Honda CIVIC 10G 2016 Manual Transmission Page 1

Manual Transmission System Description
Reverse Lockout System
A
t vehicle speeds of 12 mph (20 km/h) or more, the PCM, which monitors the signals from the output shaft (countershaft) speed
sensor, activates the reverse lockout solenoid, which pushes the select lock cam into the locked position. As a result, the select lever
cannot rotate to the reverse select position, making it impossible to engage the reverse gear. As the vehicle speed drops to 9 mph (15
km/h) or less, the PCM turns off the reverse lockout solenoid. The select lock return spring pulls back the select lock cam, enabling
the select lever to move freely so the reverse gear can be selected.
Vehicle speed Inhibitor Reverse selection
Above 12 mph (20 km/h) ON Not allowed
Below 9 mph (15 km/h) OFF Allowed
Vehicle OFF (LOCK) mode OFF Allowed
General Operation
Improve operation feeling
The modified shift piece shape and clearance between pieces provide improved diagonal shift operation with reduced looseness.
Manual Transmission System Description 4875 http://techinfo.honda.com/rjanisis/pubs/sm/1/2/Contents/enu/61TBAD/...
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Contents Summary of Manual Transmission

  • Page 1Manual Transmission System Description Reverse Lockout System At vehicle speeds of 12 mph (20 km/h) or more, the PCM, which monitors the signals from the output shaft (countershaft) speed sensor, activates the reverse lockout solenoid, which pushes the select lock cam into the locked position. As a
  • Page 2Reduction of double bump force cardiagn.com One-sided chamfering is applied to the synchro sleeve leading gear and gear dog, providing reduced "double-bump" load. MBS (Mainshaft Brake System) Mechanism When the shift lever is moved to reverse, the 3rd-gear synchro is activated to brake the mainshaft
  • Page 3cardiagn.com Constant mesh reverse gear mechanism The constantly meshed helical gears provide reduced gear noise.
  • Page 4Manual Transmission System Description Reverse Lockout System At vehicle speeds of 12 mph (20 km/h) or more, the PCM, which monitors the signals from the output shaft (countershaft) speed sensor, activates the reverse lockout solenoid, which pushes select lock cam into the select lock pin. As a resu
  • Page 5Manual Transmission Component Location Index cardiagn.com
  • Page 6cardiagn.co
  • Page 7Countershaft Assembly Clearance Inspection NOTE: Before inspection, make sure the special bolt is tightened to the specified torque. 1. Countershaft Assembly Clearance - Inspect 1. Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C). If the clea
  • Page 83. Measure the thickness of 1st gear. If the thickness is less than the service limit, replace 1st gear. If the thickness within the service limit, replace the 1st/2nd synchro hub and the 1st/2nd synchro sleeve as a set. Standard: 23.92-23.97 mm (0.9417-0.9437 in) Service Limit: 23.92 mm (0.9417 in)
  • Page 96. Measure the thickness of 2nd gear as shown. 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 1st/2nd synchro sleeve as a set. Standard: 29.42-29.47 mm (1.1583-1.1602 in) Service Limit: 29.42 mm
  • Page 10Countershaft Assembly Clearance Inspection NOTE: Before inspection, make sure the special bolt is tightened to the specified torque. 1. Countershaft Assembly Clearance - Inspect 1. Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C). If the clea
  • Page 113. Measure the thickness of 1st gear. If the thickness is less than the service limit, replace 1st gear. If the thickness within the service limit, replace the 1st/2nd synchro hub and the 1st/2nd synchro sleeve as a set. Standard: 22.91-22.99 mm (0.9020-0.9051 in) Service Limit: 22.91 mm (0.9020 in)
  • Page 126. Measure the thickness of 2nd gear as shown. 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 1st/2nd synchro sleeve as a set. Standard: 22.91-22.99 mm (0.9020-0.9051 in) Service Limit: 22.91 mm
  • Page 13Countershaft Disassembly, Reassembly, and Inspection Special Tool Required Image Description/Tool Number Driver Handle, 40 mm I.D. 07746-0030100 cardiagn.com Bearing Driver Attachment, 30 mm I.D. 07746-0030300 Driver, 58 x 62 mm 070AD-PYZA100
  • Page 14NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions Replace *1 Double cone synchro assembly
  • Page 15*2 Triple cone synchro assembly cardiagn.com
  • Page 16*3 2.0 L Engine 1. Special Bolt - Remove 1. Securely clamp the countershaft assembly in a bench vise with wood blocks. 2. Remove the special bolt (left-hand threads). cardiagn.com 2. Ball Bearing - Remove 1. Support 6th gear (A) on steel blocks, and press the countershaft (B) out of the ball bearing
  • Page 171. Support 4th gear (A) on steel blocks, and press the countershaft (B) out of 5th gear and 4th gear using an attachment (C) and a press (D). 6. 4th Gear - Remove 7. 3rd Gear - Remove cardiagn.com 1. Support 2nd gear (A) on steel blocks, and press the countershaft (B) out of 3rd gear and 2nd gear us
  • Page 1812.Inner Ring - Remove 13.Synchro Cone - Remove 14.Synchro Ring - Remove 15.Synchro Spring - Remove 16.1st/2nd Synchro Sleeve - Remove 17.1st/2nd Synchro Hub - Remove cardiagn.com 18.Synchro Spring - Remove 19.Synchro Ring - Remove 20.Synchro Cone - Remove 21.Inner Ring - Remove 22.1st Gear - Remove
  • Page 191. Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the countershaft at points A, B, C, and D. If any part of the countershaft is less than the service limit, replace it. Measurement Standard Service Limit Ball Bearing Contact Area 30.002-30.015 mm A 30.002
  • Page 20cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Double cone synchro assembly *2 Triple cone synchro assembly *3 2.0 L Engine 1. Counter Shaft Reverse Gear - Install
  • Page 212. Needle Bearing - Install 3. 1st Gear - Install 4. Inner Ring - Install 5. Synchro Cone - Install 1. Install the synchro cone (A) by aligning the synchro cone fingers (B) with the holes (C) in 1st gear. cardiagn.com 6. Synchro Ring - Install 1. Install the synchro ring (A) by aligning the synchro
  • Page 221. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub. 9. 1st/2nd Synchro Sleeve - Install 1. Install the 1st/2nd synchro sleeve (A) by aligning the slots of the 1st/2nd synchro sleeve and the 1st/2nd synchro hub (B). cardiagn
  • Page 231. Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub. 12.Synchro Cone - Install 13.Inner Ring - Install cardiagn.com 14.Friction Damper - Install (2.0 L Engine) 15.2nd Gear Distance Collar - Install 16.Needle Bearing - Install 17.2n
  • Page 241. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 58 x 62 mm driver and a press (C). NOTE: Do not exceed the maximum pressure. 19.4th Gear - Install 1. Press on 4th gear (A) using the 58 x 62 mm driver and a cardiagn.com press (B). NOTE: Do not exceed the maximum
  • Page 251. Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B). NOTE: Do not exceed the maximum pressure. cardiagn.com 21.6th Gear - Install 1. Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B). NOTE: Do not exceed the maximum pressure. 22.35 mm Shim - Clearance C
  • Page 261. Install the 35 mm shim (A), and 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 a press (C). NOTE: Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the corr
  • Page 27Type Thickness V 1.24 mm (0.0488 in) Type Thickness W 1.26 mm (0.0496 in) X 1.28 mm (0.0504 in) Y 1.30 mm (0.0512 in) Z 1.32 mm (0.0520 in) AA 1.34 mm (0.0528 in) AB 1.36 mm (0.0535 in) AC 1.38 mm (0.0543 in) AD 1.40 mm (0.0551 in) AE 1.42 mm (0.0559 in) AF 1.44 mm (0.0567 in) AG 1.46 mm (0.0575 in)
  • Page 2824.Ball Bearing - Install 1. Install the ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (B). NOTE: If necessary, replace the 35 mm shim with the correct one selected in step 22-2 (35 mm Shim - Clearance Check). Make sure the ball bearing is
  • Page 29Countershaft Disassembly, Reassembly, and Inspection Special Tool Required Image Description/Tool Number Driver Handle, 40 mm I.D. 07746-0030100 cardiagn.com Bearing Driver Attachment, 30 mm I.D. 07746-0030300 Driver, 58 x 62 mm 070AD-PYZA100
  • Page 30NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions Replace *1 Triple cone synchro assembly *2 Left-hand threads 1. Special Bolt - Remove
  • Page 311. Securely clamp the countershaft assembly in a bench vise with wood blocks (A). 2. Remove the special bolt (B). 2. Ball Bearing - Remove cardiagn.com 1. Support 6th gear (A) on steel blocks, and press the countershaft (B) out of the ball bearing and 6th gear using an attachment (C) and a press (D)
  • Page 321. Support 4th gear (A) on steel blocks, and press the countershaft (B) out of 5th gear and 4th gear using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. 6. 4th Gear - Remove 7. 3rd Gear - Remove cardiagn.com 1. Support 2nd gear (A) on steel bloc
  • Page 3312.Synchro Cone - Remove cardiagn.com
  • Page 3413.Synchro Ring - Remove 14.Synchro Spring - Remove 15.1st/2nd Synchro Sleeve - Remove 16.1st/2nd Synchro Hub - Remove 17.Synchro Spring - Remove cardiagn.com 18.Synchro Ring - Remove 19.Synchro Cone - Remove 20.Inner Ring - Remove 21.1st Gear - Remove 22.Needle Bearing - Remove 23.Counter Shaft Rev
  • Page 35Measurement Standard Service Limit Ball Bearing Contact Area 30.002-30.015 mm A 30.002 mm (1.18118 in) (Transmission Housing Side) (1.18118-1.18169 in) 2nd Gear Distance Collar 42.975-42.991 mm B 42.975 mm (1.69193 in) Contact Area (1.69193-1.69256 in) Countershaft Reverse Gear 45.934-45.950 mm C 45
  • Page 36cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Triple cone synchro assembly *2 Left-hand threads 1. Counter Shaft Reverse Gear - Install 2. Needle Bearing - Install
  • Page 373. 1st Gear - Install 4. Inner Ring - Install 5. Synchro Cone - Install 1. Install the synchro cone (A) by aligning the synchro cone fingers (B) with the holes (C) in 1st gear. cardiagn.com 6. Synchro Ring - Install 1. Install the synchro ring (A) by aligning the synchro ring fingers (B) with the gr
  • Page 381. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub. NOTE: Make sure to install the 1st/2nd synchro hub in the direction shown. 9. 1st/2nd Synchro Sleeve - Install 1. Install the 1st/2nd synchro sleeve (A) by aligning the sl
  • Page 391. Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub. cardiagn.com
