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Honda Civic Service Manual: Synchro Ring and Gear Inspection (K24Z7)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / Synchro Ring and Gear Inspection (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. M/T Mainshaft 5th and 6th Gear

1.

Remove the angular ball bearing (A) using a commercially available bearing separator (B) and a commercially available bearing puller (C).


2.

Support 5th gear (A) on steel blocks.

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

3.

Press the mainshaft out of the 5th/6th synchro hub (B).

10. M/T Mainshaft 3rd and 4th Gear


1.

Support 3rd gear (A) on steel blocks.

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

2.

Press the mainshaft out of the 3rd/4th synchro hub (B).

11. M/T Countershaft


1.

Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

2.

Remove the special bolt (B) (left-hand threads).


3.

Support 6th gear (A) on steel blocks (B).

4.

Use a press (C) and an attachment (D) to press the countershaft out of the ball bearing and 6th gear.

5.

Remove the 35 mm shim.


6.

Support 4th gear (A) on steel blocks (B).

7.

Use the press (C) and an attachment (D) to press the countershaft (E) out of 4th gear and 5th gear.


8.

Support 2nd gear (A) on steel blocks (B).

9.

Use the press (C) and an attachment (D) to press the countershaft (E) out of 2nd gear and 3rd gear.

Inspection

1. Synchro Ring and Gear Inspection


1.

Inspect the synchro rings for scoring, cracks, and damage (A).

2.

Inspect the inside of each synchro ring (B) for wear.

3.

Inspect the teeth (C) on each synchro ring for wear (rounded off).

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4.

Inspect the teeth (A) on each synchro sleeve and matching teeth on each gear for wear (rounded off).


5.

Inspect the synchro teeth on gear for scoring, cracks, and damage (A).

6.

Inspect the thrust surface (B) on each gear hub for wear.

7.

Inspect the cone surface (C) on each gear hub for wear and roughness.

8.

Inspect the teeth on all gears (D) for uneven wear, scoring, and cracks.

9.

Coat the cone surface of each gear with MTF, and place its synchro ring on it.

NOTE: Rotate the synchro ring, making sure that it does not slip.


Synchro ring-to-gear


Double cone synchro and triple cone synchro-to-gear

10.

Measure the clearance between each gear (A) and its synchro ring (B) all around the gear. Hold the synchro ring against the gear evenly while measuring the clearance. If the clearance is less than the service limit, replace the synchro ring and gear.

Synchro Ring-to-Gear Clearance

Standard:

0.70－1.49 mm
(0.028－0.058 in)

Service Limit:

0.70 mm
(0.028 in)

3rd Double Cone Synchro-to-Gear Clearance

Standard:

:

Outer Synchro Ring (B) to Synchro Cone (C) 0.46－0.97 mm
(0.019－0.038 in)

:

Synchro Cone (C) to Gear (A) 0.51－1.07 mm
(0.021－0.042 in)

:

Outer Synchro Ring (B) to Gear (A) 0.95－1.68 mm
(0.038－0.066 in)

Service Limit:

:

0.46 mm (0.019 in)

:

0.51 mm (0.021 in)

:

0.95 mm (0.038 in)

4th Double Cone Synchro-to-Gear Clearance

Standard:

:

Outer Synchro Ring (B) to Synchro Cone (C) 0.70－1.19 mm
(0.028－0.046 in)

:

Synchro Cone (C) to Gear (A) 0.50－1.04 mm
(0.020－0.040 in)

:

Outer Synchro Ring (B) to Gear (A) 0.95－1.68 mm
(0.038－0.066 in)

Service Limit:

:

0.70 mm (0.028 in)

:

0.50 mm (0.020 in)

:

0.95 mm (0.038 in)

Triple Cone Synchro-to-Gear Clearance

Standard:

:

Outer Synchro Ring (B) to Synchro Cone (C) 0.70－1.19 mm
(0.028－0.046 in)

:

Synchro Cone (C) to Gear (A) 0.50－1.04 mm
(0.020－0.040 in)

:

Outer Synchro Ring (B) to Gear (A) 0.95－1.68 mm
(0.038－0.066 in)

Service Limit:

:

0.70 mm (0.028 in)

:

0.50 mm (0.020 in)

:

0.95 mm (0.038 in)

Installation

1. M/T Countershaft


1.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

2.

Install the 1st gear distance collar (A).

3.

Install the needle bearing (B).

4.

Install 1st gear (C).


5.

Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the grooves (C) in 1st gear.

6.

Install the synchro spring (D).

7.

Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.


8.

Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B).

NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.

9.

Check the operation of the 1st/2nd synchro hub set.

10.

Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 1st/2nd synchro hub.


11.

Install the friction damper (A) to the 2nd gear distance collar (B).

12.

Install the 2nd gear distance collar and the friction damper by aligning the friction damper fingers (C) with the grooves (D) in the 1st/2nd synchro hub.


13.

Install the needle bearing (A).

14.

Install 2nd gear (B) by aligning the synchro cone fingers (C) with the grooves (D) in 2nd gear.

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15.

Support the countershaft (A) on steel blocks.

16.

Press on 3rd gear (B) using the 40 mm I.D. driver handle and a press (C).

