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

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 20 mm bolt (E) and the 20 mm sealing washer (F).

3.

Remove the drain plug (A) and the sealing washer (B).

4.

Remove the filler plug (C) and the sealing washer (D).

5.

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

6.

Remove the 32 mm sealing cap (A).

7.

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

8.

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

9.

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

1.

Remove the oil gutter plate (A).

2.

Remove the 52 x 62 mm shim (B).

3.

Remove oil guide plate M.

1.

Remove the reverse shift fork (A).

1.

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

1.

Remove the reverse lock cam (A).

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).

1.

Remove the differential assembly (A).

2.

Remove the magnet (B).

1.

Install the magnet (A).

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

2.

Install the differential assembly (B).

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.

1.

Install the reverse lock cam (A).

1.

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

1.

Install the reverse shift fork (A).

1.

Select the proper size 52 x 62 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment.

2.

Install the oil gutter plate (B).

3.

Install oil guide plate M.

4.

Install the 52 x 62 mm shim.

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:

10.

Install the 8 mm flange bolts finger-tight.

11.

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

12.

Install the drain plug (A) with a new sealing washer (B).

13.

Install the filler plug (C) with a new sealing washer (D) finger-tight.

14.

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

15.

Install the 20 mm bolt (C) with a new 20 mm sealing washer (D).

1.

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

1.

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

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:

3.

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

4.

Install the change lever assembly (B).