  • Page 4012.Synchro Cone - Install 13.Inner Ring - Install 1. Install the inner ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the inner ring. cardiagn.com 14.2nd Gear Distance Collar - Install 15.Needle Bearing - Install 16.2nd Gear - Install 1. Install 2nd gear (A) by aligning th
  • Page 411. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 58 x 62 mm driver and a press (C). NOTE: Do not exceed the maximum pressure. 18.4th Gear - Install 1. Press on 4th gear (A) using the 58 x 62 mm driver and a cardiagn.com press (B). NOTE: Do not exceed the maximum
  • Page 421. Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B). NOTE: Do not exceed the maximum pressure. cardiagn.com 20.6th Gear - Install 1. Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B). NOTE: Do not exceed the maximum pressure. 21.35 mm Shim - Clearance C
  • Page 431. Install the 35 mm shim (A), and temporarily press on the used ball bearing (B) until it bottoms in the direction shown using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (C). NOTE: Use any size of 35 mm shim, and note size you used. Measurements taken in the
  • Page 44Type Thickness AK 1.63 mm (0.0642 in) Type Thickness 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) 3. Remove 6th gear with the ball bearing and
  • Page 451. Securely clamp the countershaft assembly in a bench vise with wood blocks (A). 2. Tighten a special bolt (B). cardiagn.com
  • Page 46Gearshift Mechanism Removal and Installation SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repair or service. NOTE: Where icon is shown, click for further information. Do not bend the change wires excessively. 1 cardiagn.c
  • Page 47cardiagn.com Detailed information, notes, and precautions Replace *1 Do not wipe off the special grease applied to the area of the change wire ends *2 Si *3 For some models 1. Vehicle - Lift
  • Page 482. Shift Lever Knob - Remove (Except Si) 1. Lower the shift lever boot (A) to release the hooks from the boot. 2. Remove the shift lever knob (B). cardiagn.com 3. Shift Lever Knob - Remove (Si) 1. Lower the shift lever boot (A) while releasing the hooks (B) from the shift lever boot ring (C). 2. Loo
  • Page 496. Shift Lever Housing - Remove cardiagn.com
  • Page 507. Clip Spring - Remove 8. Clamp - Remove 9. Change Wire - Remove (Shift Lever Side) NOTE: While expanding the lock tab (A), rotate the socket holder retainer (B) counterclockwise until it stops, then remove the socket holder (C). Do not remove the change wire by pulling the change wire guide (D). c
  • Page 5111. Exhaust Pipe A - Remove cardiagn.com
  • Page 5212.Change Wire Bracket - Remove 13.Air Cleaner - Remove 14.Intake Air Duct - Remove 15.Change Wire Crip - Remove 16.Lock Pin - Remove cardiagn.com 17.Change Wire - Remove (Transmission Side) SRS components are located in this area. Review the SRS component locations and the precautions and procedure
  • Page 53cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Do not wipe off the special grease applied to the area of the change wire ends *2 Si *3 For some models
  • Page 541. Change Wire - Install (Transmission Side) cardiagn.com
  • Page 552. Lock Pin - Install 3. Change Wire Crip - Install 4. Intake Air Duct - Install 5. Air Cleaner - Install 6. Change Wire Bracket - Install cardiagn.com 7. Exhaust Pipe A - Install 8. Engine Undercover - Install 9. Change Wire - Install (Shift Lever Side) NOTE: Install the socket holder (A), then rot
  • Page 56cardiagn.com 10.Clamp - Install 11. Clip Spring - Install 12.Shift Lever Housing - Install 13.Center Console - Install 14.Shift Lever Boot Ring and Shift Lever Knob - Install (Si)
  • Page 571. Install and turn the shift lever boot ring (A) until it reaches the bottom of the threads on the shift lever. 2. Install and turn the shift lever knob (B) until it contacts the shift lever boot ring. NOTE: Make sure the shift lever knob is installed in the correct direction. 3. Tighten the shift
  • Page 58Gearshift Mechanism Removal and Installation SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repair or service. NOTE: Where icon is shown, click for further information. Do not bend the change wires excessively. 1 cardiagn.c
  • Page 59cardiagn.com Detailed information, notes, and precautions Replace *1 Do not wipe off the special grease applied to the area of the change wire ends *2 For some models 1. Vehicle - Lift
  • Page 60cardiagn.co
  • Page 612. Shift Lever Knob - Remove 1. Lower the shift lever boot (A) while releasing the hooks (B) from the shift lever boot ring (C). 2. Loosen the shift lever boot ring clockwise. 3. Remove the shift lever knob (D). cardiagn.com 3. Shift Lever Boot Ring - Remove 4. Center Console - Remove 5. Clip Spring
  • Page 62cardiagn.com 8. Shift Lever Housing - Remove 9. Engine Undercover - Remove NOTE: Remove the necessary part(s). 10.Exhaust Pipe A - Remove 11. Change Wire Bracket - Remove 12.Air Cleaner - Remove 13.Charge Air Cooler Hose - Disconnect
  • Page 63cardiagn.co
  • Page 64NOTE: Remove the necessary part(s). 14.Change Wire Crip - Remove 15.Lock Pin - Remove 16.Change Wire - Remove (Transmission Side) SRS components are located in this area. Review the SRS component locations and the precautions and procedures before doing repair or service. cardiagn.com NOTE: Where ic
  • Page 65cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 Do not wipe off the special grease applied to the area of the change wire ends *2 For some models 1. Change Wire - Install (Transmission Side)
  • Page 66cardiagn.co
  • Page 672. Lock Pin - Install 3. Change Wire Crip - Install 4. Charge Air Cooler Hose - Install 5. Air Cleaner - Install 6. Change Wire Bracket - Install NOTE: When installing the change wires, visibly the wire with cardiagn.com the white tape and line must be located under the wire without it. 7. Exhaust P
  • Page 68cardiagn.com 10.Clamp - Install 11. Clip Spring - Install 12.Shift Lever Housing - Install 13.Center Console - Install 14.Shift Lever Boot Ring and Shift Lever Knob - Install
  • Page 691. Install and turn the shift lever boot ring (A) until it reaches the bottom of the threads on the shift lever. 2. Install and turn the shift lever knob (B) until it contacts the shift lever boot ring. NOTE: Make sure the shift lever knob is installed in the correct direction. 3. Tighten the shift
  • Page 70Intermediate Shaft Disassembly and Reassembly Special Tool Required Image Description/Tool Number Bearing Driver Attachment, 37 x 40 mm 07746-0010200 cardiagn.com Bearing Driver Attachment, 52 x 55 mm 07746-0010400 Bearing Driver Attachment, 35 mm I.D. 07746-0030400
  • Page 71Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 Oil Seal Driver, 44.5 mm 07947-SB0A100 cardiagn.com Driver, 32.5 mm 070AD-SAAA100 Oil Seal Driver, 65 mm 07JAD-PL9A100
  • Page 72Image Description/Tool Number Installer Attachment 40 mm 07LAD-PW50601 Half Shaft Base 07NAF-SR3A101 cardiagn.com Where icon is shown, click for further information. Clean the disassembled parts with solvent, then dry the disassembled parts with compressed air. Do not wash the rubber parts with solv
  • Page 73cardiagn.com Detailed information, notes, and precautions Replace 2 2.0 L engine
  • Page 74cardiagn.com Detailed information, notes, and precautions Replace 1.5 L engine 1. Outer Seal - Remove 2. External Snap Ring - Remove
  • Page 751. Remove the external snap ring (A). 3. Intermediate Shaft - Remove cardiagn.com 1. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using the half shaft base and a press. NOTE: Be careful not to damage the bearing support ring (C) on the intermediate shaft during disassem
  • Page 761. Press the intermediate shaft bearing (A) out of the bearing support (B) using the 15 x 135L driver handle, the half shaft base, the 37 x 40 mm bearing driver attachment, and a press. cardiagn.com 2.0 L engine 1. Outer Seal - Remove 2. External Snap Ring - Remove 1. Remove the external snap ring (
  • Page 771. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using the half shaft base and a press. NOTE: Be careful not to damage the bearing support ring (C) on the intermediate shaft during disassembly. cardiagn.com 4. Internal Snap Ring - Remove 5. Intermediate Shaft Bearing - R
  • Page 78Clean the disassembled parts with solvent, then dry the disassembled parts with compressed air. Do not wash the rubber parts with solvent. cardiagn.com
  • Page 791 1.5 L engine cardiagn.com Detailed information, notes, and precautions Replace 2 2.0 L engine
  • Page 80cardiagn.com Detailed information, notes, and precautions Replace 1.5 L engine 1. Intermediate Shaft Bearing - Install
  • Page 811. Press the intermediate shaft bearing (A) into the bearing support (B) using the 52 x 55 mm bearing driver attachment, the 15 x 135L driver handle, the half shaft base, and a press. cardiagn.com 2. Internal Snap Ring - Install 3. Intermediate Shaft - Install 1. Press the intermediate shaft (A) int
  • Page 82cardiagn.co
  • Page 834. External Snap Ring - Install 1. Install the external snap ring (A). cardiagn.com 5. Outer Seal - Install Install the outer seal (A) into the bearing support (B) using the 65 mm oil seal driver, the half shaft base, and a press. Press in the seal until it is even with the surface of the bearing su
  • Page 841. Press the intermediate shaft bearing (A) into the bearing support (B) using the 52 x 55 mm bearing driver attachment, the 15 x 135L driver handle, the half shaft base, and a press. cardiagn.com 2. Internal Snap Ring - Install 3. Intermediate Shaft - Install 1. Press the intermediate shaft (A) int
  • Page 851. Install the external snap ring (A). 5. Outer Seal - Install cardiagn.com Install the outer seal (A) into the bearing support (B) using the 40 mm installer attachment, the half shaft base, and a press. Press in the seal until it is 4 0.2 mm (0.16 0.008 in) (C) below the surface of the bearing supp
  • Page 86Intermediate Shaft Disassembly and Reassembly Special Tool Required Image Description/Tool Number Bearing Driver Attachment, 42 x 47 mm 07746-0010300 cardiagn.com Bearing Driver Attachment, 52 x 55 mm 07746-0010400 Driver Handle, 15 x 135L 07749-0010000
  • Page 87Image Description/Tool Number Support Base 07965-SD90100 Support Base Attachment 07LAF-SM40300 cardiagn.com Installer Attachment, 45 x 55 mm 07MAD-PR90100 Where icon is shown, click for further information. Clean the disassembled parts with solvent, then dry the disassembled parts with compressed ai