NOTE: Do not exceed the maximum pressure.

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17.

Press on 4th gear (A) using the 40 mm I.D. driver handle and the press (B).

NOTE: Do not exceed the maximum pressure.

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18.

Press on 5th gear (A) using the 40 mm I.D. driver handle and the press (B).

NOTE: Do not exceed the maximum pressure.

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19.

Press on 6th gear (A) using the 40 mm I.D. driver handle and the press (B).

NOTE: Do not exceed the maximum pressure.

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20.

Install the 35 mm shim (A).

21.

Temporarily press on the used ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press (C).

NOTE:

Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.

Make sure the ball bearing is installed in the correct direction.


22.

Measure the clearance between the ball bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

Standard:

0.04－0.10 mm
(0.002－0.003 in)

23.

If the measured clearance in step 22 is not within the standard, select another suitable 35 mm shim from the table, then go to next step to replace the 35 mm shim and the ball bearing with new ones. If the measured clearance in step 22 is within the standard, go to next step to replace only the ball bearing with a new one.

35 mm Shim

Type

Thickness

A

0.87 mm (0.0343 in)

AA

0.91 mm (0.0358 in)

B

0.95 mm (0.0374 in)

AB

0.99 mm (0.0390 in)

C

1.03 mm (0.0406 in)

AC

1.07 mm (0.0421 in)

D

1.11 mm (0.0437 in)

AD

1.15 mm (0.0453 in)

E

1.19 mm (0.0469 in)

AE

1.23 mm (0.0484 in)

F

1.27 mm (0.0500 in)

AF

1.31 mm (0.0516 in)

G

1.35 mm (0.0531 in)

AG

1.39 mm (0.0547 in)

H

1.43 mm (0.0563 in)

AH

1.47 mm (0.0579 in)

J

1.51 mm (0.0594 in)

AJ

1.55 mm (0.0610 in)

K

1.59 mm (0.0626 in)

AK

1.63 mm (0.0642 in)

L

1.67 mm (0.0657 in)

AL

1.71 mm (0.0673 in)

M

1.75 mm (0.0689 in)

AM

1.79 mm (0.0705 in)

N

1.83 mm (0.0720 in)

AN

1.87 mm (0.0736 in)

P

1.91 mm (0.0752 in)

AP

1.95 mm (0.0768 in)

Q

1.99 mm (0.0783 in)


24.

Support 6th gear (A) on steel blocks (B).

25.

Use the press (C) and an attachment (D) to press the countershaft out of the ball bearing and 6th gear.

26.

Remove the 35 mm shim.

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27.

Press on 6th gear (A) using the 40 mm I.D. driver handle and the press (B).

NOTE: Do not exceed the maximum pressure.

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28.

Install the correct 35 mm shim (A).

NOTE: If necessary, replace the 35 mm shim with the correct one selected in step 23.

29.

Press on a new ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press (C).

NOTE: Make sure the ball bearing is installed in the correct direction.

30.

Recheck the clearance between the bearing and the 35 mm shim with a feeler gauge.

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31.

Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

32.

Tighten a new special bolt (B) (left-hand threads).

NOTE: Apply new MTF to the bolt threads and flange.

2. M/T Mainshaft 3rd and 4th Gear


1.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

2.

Install the needle bearing (A).

3.

Install 3rd gear (B).

4.

Install the double cone synchro assembly (A) with the synchro spring (B) by aligning the synchro cone fingers (C) with the holes (D) in 3rd gear.

5.

Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 3rd/4th synchro hub.

NOTE: Make sure to install the 3rd/4th synchro hub in the direction shown.

6.

Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle and a press.


7.

Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub.

8.

Check the operation of the 3rd/4th synchro hub set.

9.

Install the double cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 3rd/4th synchro hub.

10.

Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes (C) in 4th gear

3. M/T Mainshaft 5th and 6th Gear


1.

Install the 4th/5th gear distance collar (A) with the needle bearings (B).

2.

Install 5th gear (C).

3.

Install the synchro ring (D) with the synchro spring (E).

4.

Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub.

5.

Press on the 5th/6th synchro hub (A) using the 40 mm I.D. driver handle and the 30 mm I.D. bearing driver attachment.


6.

Install the 5th/6th synchro sleeve (A) by aligning the slots of the 5th/6th synchro sleeve and the 5th/6th synchro hub (B).

NOTE: Make sure to align the slots in the 5th/6th synchro hub as shown.

7.

Check the operation of the 5th/6th synchro hub set.


8.

Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 5th/6th synchro hub.

9.

Install the 6th gear distance collar (E).

10.

Install the needle bearing (F).

11.

Install 6th gear (G).

12.

Press on a new angular ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.

4. 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.

5. 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).

6. Baffle Plate

1.

Install the baffle plate (A).

7. Reverse Shift Fork

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1.

Install the reverse shift fork (A).

8. 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).

9. 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).

10. 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.

11. 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 Shift Fork Disassembly and Reassembly (R18Z1 M/T)
View NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to any contact surfaces. 1. M/T Shift Fork Exploded View ...

Synchro Ring and Gear Inspection (R18Z1 M/T)
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