  • Page 88cardiagn.com Detailed information, notes, and precautions Replace 1. Outer Seal - Remove 2. External Snap Ring - Remove 3. Intermediate Shaft - Remove
  • Page 891. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using the support base attachment, the support base, and a press. NOTE: Be careful not to damage the bearing support ring (C) on the intermediate shaft during disassembly. cardiagn.com 4. Internal Snap Ring - Remove 5. Int
  • Page 90Where icon is shown, click for further information. Clean the disassembled parts with solvent, then dry the disassembled parts with compressed air. Do not wash the rubber parts with solvent. cardiagn.com
  • Page 911 cardiagn.com Detailed information, notes, and precautions Replace 1. Intermediate Shaft Bearing - Install
  • Page 921. Press the intermediate shaft bearing (A) into the bearing support (B) using the 15 x 135L driver handle, the 52 x 55 mm bearing driver attachment, and a press. cardiagn.com 2. Internal Snap Ring - Install 3. Intermediate Shaft - Install 1. Press the intermediate shaft (A) into the shaft bearing (
  • Page 934. External Snap Ring - Install 5. Outer Seal - Install 1. Install the outer seal (A) into the bearing support (B) using the 45 x 55 mm installer attachment and a press. Press in the seal until it is even with the surface of the bearing support. cardiagn.com
  • Page 94Intermediate Shaft Removal and Installation NOTE: Unless otherwise indicated, illustrations used in the procedure are for 1.5 L engine. 1. Vehicle - Lift 2. Transmission Fluid - Drain M/T CVT 3. Right Front Wheel - Remove cardiagn.com 4. Right Driveshaft - Remove 5. Intermediate Shaft Assembly - Rem
  • Page 95NOTE: Do not wash the rubber parts with solvent. 2. Install the parts in the reverse order of removal. 7. Wheel Alignment - Check 8. Test Drive - Check cardiagn.com
  • Page 96Intermediate Shaft Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com
  • Page 97cardiagn.co
  • Page 98Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 1. Vehicle - Lift 2. Engine Undercover - Remove NOTE: Remove the necessary part(s). 3. Transmission Fluid - Drain 4. Right Front Wheel - Remove (Both Side) cardiagn.com 5. Right Driveshaft Inboard Joint - Disconnect 6. Intermed
  • Page 99Mainshaft Assembly Clearance Inspection 1. Mainshaft Assembly Clearance - Inspect 1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B). 2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E). If the clearance excee
  • Page 1004. Measure the clearance between 4th gear (A) and the 4th/5th gear distance collar (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 5. If the clearance is within the service limit, go to step 7. Standard: 0.06-0.16 mm (0.0024- 0.0063 in) Service Limit: 0.16 mm (0
  • Page 1017. Measure the clearance between the 4th/5th gear distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 8. If the clearance is within the service limit, go to step 10. Standard: 0.06-0.16 mm (0.0024- 0.0063 in) Service Limit: 0.16 mm (
  • Page 10210. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 11. Standard: 0.06-0.16 mm (0.0024- 0.0063 in) Service Limit: 0.16 mm (0.0063 in) cardiagn.com 11. Measure the length of the 6t
  • Page 103cardiagn.co
  • Page 104Mainshaft Assembly Clearance Inspection 1. Mainshaft Assembly Clearance - Inspect 1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B). 2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E). If the clearance excee
  • Page 1054. Measure the clearance between 4th gear (A) and the 4th/5th gear distance collar (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 5. If the clearance is within the service limit, go to step 7. Standard: 0.06-0.19 mm (0.0024-0.0075 in) Service Limit: 0.19 mm (0.
  • Page 1067. Measure the clearance between the 4th/5th gear distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 8. If the clearance is within the service limit, go to step 10. Standard: 0.06-0.19 mm (0.0024-0.0075 in) Service Limit: 0.19 mm (0
  • Page 10710. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 11. Standard: 0.06-0.19 mm (0.0024-0.0075 in) Service Limit: 0.19 mm (0.0075 in) cardiagn.com 11. Measure the length of the 6th
  • Page 108Mainshaft Disassembly, Reassembly, and Inspection Special Tool Required Image Description/Tool Number Driver Handle, 40 mm I.D. 07746-0030100 cardiagn.com Driver, 30 mm I.D. 07946-MB00000 NOTE: Where icon is shown, click for further information. 1
  • Page 109cardiagn.com Detailed information, notes, and precautions Replace 1. Ball Bearing - Remove
  • Page 1101. Support 6th gear (A) on steel blocks, and press the mainshaft out of the angular ball bearing (B) using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. 2. 6th Gear - Remove cardiagn.com 3. Needle Bearing - Remove 4. 6th Gear Distance Collar - R
  • Page 1111. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B) using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. cardiagn.com
  • Page 1129. Synchro Spring - Remove 10.Synchro Ring - Remove 11. 5th Gear - Remove 12.Needle Bearing - Remove 13.4th/5th Gear Distance Collar - Remove cardiagn.com 14.Needle Bearing - Remove 15.4th Gear - Remove 16.Synchro Ring - Remove 17.Synchro Spring - Remove 18.3rd/4th Synchro Sleeve - Remove 19.3rd/4th
  • Page 1131. Support 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B) and 3rd gear using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. 20.Synchro Spring - Remove cardiagn.com 21.Synchro Ring - Remove 22.3rd Gear - R
  • Page 114cardiagn.co
  • Page 1151. Mainshaft - Inspect 1. Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the mainshaft at points A, B, C, D, E, and F. If any part of the mainshaft is less than the service limit, replace it. Measurement Standard Service Limit Ball Bearing Contact Area 30.
  • Page 1161 cardiagn.com Detailed information, notes, and precautions Replace 1. Angular Ball Bearing - Install
  • Page 1171. Press in the angular ball bearing (A) using the 30 mm I.D. driver and a press (B). NOTE: Check the ball bearing install direction. cardiagn.com 2. Needle Bearing - Install 3. 3rd Gear - Install 4. Synchro Ring - Install 5. Synchro Spring - Install 6. 3rd/4th Synchro Hub - Install 1. Install the 3
  • Page 118cardiagn.co
  • Page 1192. Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle and a press (B). 7. 3rd/4th Synchro Sleeve - Install 1. Install the 3rd/4th synchro sleeve (A) by aligning the stops cardiagn.com (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub. 2. Check the operation of the 3r
  • Page 1201. Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves in 3rd/4th synchro hub (C). 10.4th Gear - Install 11. Needle Bearing - Install cardiagn.com 12.4th/5th Gear Distance Collar - Install 13.Needle Bearing - Install 14.5th Gear - Install 15.Synchro Ring - Install
  • Page 1211. Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub. cardiagn.com 2. Press on the 5th/6th synchro hub (A) using the 40 mm I.D. driver handle and a press (B). 18.5th/6th Synchro Sleeve - Install
  • Page 1221. 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 sleeve as shown. 2. Check the operation of the 5th/6th synchro hub set. cardiagn.com 19.Synchro Spring - Install 20
  • Page 12324.Ball Bearing - Install 1. Press on a angular ball bearing (A) using the 40 mm I.D. driver handle and a press (B). NOTE: Check the ball bearing install direction. cardiagn.com
  • Page 124Mainshaft Disassembly, Reassembly, and Inspection Special Tool Required Image Description/Tool Number Driver Handle, 40 mm I.D. 07746-0030100 cardiagn.com Driver, 30 mm I.D. 07946-MB00000 NOTE: Where icon is shown, click for further information. 1
  • Page 125cardiagn.com Detailed information, notes, and precautions Replace *1 Double cone synchro assembly 1. Angular Ball Bearing - Remove
  • Page 1261. Support 6th gear (A) on steel blocks, and press the mainshaft out of the angular ball bearing (B) using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. 2. 6th Gear - Remove cardiagn.com 3. Needle Bearing - Remove 4. 6th Gear Distance Collar - R
  • Page 1271. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B) using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. cardiagn.com
  • Page 1289. Synchro Spring - Remove 10.Synchro Ring - Remove 11. 5th Gear - Remove 12.Needle Bearing - Remove 13.4th/5th Gear Distance Collar - Remove cardiagn.com 14.Needle Bearing - Remove 15.4th Gear - Remove 16.Inner Ring - Remove 17.Synchro Cone - Remove 18.Synchro Ring - Remove 19.Synchro Spring - Remo
  • Page 1291. Support 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B) and 3rd gear using an attachment (C) and a press (D). NOTE: Do not use a jaw-type puller; it can damage the gear teeth. 22.Synchro Spring - Remove cardiagn.com 23.Synchro Ring - Remove 24.Synchro Cone
  • Page 1301. Support the angular ball bearing (A) on steel blocks, and press out the mainshaft using an attachment (B) and a press (C). cardiagn.com 1. Mainshaft - Inspect 1. Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the mainshaft at points A, B, C, D, E, and F
  • Page 1312. Inspect the runout by supporting both ends of the mainshaft. Then rotate the mainshaft two complete turns while measuring with a dial gauge. If the runout exceeds the standard, replace the mainshaft. Standard: 0.02 mm (0.0008 in) max. NOTE: Where icon is shown, click for further information. Clea
  • Page 132cardiagn.com Detailed information, notes, and precautions Replace *1 Double cone synchro assembly 1. Angular Ball Bearing - Install
  • Page 1331. Press in a angular ball bearing (A) using the 30 mm I.D. driver and a press (B). NOTE: Check the ball bearing install direction. cardiagn.com 2. Needle Bearing - Install 3. 3rd Gear - Install 4. Inner Ring - Install 5. Synchro Cone - Install 1. Install the synchro cone (A) by aligning the synchro
  • Page 1341. Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C). 7. Synchro Spring - Install cardiagn.com 8. 3rd/4th Synchro Hub - Install 1. Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 3rd/4th synchro hub. NO
  • Page 1352. Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle and a press (B). 9. 3rd/4th Synchro Sleeve - Install 1. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro cardiagn.com hub. 2. Check the operation of the 3r
  • Page 1361. Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in 3rd/4th synchro hub. 12.Synchro Cone - Install cardiagn.com 13.Inner Ring - Install 1. Install the inner ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the inner ring. 14.4th G
  • Page 1371. Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes (C) in 4th gear. 15.Needle Bearing - Install 16.4th/5th Gear Distance Collar - Install cardiagn.com 17.Needle Bearing - Install 18.5th Gear - Install 19.Synchro Ring - Install 20.Synchro Spring - Install 21.5th/6th Synch
  • Page 1381. Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub. NOTE: Make sure to install the 5th/6th synchro hub in the direction shown. cardiagn.com 2. Press on the 5th/6th synchro hub (A) using the 40 mm I.D. driver handle and a pr
  • Page 1391. 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 sleeve as shown. 2. Check the operation of the 5th/6th synchro hub set. cardiagn.com 23.Synchro Spring - Install 24
  • Page 14028.Angular Ball Bearing - Install 1. Press on an angular ball bearing (A) using the 40 mm I.D. driver handle and a press (B). NOTE: Make sure the angular ball bearing is installed in the correct direction. cardiagn.com
  • Page 141Mainshaft Thrust Clearance Adjustment Special Tool Required Image Description/Tool Number Mainshaft Holder 07GAJ-PG20110 cardiagn.com Mainshaft Base 07GAJ-PG20130 NOTE: Take measurements at normal room temperature. Clean all parts thoroughly before installation. 1. Mainshaft Thrust Clearance - Adjus
  • Page 1421. Remove the 72 mm shim (A) and oil guide plate M. cardiagn.com 2. Thoroughly clean the 64 mm spring washer (A) before installing it on the clutch housing (B). NOTE: Be sure to install the spring washer in the direction shown. 3. Assemble all of the mainshaft components. NOTE: Refer to the Exploded
  • Page 1438. Attach the mainshaft holder and the mainshaft base to the mainshaft as shown. 9. Back out the mainshaft holder bolt (A), and loosen the two hex bolts (B). 10. Fit the mainshaft holder over the mainshaft so its lip is towards the transmission. 11. Align the mainshaft holder lip around the groove a
  • Page 14472 mm Shim '16 Type Thickness A 0.60 mm (0.0236 in) B 0.62 mm (0.0244 in) C 0.64 mm (0.0252 in) D 0.66 mm (0.0260 in) E 0.68 mm (0.0268 in) F 0.70 mm (0.0276 in) G 0.72 mm (0.0283 in) H 0.74 mm (0.0291 in) I 0.76 mm (0.0299 in) J 0.78 mm (0.0307 in) K 0.80 mm (0.0315 in) L 0.82 mm (0.0323 in) M 0.84
  • Page 145Type Thickness AU 1.52 mm (0.0598 in) AV 1.54 mm (0.0606 in) AW 1.56 mm (0.0614 in) AX 1.58 mm (0.0622 in) AY 1.60 mm (0.0630 in) AZ 1.62 mm (0.0638 in) AAA 1.64 mm (0.0646 in) AAB 1.66 mm (0.0654 in) AAC 1.68 mm (0.0661 in) AAD 1.70 mm (0.0669 in) AAE 1.72 mm (0.0677 in) AAF 1.74 mm (0.0685 in) AAG
  • Page 146Type Thickness AC 1.16 mm (0.0457 in) AD 1.18 mm (0.0465 in) AE 1.20 mm (0.0472 in) AF 1.22 mm (0.0480 in) AG 1.24 mm (0.0488 in) AH 1.26 mm (0.0496 in) AI 1.28 mm (0.0504 in) AJ 1.30 mm (0.0512 in) AK 1.32 mm (0.0520 in) AL 1.34 mm (0.0528 in) AM 1.36 mm (0.0535 in) AN 1.38 mm (0.0543 in) AO 1.40 m
  • Page 147Mainshaft Thrust Clearance Adjustment Special Tool Required Image Description/Tool Number Mainshaft Holder 07GAJ-PG20110 cardiagn.com Mainshaft Base 07GAJ-PG20130 NOTE: Take measurements at normal room temperature. Clean all parts thoroughly before installation. 1. Mainshaft Thrust Clearance - Adjus
  • Page 1481. Remove the 87 mm shim (A). cardiagn.com 2. Thoroughly clean the spring washer (A) before installing it on the clutch housing (B). NOTE: Be sure to install the spring washer in the direction shown. 3. Assemble all of the mainshaft components. NOTE: Refer to the Exploded View as needed. 4. Install
  • Page 1498. Attach the mainshaft holder and the mainshaft base to the mainshaft as shown. 9. Back out the mainshaft holder bolt (A), and loosen the two hex bolts (B). 10. Fit the mainshaft holder over the mainshaft so its lip is towards the transmission. 11. Align the mainshaft holder lip around the groove a
  • Page 15017. With the appropriate size shim installed in the transmission housing, check the thrust clearance again to verify the clearance is within the standard. 87 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
  • Page 151Manual Transmission Disassembly and Reassembly Special Tool Required Image Description/Tool Number Bearing Driver Attachment, 42 x 47 mm 07746-0010300 cardiagn.com Bearing Driver Attachment, 62 x 68 mm 07746-0010500 Driver Handle, 15 x 135L 07749-0010000
  • Page 152Image Description/Tool Number Oil Seal Driver, 65 mm 07JAD-PL9A100 Snap Ring Pliers 07LGC-0010100 cardiagn.com Adjustable Bearing Puller, 45-75 mm 07YAC-0010102 NOTE: Where icon is shown, click for further information. Place the clutch housing on two pieces of wood thick enough to keep the mainshaft
  • Page 1532 1 Replace cardiagn.com
  • Page 154cardiagn.com Detailed information, notes, and precautions Replace 3
  • Page 155cardiagn.com Detailed information, notes, and precautions Replace *1 1.5 L Engine 1. Detent Bolt - Remove 2. 26.0 mm Detent Ball Spring - Remove
  • Page 1563. 7.94 mm Steel Ball - Remove 4. Detent Bolt - Remove 5. 23.4 mm Detent Ball Spring - Remove 6. 7.94 mm Steel Ball - Remove 7. Breather Cap - Remove cardiagn.com 8. Change Lever Assembly - Remove 9. Detent Bolt - Remove 10.26.0 mm Detent Ball Spring - Remove 11. 7.94 mm Steel Ball - Remove 12.Trans
  • Page 15717.Detent Bolt - Remove 18.26.0 mm Detent Ball Spring - Remove 19.7.94 mm Steel Ball - Remove 20.Oil Check Bolt - Remove 21.8 mm Flange Bolt - Remove cardiagn.com 22.Drain Plug - Remove 23.32 mm Sealing Cap - Remove 24.8 mm Flange Bolt - Loosen NOTE: Loosen the 8 mm flange bolts in a crisscross patt
  • Page 1581. While expanding the 72 mm snap ring (A) on the countershaft ball bearing with the snap ring pliers, lift the transmission housing (B). Release the snap ring pliers, and remove the transmission housing with the 14 x 20 mm dowel pins (C). cardiagn.com 28.Oil Seal - Remove NOTE: Be careful not to da
  • Page 15932.Oil Gutter Plate B - Remove 33.90 mm Shim - Remove 34.72 mm Snap Ring - Remove 35.Oil Guide Plate C - Remove 36.Reverse Shift Holder - Remove cardiagn.com 37.Baffle Plate - Remove 38.Reverse Idler Gear Shaft Assembly/Reverse Shift Fork - Remove 1. Remove the reverse idler gear shaft assembly (A),
  • Page 16041.Interlock - Remove 42.Select Return Spring - Remove 43.Shift Piece Collar - Remove 44.8 x 50 mm Pin - Remove 45.Mainshaft, Countershaft, and Shift Fork Assembly - Remove 1. Apply a thin layer of tape to the mainshaft splines (A) to protect the oil seal. cardiagn.com NOTE: Do not apply too much ta
  • Page 161NOTE: Be careful not to damage the clutch housing while removing the mainshaft oil seal. 48.Bearing Set Plate - Remove cardiagn.com 49.Countershaft Bearing - Remove 1. Remove the bearing (A) using the 45-75 mm adjustable bearing puller and a commercially available 3/8''-16 UNF slide hammer (B). 50.D
  • Page 16252.Oil Gutter Plate C - Remove (1.5 L Engine) cardiagn.com
  • Page 16353.Oil Seal - Remove NOTE: Be careful not to damage the clutch housing while removing the oil seal. cardiagn.com NOTE: Where icon is shown, click for further information. Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces and the O-rings. When applying
  • Page 164cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace *1 1.5 L Engine 2
  • Page 165cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 3
  • Page 166cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 1. Oil Seal - Install
  • Page 1671. Install the oil seal flush with the clutch housing using the 65 mm oil seal driver. cardiagn.com 2. Oil Gutter Plate C - Install (1.5 L Engine) 3. Magnet - Install 4. Differential Assembly - Install 5. Countershaft Bearing - Install 1. Install the bearing using the 15 x 135L driver handle and the
  • Page 1686. Bearing Set Plate - Install 7. Mainshaft Oil Seal - Install 1. Install the oil seal flush with the clutch housing using the 15 x 135L driver handle and the 42 x 47 mm bearing driver attachment. Oil Seal Installed Height: 1.0-1.4 mm (0.039-0.055 in) cardiagn.com 8. 64 mm Spring Washer - Install NO
  • Page 1692. Install the mainshaft (B) and the countershaft (C) with the shift fork assembly (D) as an assembly. Shift Piece Assembly (Shift Piece Shaft, Shift Piece, Interlock, Select Return Spring, Shift piece Collar, 8 x 50 mm Pin) - 10. Install 11. Reverse Idler Gear Shaft Assembly - Install 1. Assemble t
  • Page 1702. Slide the reverse idler gear shaft assembly (A) on the rib (B) of the clutch housing, then install it into the hole (C) of the clutch housing. cardiagn.com 3. Align the mark (A) on the clutch housing with the reverse gear holder hole (B). 12.Baffle Plate - Install
  • Page 1711. Set the baffle plate (A) into the reverse gear holder hole (B). 13.Reverse Shift Holder - Install cardiagn.com 14.Oil Seal - Install 1. Install the oil seal flush with the transmission housing using the 65 mm oil seal driver. 15.Oil Guide Plate C - Install 16.72 mm Snap Ring - Install
  • Page 172cardiagn.co
  • Page 17317.Proper Size 90 mm Shim - Select 18.90 mm Shim - Install 19.Oil Gutter Plate B - Install 20.Oil Guide Plate M - Install 21.Proper Size 72 mm Shim - Select 22.72 mm Shim - Install cardiagn.com 23.Oil Gutter Plate A - Install 24.Transmission Housing - Install NOTE: Do the following procedure wheneve
  • Page 1742. Install the 14 x 20 mm dowel pins (A). 3. Place the transmission housing on the clutch housing, making sure to line up the shafts. 4. While expanding the 72 mm snap ring (B) on the countershaft ball bearing using the snap ring pliers, push the transmission housing down to start the countershaft b
  • Page 1756. Make sure oil guide plate C is positioned on the transmission housing as shown. 25.Clutch Line Bracket - Loosely Install cardiagn.com 26.Transmission Hanger B - Loosely Install 27.Transmission Housing Bolt - Tighten 1. Install the 8 mm flange bolts finger-tight. 2. Tighten the 8 mm flange bolts i
  • Page 17631.7.94 mm Steel Ball - Install 32.26.0 mm Detent Ball Spring - Install 33.Detent Bolt - Install NOTE: Do the following procedure whenever installing the parts. 1. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes
  • Page 17740.Detent Bolt - Install NOTE: Do the following procedure whenever installing the parts. 1. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket. NOTE: If too much time has passed after
  • Page 17846.26.0 mm Detent Ball Spring - Install 47.Detent Bolt - Install NOTE: Do the following procedure whenever installing the parts. 1. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket.
  • Page 179Manual Transmission Disassembly and Reassembly Special Tool Required Image Description/Tool Number Weight, Remover 07741-0010201 cardiagn.com Bearing Driver Attachment, 52 x 55 mm 07746-0010400 Bearing Driver Attachment, 72 x 75 mm 07746-0010600
  • Page 180Image Description/Tool Number Bearing Driver Attachment, 24 x 26 mm 07746-0010700 Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Bearing Remover Shaft 07JAC-PH80200 Oil Seal Driver Attachment, 60 mm 07LAD-SM40100
  • Page 181Image Description/Tool Number Snap Ring Pliers 07LGC-0010100 Oil Seal Driver Attachment 07NAD-P200100 cardiagn.com Bearing Driver Attachment, 78 x 80 mm 07NAD-PX40100
  • Page 182Image Description/Tool Number Adjustable Bearing Puller, 45-75 mm 07YAC-0010102 cardiagn.com NOTE: Where icon is shown, click for further information. Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench. 1
  • Page 183cardiagn.com Detailed information, notes, and precautions Replace 2
  • Page 184cardiagn.com Detailed information, notes, and precautions Replace 3
  • Page 185cardiagn.com Detailed information, notes, and precautions Replace 1. Release Bearing - Remove 2. Reverse Lockout Solenoid - Remove
  • Page 186cardiagn.co
  • Page 1873. Oil Pump Strainer - Remove NOTE: Clean the strainer anytime the transmission is disassembled. 4. Back-Up Light Switch - Remove 5. Neutral Position Sensor - Remove 6. Input Shaft (Mainshaft) Speed Sensor - Remove 7. Output Shaft (Countershaft) Speed Sensor - Remove cardiagn.com 8. Detent Bolt - Re
  • Page 18817.Filler Plug - Remove 18.Oil Check Bolt - Remove 19.Drain Plug - Remove 20.Transmission Hanger D - Remove 21.Breather Cap - Remove cardiagn.com 22.Transmission Case Cap - Remove 23.10 mm Flange Bolt - Loosen 24.Transmission Hanger B - Remove 25.Clutch Pipe Bracket - Remove 26.Transmission Housing
  • Page 1891. Expand the 75 mm snap ring (A) on the countershaft ball bearing, and remove it from the groove using the snap ring pliers. 2. Remove the transmission housing (B) and the 14 x 20 mm dowel pins (C). cardiagn.com 27.87 mm Shim - Remove 28.8 mm Special Bolt - Remove 29.Spring Washer - Remove 30.Shift
  • Page 19035.50 x 81 x 18 mm Bearing Outer Race, 46 x 81 x 1 mm Spacer and 81 mm Shim - Remove (Transmission Housing Side) 1. Remove the 50 x 81 x 18 mm bearing outer race (A), the 46 x 81 x 1 mm spacer (B), and the 81 mm shim (C) by heating the transmission housing to about 212 °F (100 °C) with a heat gun. 3
  • Page 19145.Reverse Synchro Sleeve - Remove 46.Reverse Shift Fork - Remove 47.Synchro Spring - Remove 48.Reverse Synchro Ring - Remove 49.Needle Bearing - Remove cardiagn.com 50.Thrust Needle Bearing - Remove 51.Thrust Washer - Remove 52.Thrust Needle Bearing - Remove 53.Needle Bearing - Remove 54.Reverse Dr
  • Page 19259.Shift Piece Shaft - Remove 60.Shift Piece - Remove 61.Interlock - Remove 62.Return Spring - Remove 63.5 x 22 mm Spring Pin and 3 x 22 mm Spring Pin - Remove 1. Remove the 5 x 22 mm spring pin and the 3 x 22 mm spring pin together as shown. cardiagn.com 64.Select Lever and Select Arm - Remove 65.1
  • Page 1931. Apply a thin layer of tape to the mainshaft splines to protect the oil 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). cardiagn.com 67.Spring Washer - Remove 68.28 x 43
  • Page 1941. Remove the countershaft bearing using the 45-75 mm adjustable bearing puller, the bearing remover shaft, and the remover weight. cardiagn.com 74.Oil Pump Plate - Remove 75.Oil Pump Inner Rotor - Remove 76.Oil Pump Outer Rotor - Remove 77.16.1 mm Detent Ball Spring - Remove 78.Steel Ball - Remove
  • Page 1951. Remove the 45 x 80 x 21 mm bearing outer race (A) and the 46 x 80 x 1 mm spacer (B) by heating the clutch housing to about 212 °F (100 °C) with a heat gun. cardiagn.com NOTE: Where icon is shown, click for further information. Prior to reassembling, clean all parts in solvent, dry them, and apply
  • Page 196cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 2
  • Page 197cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 3
  • Page 198cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 1. 46 x 80 x 1 mm Spacer - Install 2. 45 x 80 x 21 mm Bearing Outer Race - Install (Clutch Housing Side)
  • Page 1991. Install the 45 x 80 x 21 mm bearing outer race using the 15 x 135L driver handle and the 78 x 80 mm bearing driver attachment. cardiagn.com 3. 37 x 56 x 8 mm Oil Seal - Install (Clutch Housing Side) 1. Install the 37 x 56 x 8 mm oil seal flush with the clutch housing using the 15 x 135L driver ha
  • Page 2006. Oil Pump Outer Rotor - Install cardiagn.com
  • Page 2017. Oil Pump Inner Rotor - Install 8. Oil Pump Plate - Install 9. Countershaft Bearing - Install (Clutch Housing Side) 1. Install the countershaft bearing using the 15 x 135L driver handle and the 72 x 75 mm bearing driver attachment. cardiagn.com 10.Bearing Set Plate - Install 11. Oil Gutter Plate -
  • Page 2021. Install the oil gutter plate (A) press-fit to the clutch housing surface (B). cardiagn.com 12.Differential Assembly - Install 13.Oil Pump Shaft - Install 1. Install the oil pump shaft (A) while aligning the notch cut (B) of the oil pump shaft with the notch cut of the oil pump inner rotor (C) as
  • Page 2031. Install the 28 x 43 x 7 mm oil seal (A) flush with the clutch housing (B) as shown using the 15 x 135L driver handle and the 52 x 55 mm bearing driver attachment. cardiagn.com 15.Spring Washer - Install NOTE: Be sure to install the spring washer in the direction shown. 16.Mainshaft, Countershaft,
  • Page 2041. Install the 14 x 20 x 4 mm dust seal flush with the clutch housing surface using the 15 x 135L driver handle and the 24 x 26 mm bearing driver attachment. 18.Select Lever and Select Arm - Install cardiagn.com 1. Install the select lever (A) and the select arm (B) as shown. 19.5 x 22 mm Spring Pin
  • Page 2051. Install the 5 x 22 mm spring pin (A) and the 3 x 22 mm spring pin (B) together as shown. NOTE: Make sure the seams (C) of the 5 x 22 mm and the3 x 22 mm spring pin are opposite side. cardiagn.com 20.Return Spring and 8 x 50 mm Pin - Install 1. Install the select return spring (A) and the 8 x 50 m
  • Page 2061. Install the interlock (A). NOTE: Align the interlock with the select arm (B), the select return spring (C), and the shift fork assembly (D). cardiagn.com 22.Shift Piece and Shift Piece Shaft - Install 1. Install the shift piece (A) and the shift piece shaft (B). NOTE: Align the shift piece with t
  • Page 2071. Install these parts in the following order: -1. Reverse drive gear (A) -2. Reverse idler gear shaft (B) -3. Needle bearing (C) -4. Thrust needle bearing (D) -5. Thrust washer (E) -6. Thrust needle bearing (F) -7. Needle bearing (G) cardiagn.com 2. Install the reverse synchro sleeve (A) in the dir
  • Page 2083. Set the synchro spring (A) to the synchro ring (B) and install to the reverse driven gear (C) as shown. cardiagn.com 4. Install the reverse driven gear set (A) in the reverse driven gear set (B).
  • Page 2095. Assemble the thrust needle bearings (A), the thrust washers (B), the spring washer (C), the reverse idler gear shaft assembly (D), and the reverse shift fork (E). NOTE: Be sure to install the spring washer in the direction shown. 6. Slide the reverse idler gear shaft assembly (A) on the rib cardi
  • Page 21025.Magnet - Install cardiagn.com
  • Page 21126.81 mm Shim - Select 27.81 mm Shim - Install 28.46 x 81 x 1 mm Spacer - Install 29.50 x 81 x 18 mm Bearing Outer Race - Install (Transmission Housing Side) 1. Install the 50 x 81 x 18 mm bearing outer race using the 15 x 135L driver handle and the 78 x 80 mm bearing driver attachment. cardiagn.com
  • Page 2121. Install the 42 x 58 x 12.5 mm oil seal flush with the transmission housing using the 15 x 135L driver handle and the 60 mm oil seal driver attachment. cardiagn.com 31.75 mm Snap Ring - Install NOTE: Make sure the snap ring is firmly installed in the groove. 32.16 x 23 x 5 mm Dust Seal - Install 1
  • Page 21334.Shift Arm - Install cardiagn.com
  • Page 21435.Spring Washer - Install NOTE: Be sure to install the spring washer in the direction shown. 36.8 mm Special Bolt - Install 37.87 mm Shim - Select 38.87 mm Shim - Install 39.Oil Guide Pipe B - Install cardiagn.com 1. Install oil guide pipe B while aligning the tip (A) with the hole (C) in the clutc
  • Page 2151. Clean any dirt and oil from the sealing surface of the transmission housing and the clutch housing. 2. Apply liquid gasket (P/N 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 li
  • Page 21642.Clutch Pipe Bracket - Loosely Install 43.Transmission Hanger B - Loosely Install cardiagn.com 44.10 mm Flange Bolt - Tighten NOTE: Install the 10 mm flange bolts with transmission hanger B and the clutch pipe bracket in a crisscross pattern in several steps. 45.Transmission Case Cap - Install 46.
  • Page 21752.27.4 mm Detent Ball Spring - Install 53.Detent Bolt - Install 1. Clean any dirt and oil from the sealing surface of the detent bolt and the transmission housing. 2. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 min
  • Page 2181. Clean any dirt and oil from the sealing surface of the detent bolt and the transmission housing. 2. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolt. Install the component within 5 minutes of applying the liquid gasket. NOTE: If too much time has pa
  • Page 219Manual Transmission Removal and Installation Special Tool Required Image Description/Tool Number Universal Lifting Eyelet 07AAK-SNAA120 cardiagn.com Engine Support Hanger, A and Reds AAR-T1256* Subframe Adapter VSB02C000016* *: Available through the Honda Tool and Equipment Program 888-424-6857.
  • Page 220NOTE: How to read the torque specifications. 1. Transmission Assembly Mounting Bolt - Exploded View Exploded View cardiagn.com
  • Page 221NOTE: Engine support hanger AAR-T1256 must be used with the side engine mount installed. Use fender covers to avoid damaging painted surfaces. 1. Vehicle - Lift Set 2. Front Grille Cover - Remove 3. Air Cleaner - Remove 4. 12 Volt Battery - Remove cardiagn.com 5. 12 Volt Battery Base - Remove 6. Int
  • Page 2229. Intake Air Duct - Remove 10.EVAP Canister Purge Valve - Remove (2.0 L Engine) 11. Engine Wire Harness (Transmission Side) - Remove 1. Disconnect the connectors (A). cardiagn.com 2. Remove the connector (B) from the bracket. 3. Remove the brackets (C).
  • Page 2234. Disconnect the connector (A). 5. Remove the harness bracket (B). cardiagn.com 12.Engine Wire Harness (Engine Side) - Remove (1.5 L Engine) 1. Disconnect the connectors (A).
  • Page 2242. Remove the ground cables (B). cardiagn.com 3. Remove the harness covers (C) and the harness brackets (D), then swing the engine wire harness (E) out of the way. 13.Engine Wire Harness (Engine Side) - Remove (2.0 L Engine) 1. Disconnect the connectors (A).
  • Page 225cardiagn.com 2. Remove the ground cable (B). 3. Remove the harness clamps (C), then swing the engine wire harness (D) out of the way. 14.Change Wire Bracket - Remove 1. Remove the lock pins (A).
  • Page 226cardiagn.com 2. Carefully remove the change wire and the change wire bracket (B) together to avoid bending the change wire. NOTE: Do not wipe off the grease of the change wire ends (C). 15.Intake Manifold Bracket - Remove (1.5 L Engine) 16.Engine Support Hanger - Install 1. Remove the front damper c
  • Page 227cardiagn.com 2. Install the universal lifting eyelet with an about 50 mm (2.00 in) commercially available spacer (A). 3. Install the engine support hanger onto the vehicle as shown. 4. Attach the hook (B) to the slotted hole in the universal lifting eyelet. 5. Tighten the wing nut (C) by hand, and l
  • Page 22818.Transmission Mount - Remove 19.Steering Joint - Disconnect NOTE: Hold the steering wheel with the steering wheel holder tool. 20.Vehicle - Lift Up 21.Front Wheel - Remove 22.Engine Undercover - Remove cardiagn.com 23.Engine Undercover Lid - Remove (With Engine Undercover Lid) 24.Transmission Flui
  • Page 229cardiagn.com 28.Tie-Rod End Ball Joint - Disconnect (Both Sides) 29.Lower Stabilizer Link Ball Joint- Disconnect (Both Sides) 30.Lower Arm Ball Joint - Disconnect (Both Sides) 31.Lower Arm Mounting Bolt - Remove (Both Sides)
  • Page 23032.Front Brace - Remove 33.Intake Air Resonator - Remove (1.5 L Engine) 34.Torque Rod Mounting Bolt - Remove cardiagn.com 35.Front Subframe - Remove 1. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base
  • Page 23136.Transmission - Support 1. Support the transmission with the transmission jack. 37.Intake Air Resonator - Remove (2.0 L Engine) 38.Clutch Cover - Remove cardiagn.com 39.Driveshaft Inboard Joint - Disconnect (Both Sides) NOTE: Secure the driveshaft to the body with a nylon strap on both sides. 40.I
  • Page 2323. Check once again that all hoses and harness are disconnected and free from the transmission. 4. Lower the transmission. NOTE: How to read the torque specifications. Use fender covers to avoid damaging painted surfaces. 1. Release Bearing - Check 1. Check the release bearing, then install the rele
  • Page 2336. Clutch Cover - Install cardiagn.com 7. Intake Air Resonator - Install 8. Front Subframe - Install 1. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe
  • Page 23410.Front Brace - Install cardiagn.com 11. Lower Arm Mounting Bolt - Install (Both Sides) 12.Lower Arm Ball Joint - Connect (Both Sides) 13.Lower Stabilizer Link Ball Joint - Connect (Both Sides) 14.Tie-Rod End Ball Joint - Connect (Both Sides)
  • Page 23515.Connector (EPS Subharness) - Connect cardiagn.com 16.Exhaust Pipe A - Install 17.Front Floor Brace - Install (With Front Floor Brace) 18.Vehicle - Lift Down 19.Transmission Mount - Loosely Install 20.Upper Transmission Assembly Mounting Bolt - Install NOTE: Refer to the Exploded View as needed du
  • Page 2363. Install the front damper caps. 22.Engine/Transmission Mount - Tightening Procedure 23.Intake Manifold Bracket - Install (1.5 L Engine) 24.Change Wire Bracket - Install 1. Install the change wire bracket with the change wires (A). NOTE: Do not wipe off the grease of the change wire ends (B). Tight
  • Page 23725.Engine Wire Harness (Engine Side) - Install (2.0 L Engine) 1. Install the harness clamps (A). cardiagn.com 2. Install the ground cable (B). 3. Connect the connectors (C). 26.Engine Wire Harness (Engine Side) - Install (1.5 L Engine) 1. Install the harness brackets (A) and the harness covers (B).
  • Page 2382. Install the ground cables (C). cardiagn.com 3. Connect the connectors (D), and make sure they are fully seated. 27.Engine Wire Harness (Transmission Side) - Install
  • Page 2391. Connect the connector (A). 2. Install the harness bracket (B). cardiagn.com 3. Install the brackets (A).
  • Page 2404. Install the connector (B) to the bracket. cardiagn.com 5. Connect the connectors (C). 28.EVAP Canister Purge Valve - Install (2.0 L Engine) 29.Intake Air Duct - Install 30.Slave Cylinder - Install
  • Page 2411. Install the clutch line brackets (A). NOTE: Be careful not to bend the clutch line. 2. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the push rod (B) of the slave cylinder (C). 3. Install the slave cylinder. cardiagn.com 31.Intake Air Duct F - Install (1.5 L Engine) 32.Int
  • Page 24239.Vehicle - Lift Up 40.Engine Undercover Lid - Install (With Engine Undercover Lid) 41.Engine Undercover - Install 42.Front Wheel - Install 43.Vehicle - Lift Down 44.Transmission Gear - Check cardiagn.com 1. Check that the transmission shifts into all gears smoothly. 45.Wheel Alignment - Check 46.V
  • Page 243Manual Transmission Removal and Installation Special Tool Required Image Description/Tool Number Offset Socket 17mm 070AA-R3P0100 cardiagn.com Universal Lifting Eyelet 07AAK-SNAA120 Engine Support Hanger, A and Reds AAR-T1256*
  • Page 244Image Description/Tool Number Subframe Adapter VSB02C000016* *: Available through the Honda Tool and Equipment Program 888-424-6857. cardiagn.com NOTE: How to read the torque specifications. 1. Transmission Assembly Mounting Bolt - Exploded View Exploded View
  • Page 245cardiagn.com NOTE: Use fender covers to avoid damaging painted surfaces. Keep all foreign particles out of the transmission. Special tool Reds engine support hanger AAR-T1256 must be used with the side engine mount installed. 1. Vehicle - Lift 2. Engine Cover - Remove
  • Page 2463. Air Cleaner - Remove 4. Front Grille Cover - Remove 5. 12 Volt Battery - Remove 6. 12 Volt Battery Base - Remove 7. High Pressure Fuel Pump Cover - Remove 8. EVAP Canister Purge Valve - Remove cardiagn.com 9. Charge Air Cooler Hose - Disconnect NOTE: Remove the necessary part(s). 10.Slave Cylinde
  • Page 24711. Engine Wire Harness - Remove 1. Disconnect the connectors (A). cardiagn.com 2. Remove the harness clamps (B). 3. Remove the engine wire harness with the harness holder bracket (C). 12.Change Wire - Remove
  • Page 2481. Remove the lock pins (A). 2. Remove the change wire clips (B). 3. Carefully remove the change wires (C) together to avoid bending the change wires. NOTE: Do not wipe off the grease of the change wire ends (D). cardiagn.com 13.Change Wire Bracket and Mass - Remove 1. If necessary, remove the chang
  • Page 249cardiagn.com 15.Engine Support Hanger - Install NOTE: Be careful when working around the windshield. Be careful not to damage the hood opener cable when installing the engine support hanger at the front bulkhead. 1. Install the universal lifting eyelet with an about 60 mm (2.36 in) commercially avai
  • Page 250cardiagn.com 2. Install the engine support hanger onto the vehicle as shown. 3. Attach the hook (B) to the slotted hole in the universal lifting eyelet. 4. Tighten the wing nut (C) by hand, and lift and support the engine/transmission. 16.Upper Transmission Assembly Mounting Bolt - Remove
  • Page 251NOTE: Refer to the Exploded View as needed during this procedure. 17.Transmission Mount - Remove 18.Steering Joint - Disconnect NOTE: Hold the steering wheel with the steering wheel holder tool. 19.Vehicle - Lift Up 20.Front Wheel - Remove (Both Sides) cardiagn.com 21.Engine Undercover - Remove NOTE
  • Page 252Right side cardiagn.com 24.Front Suspension Stroke Sensor - Remove (Both Sides) 25.Exhaust Pipe A - Remove 26.Stopper Link - Disconnect (Both Sides) 27.Lower Stabilizer Link - Disconnect (Both Sides) 28.Tie-Rod End Ball Joint - Disconnect (Both Sides) 29.Lower Arm Ball Joint - Disconnect (Both Sides
  • Page 2531. Remove MTF cooler pipes A and B with the washers (C). NOTE: Turn the end of MTF cooler pipes up to prevent MTF from flowing out, then winding a shop towel. cardiagn.com 32.MTF Cooler - Remove NOTE: Do not disconnect the MTF cooler hoses. The MTF cooler is aluminum part. Be careful not to damage t
  • Page 25435.Lower Arm Mounting Bolt - Remove (Both Sides) cardiagn.com
  • Page 25536.Front Subframe - Support cardiagn.com 1. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe adapter to the front subframe (B). 37.Front Subframe - Remov
  • Page 256cardiagn.com 40.Driveshaft Inboard Joint - Disconnect (Both Sides) NOTE: Secure the driveshaft to the body with a nylon strap on both sides. 41.Intermediate Shaft - Remove 42.Lower Transmission Assembly Mounting Bolt - Remove NOTE: Refer to the Exploded View as needed during this procedure. 43.Trans
  • Page 257NOTE: How to read the torque specifications. Use fender covers to avoid damaging painted surfaces. 1. Release Bearing - Check 1. Check the release bearing, then install the release bearing and the release fork with specified grease. 2. Dowel Pin - Install NOTE: Refer to the Exploded View as needed d
  • Page 258NOTE: Refer to the Exploded View as needed during this procedure. 1. Set the 17mm offset socket to the torque wrench as shown. 2. Tighten the lower transmission assembly mounting bolt (A) to the specified torque using the 17mm offset socket and the torque wrench. NOTE: In this case, the tightening t
  • Page 259cardiagn.com 8. Front Subframe - Support 1. Set the subframe adapter (VSB02C000016) on a transmission jack (A), line up the slots in the arms with the bolt holes on the corner of the jack base, and tighten the bolts. 2. Attach the subframe adapter to the front subframe (B). 9. Front Subframe - Insta
  • Page 26011. Front Brace - Install cardiagn.com 12.Torque Rod Mounting Bolt - Loosely Install 13.MTF Cooler - Install NOTE: The MTF cooler is aluminum part. Be careful not to damage the MTF cooler. 14.MTF Cooler Pipe A and B - Install (Transmission Side)
  • Page 2611. Install MTF cooler pipes A and B with new washers (C). cardiagn.com 15.Connector (EPS Subharness) - Connect 16.Lower Arm Ball Joint - Connect (Both Sides) 17.Tie-Rod End Ball Joint - Connect (Both Sides) 18.Lower Stabilizer Link - Connect (Both Sides) 19.Stopper Link - Connect (Both Sides) 20.Exh
  • Page 262Left side Right side cardiagn.com 23.Vehicle - Lift Down 24.Transmission Mount - Loosely Install 25.Upper Transmission Assembly Mounting Bolt - Install NOTE: Refer to the Exploded View as needed during this procedure. 26.Engine Support Hanger - Remove 1. Remove the engine support hanger.
  • Page 2632. Remove the universal lifting eyelet with an about 60 mm (2.36 in) commercially available spacer. 27.Engine/Transmission Mount - Tightening Procedure 28.Transmission Fluid - Refill 29.Water Bypass Pipe - Install cardiagn.com 30.Change Wire Bracket - Install
  • Page 264cardiagn.com 31.Change Wire - Install 1. Connect the change wires (A). NOTE: Do not wipe off the grease of the change wire ends (B). 2. Install new change wire clips (C). 3. Install the lock pins (D). 4. Check that the transmission shifts into all gears smoothly. 32.Engine Wire Harness - Install
  • Page 2651. Install the engine wire harness with the harness holder bracket (A). cardiagn.com 2. Install the harness clamps (B). 3. Connect the connectors (C). 33.Slave Cylinder - Install
  • Page 2661. Install the clutch line brackets (A). NOTE: Be careful not to bend the clutch line. 2. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the push rod (B) of the slave cylinder (C). 3. Install the slave cylinder. cardiagn.com 34.Charge Air Cooler Hose - Install 35.EVAP Canister
  • Page 26741.Engine Cover - Install 42.Steering Joint - Connect 43.Engine Undercover - Install 44.Transmission Gear - Check NOTE: Check that the transmission shifts into all gears smoothly. 45.Front Wheel - Install (Both Sides) cardiagn.com 46.Wheel Alignment - Check 47.VSA Sensor Neutral Position - Memorize
  • Page 268MTF Cooler Hose Removal and Installation NOTE: Where icon is shown, click for further information. 1 cardiagn.com Detailed information, notes, and precautions
  • Page 2691. Vehicle - Lift cardiagn.com
  • Page 2702. Air Cleaner - Remove 3. Engine Undercover - Remove NOTE: Remove the necessary part(s). 4. Transmission Fluid - Drain 5. Engine Coolant - Drain 6. MTF Cooler Hose - Disconnect cardiagn.com NOTE for installation Connect MTF cooler hoses (A) until the hose ends contact the bulges (B) or the pipe end
  • Page 271cardiagn.com 7. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 272MTF Cooler Removal and Installation NOTE: The MTF cooler is aluminum part. Be careful not to damage the MTF cooler. 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) 1. Vehicle - Lift
  • Page 273cardiagn.co
  • Page 2742. Air Cleaner - Remove 3. Engine Undercover - Remove NOTE: Remove the necessary part(s). 4. Transmission Fluid - Drain 5. Engine Coolant - Drain 6. MTF Cooler Hose - Disconnect (MTF Cooler Side) NOTE for installation cardiagn.com Make sure the MTF cooler hoses and the clamps are properly installed.
  • Page 275MTF Inspection and Replacement 1. Vehicle - Lift 2. Engine Undercover Plate - Remove 3. MTF - Check 1. Remove the oil check bolt (A) and the 6 mm sealing washer (B). 2. Check the condition of the MTF and make sure it is at the proper level (C). cardiagn.com NOTE: If the MTF is dirty, replace the MTF
  • Page 2761. Remove the oil check bolt (A) and the 6 mm sealing washer (B). 2. Remove the drain plug (C) and the 20 mm sealing washer (D), and drain the MTF. 3. Install the drain plug with a new 20 mm sealing washer. cardiagn.com 5. MTF - Refill 1. Remove the filler plug (A). 2. Refill the MTF through the fil
  • Page 277cardiagn.com 6. Filler Plug - Install 1. Clean any dirt and oil from the sealing surface of the filler plug (A) and the transmission housing. 2. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the threads of the filler plug. Install the filler plug within 5 minutes of applying the
  • Page 2788. Maintenance Minder - Reset (With Maintenance Minder System) cardiagn.com
  • Page 279If the Maintenance Minder required to replace the MTF, reset the Maintenance Minder with the gauge (see "Resetting the Maintenance Minder"). If the Maintenance Minder did not require to replace the MTF, reset the Maintenance Minder with the HDS (see "Resetting the Individual Maintenance Items"). car
  • Page 280MTF Inspection and Replacement NOTE: How to read the torque specifications. 1. Vehicle - Lift 2. Engine Undercover Plate - Remove 3. MTF - Check 1. Remove the oil check bolt (A) with the sealing washer (B). cardiagn.com 2. Check the condition of the MTF and make sure it is at the proper level (C). N
  • Page 2811. Vehicle - Lift cardiagn.com
  • Page 2822. Engine Undercover Plate - Remove 3. MTF - Drain 1. Remove the oil check bolt (A) with the sealing washer (B). 2. Remove the drain plug (C) with the sealing washer (D), and drain the MTF. 3. Install the drain plug with a new sealing washer. cardiagn.com 4. Air Cleaner - Remove 5. MTF - Refill
  • Page 2831. Remove the filler plug (A) with the sealing washer (B). 2. Refill the MTF from the filler plug hole on the transmission, until the MTF overflows from the oil check bolt hole (C). Always use Honda Manual Transmission Fluid (MTF). Fluid Capacity: 2.2 L (2.3 US qt) at change 2.6 L (2.7 US qt) at ove
  • Page 2841. Install the filler plug (A) with a new sealing washer (B). cardiagn.com 7. All Removed Parts - Install 1. Install the parts in the reverse order of removal. 8. Maintenance Minder - Reset (With Maintenance Minder System) 1. If the Maintenance Minder required to replace the MTF, reset the Maintenan
  • Page 285Neutral Position Sensor Removal and Installation 1. 12 Volt Battery - Remove 2. Neutral Position Sensor - Remove 1. Disconnect the connector (A). cardiagn.com 2. Remove the neutral position sensor (B) with the O-ring (C). 3. All Removed Parts - Install 1. Install the parts in the reverse order of re
  • Page 286Neutral Position Sensor Removal and Installation NOTE: How to read the torque specifications. 1. Air Cleaner - Remove 2. Neutral Position Sensor - Remove 1. Disconnect the connector (A). 2. Remove the neutral position sensor (B) with the O-ring (C). cardiagn.com 3. All Removed Parts - Install 1. Ins
  • Page 287Oil Pump Clearance Inspection 1. Oil Pump Clearance - Inspect 1. Measure the thrust clearance between the oil pump rotors (A) and the clutch housing (B) with a straight edge (C) and a feeler gauge (D). Standard (new): 0.03-0.13 mm (0.002-0.005 in) Service Limit: 0.13 mm (0.005 in) cardiagn.com 2. Me
  • Page 2883. Measure the side clearance between the oil pump outer rotor (A) and the oil pump inner rotor (B) with a feeler gauge (C). Standard (new): 0.1-0.4 mm (0.004-0.016 in) Service Limit: 0.4 mm (0.016 in) 4. If any clearance is not within the standard, replace the oil pump outer and inner rotors as a s
  • Page 289Output Shaft (Countershaft) Speed Sensor Removal and Installation 1 cardiagn.com Torque: N·m (kgf·m, lbf·ft) Replace 1. Air Cleaner - Remove 2. Output Shaft (Countershaft) Speed Sensor - Remove 3. All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 290Reverse Idler Gear Shaft Assembly Disassembly and Reassembly NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces. 1 cardiagn.com
  • Page 291cardiagn.co
  • Page 292*1 Check for wear and operation 1. Reverse Gear Holder - Remove 2. 20 mm Thrust Washer - Remove 3. 20 mm Thrust Needle Bearing - Remove 4. Needle Bearing - Remove 5. Reverse Driven Gear - Remove cardiagn.com 6. 20 mm Thrust Needle Bearing - Remove 7. 20 mm Thrust Washer - Remove 8. 20 mm Thrust Need
  • Page 29315.All Removed Parts - Install 1. Install the parts in the reverse order of removal. cardiagn.com
  • Page 294Reverse Lockout Solenoid Disassembly and Reassembly 1. Air Cleaner - Remove 2. Reverse Lockout Solenoid - Remove 1. Disconnect the connector (A). 2. Remove the reverse lockout solenoid (B). NOTE: Do not directly hit the reverse lockout solenoid with the hammer. 3. Reverse Lockout Solenoid - Disassem
  • Page 295cardiagn.co
  • Page 2961. Reverse Lockout Solenoid - Reassemble 1. Install the pin (A), the select lock return spring (C), and select lock cam B. cardiagn.com 2. Reverse Lockout Solenoid - Install 1. Clean any dirt and oil from the sealing surface of the reverse lockout solenoid and the shift arm cover. 2. Apply liquid ga
  • Page 2973. Install the reverse lockout solenoid (A). 4. Connect the connector (B). cardiagn.com 3. Air Cleaner - Install
  • Page 298Reverse Lockout Solenoid Disassembly and Reassembly NOTE: Do not directly hit the reverse lockout solenoid with the hammer. 1 cardiagn.com 1. Transmission Mount - Remove 2. Reverse Lockout Solenoid - Remove
  • Page 299cardiagn.co
  • Page 3003. Select Lock Pin - Remove 4. Select Lock Pin Spring - Remove 5. Pin - Remove 6. Select Lock Cam - Remove NOTE: Where icon is shown, click for further information. cardiagn.com 1
  • Page 301cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 1. Select Lock Cam - Install 2. Pin - Install 3. Select Lock Pin Spring - Install 4. Select Lock Pin - Install
  • Page 302NOTE: Apply MTF to the select lock pin. Check the operation of the select lock pin. 5. Reverse Lockout Solenoid - Install 1. Clean any dirt and oil from the sealing surface of the reverse lockout solenoid and the transmission housing. 2. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009
  • Page 303Reverse Lockout Solenoid Test 1. Reverse Lockout Solenoid - Remove 2. Reverse Lockout Solenoid - Test 1. Connect jumper wires from the 12 volt battery positive terminal to connector terminal No. 1, and from the 12 volt battery negative terminal to connector terminal No. 2. 2. Make sure the reverse l
  • Page 304Reverse Lockout System Circuit Diagram L15BA/L15B7 Engine cardiagn.com K20C1 Engine
  • Page 305cardiagn.com K20C2 Engine
  • Page 306cardiagn.co
  • Page 307Reverse Lockout System Component Location Index cardiagn.com
  • Page 308Reverse Lockout System Component Location Index cardiagn.com
  • Page 309Reverse Lockout System Symptom Troubleshooting - Driver cannot select reverse gear when vehicle speed is 9 mph (15 km/h) or less Driver cannot select reverse gear when vehicle speed is 9 mph (15 km/h) cardiagn.com or less NOTE: Do not release the clutch pedal if you can select reverse gear while the
  • Page 310Is the reverse lockout solenoid OK? YES The reverse lockout solenoid is OK. Check the change lever assembly, or inspect the internal transmission.■ NO Repair or replace the reverse lockout solenoid.■ 3. Problem verification (with engine running): ‐1. Start the engine, and try to shift the transmissi
  • Page 311Reverse Lockout System Symptom Troubleshooting - Driver can select reverse gear when vehicle speed is 12 mph (20 km/h) or more cardiagn.com Driver can select reverse gear when vehicle speed is 12 mph (20 km/h) or more NOTE: Refer to How to Troubleshoot Circuits at the PCM connectors in the Fuel and
  • Page 312YES Go to the indicated DTC's troubleshooting.■ NO DTC is not indicated. Go to step 2. 2. Open wire check (IG1 (RVSLCK line)*1/IG1(RVS LCK SOL) line*2/IG1(RVS LCK) line*3): ‐1. Turn the vehicle to the OFF (LOCK) mode. ‐2. Disconnect the following connector. Reverse lockout solenoid 2P connector ‐3.
  • Page 313Test point 2 Reverse lockout solenoid 2P connector (female terminals) No. 2: Is there continuity? YES The RVSLCK wire*1/RVSLCK/REVERSE LOCK SOL wire*2/RVS LCK wire*3 is OK. Go to step 4. NO Repair an open in the RVSLCK wire*1/RVSLCK/REVERSE LOCK SOL wire*2/RVS LCK wire*3 between the reverse lockout
  • Page 314Reverse Shift Lever Clearance Inspection 1. Reverse Shift Lever Clearance - Inspect 1. Measure the clearance between the reverse shift lever (A) and the reverse shift fork (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2. Standard: 0.40-0.85 mm (0.016-0.033 in) S
  • Page 3153. Measure the clearance between the reverse shift lever (A) and the reverse shift piece (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 4. Standard: 0-0.4 mm (0-0.01 in) Service Limit: 0.4 mm (0.01 in) 4. Measure the width of the reverse shift lever. cardiagn.com
  • Page 316Reverse Shift Lever Clearance Inspection 1. Reverse Shift Lever Clearance - Inspect 1. Measure the clearance between the reverse shift lever (A) and the reverse shift fork (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2. Standard: 0.05-0.50 mm (0.002-0.019 in) S
  • Page 317cardiagn.co
  • Page 3184. Measure the width of the reverse shift lever. If the width is not within the standard, replace the reverse shift lever. If the width is within the standard, replace the reverse shift piece. Standard: 13.0-13.2 mm (0.512-0.520 in) cardiagn.com
  • Page 319Select Arm Clearance Inspection 1. Select Arm Clearance - Inspect 1. Measure the clearance between the select arm (A) and the interlock (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2. Standard: 0.01-0.21 mm (0.001-0.008 in) Service Limit: 0.21 mm (0.008 in) car
  • Page 320Select Arm Clearance Inspection 1. Select Arm Clearance - Inspect 1. Measure the clearance between the select arm (A) and the interlock (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2. Standard: 0.05-0.25 mm (0.002-0.009 in) Service Limit: 0.25 mm (0.009 in) car
  • Page 321Shift Arm Clearance Inspection 1. Shift Arm Clearance - Inspect 1. Measure the clearance between the shift arm (A) and the shift piece (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2. Standard: 0-0.4 mm (0-0.01 in) Service Limit: 0.4 mm (0.01 in) cardiagn.com 2.
  • Page 322Shift Arm Clearance Inspection 1. Shift Arm Clearance - Inspect 1. Measure the clearance between the shift arm (A) and the shift piece (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2. Standard: 0.65-0.95 mm (0.026-0.037 in) Service Limit: 0.95 mm (0.037 in) card
  • Page 323Shift Fork Clearance Inspection 1. Shift Fork Clearance - Inspect 1st/2nd, 3rd/4th, 5th/6th 1. Measure the clearance between each shift fork (A) and its matching synchro sleeve (B). If the clearance exceeds the service limit, go to step 2. Standard: 0.4-0.6 mm (0.02- 0.02 in) Service Limit: 0.6 mm (
  • Page 3243. Measure the clearance between each shift fork (A) and the shift piece (B). If the clearance exceeds the service limit, go to step 4. Standard: 0.2-0.5 mm (0.01- 0.02 in) Service Limit: 0.5 mm (0.02 in) cardiagn.com 4. Measure the width of the shift piece. If the width is not within the standard,
  • Page 325Shift Fork Clearance Inspection 1. Shift Fork Clearance - Inspect 1st/2nd, 3rd/4th, 5th/6th 1. Measure the clearance between each shift fork (A) and its matching synchro sleeve (B). If the clearance exceeds the service limit, go to step 2. Standard: 0.35-0.65 mm (0.014-0.025 in) Service Limit: 0.65
  • Page 3263. Measure the clearance between each shift fork (A) and the shift piece (B). If the clearance exceeds the service limit, go to step 4. Standard: 0.2-0.6 mm (0.008-0.024 in) Service Limit: 0.6 mm (0.024 in) cardiagn.com 4. Measure the width of the shift piece. If the width is not within the standard
  • Page 327Shift Fork Disassembly and Reassembly NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces. cardiagn.com
  • Page 3281. Shift Fork - Exploded View Exploded View cardiagn.com
  • Page 329Shift Fork Disassembly and Reassembly NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces. 1. Shift Fork - Exploded View Exploded View cardiagn.com
  • Page 330Synchro Ring and Gear Inspection 1. Synchro Ring and Gear - Inspect 1. Inspect the synchro rings for scoring, cracks, and damage (A). 2. Inspect the inside of each synchro ring (B) for wear. Inspect the teeth (C) on each synchro ring for wear (rounded off). cardiagn.com 3. Inspect the teeth (A) on e
  • Page 3314. Inspect the synchro teeth on gear for scoring, cracks, and damage (A). 5. Inspect the thrust surface (B) on each gear hub for wear. 6. Inspect the cone surface (C) on each gear hub for wear and roughness. 7. Inspect the teeth on all gears (D) for uneven wear, scoring, and cracks. 8. Coat the cone
  • Page 332cardiagn.co
  • Page 333Synchro Ring and Gear Inspection 1. Synchro Ring and Gear - Inspect 1. Inspect the synchro rings for scoring, cracks, and damage (A). 2. Inspect the inside of each synchro ring (B) for wear. Inspect the teeth (C) on each synchro ring for wear (rounded off). cardiagn.com 3. Inspect the teeth (A) on e
  • Page 3344. Inspect the synchro teeth on gear for scoring, cracks, and damage (A). 5. Inspect the thrust surface (B) on each gear hub for wear. 6. Inspect the cone surface (C) on each gear hub for wear and roughness. 7. Inspect the teeth (D) on all gears for uneven wear, scoring, and cracks. 8. Coat the cone
  • Page 335cardiagn.co
  • Page 336Synchro Sleeve and Hub Disassembly, Reassembly, and Inspection 1. Synchro Sleeve and Hub - Inspect 1. Inspect the gear teeth on all synchro hubs and synchro sleeves for wear (rounded off corners). 2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for free movement. Make sur
  • Page 337Transmission End Crankshaft Oil Seal Replacement - In Car Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Oil Seal Driver Attachment, 92 mm 070AD-5R00100 1. Transmission - Remove M/T CVT 2. Pressure Plate, Clutch Disc, and Flywheel - Remove (M/
  • Page 3384. Transmission End Crankshaft Oil Seal - Remove cardiagn.com 5. Transmission End Crankshaft Oil Seal - Install 1. Clean and dry the transmission end crankshaft oil seal housing. 2. Apply a light coat of new engine oil to the crankshaft and to the lip of the new transmission end crankshaft oil seal.
  • Page 3395. Measure the distance between the oil seal case (A) and the transmission end crankshaft oil seal (B). Oil Seal Installed Height: 0.75-1.25 mm (0.0295-0.0492 in) cardiagn.com 6. Drive Plate - Install (CVT) 7. Pressure Plate, Clutch Disc, and Flywheel - Install (M/T) 8. Transmission - Install M/T CV
  • Page 340Transmission End Crankshaft Oil Seal Replacement - In Car Special Tool Required Image Description/Tool Number Driver Handle, 15 x 135L 07749-0010000 cardiagn.com Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100 NOTE: Unless otherwise indicated, illustrations used in the procedure are for K20C2 engine
  • Page 3414. Transmission End Crankshaft Oil Seal - Remove cardiagn.com 5. Transmission End Crankshaft Oil Seal - Install 1. Clean and dry the transmission end crankshaft oil seal housing. 2. Apply a light coat of new engine oil to the crankshaft and to the lip of the new transmission end crankshaft oil seal.
  • Page 3424. Measure the distance between the lower block (A) and transmission end crankshaft oil seal (B). Oil Seal Installed Height: 0.2-1.2 mm (0.008-0.047 in) 5. Clean the excess oil off the crankshaft, and check that the transmission end crankshaft oil seal lip is not distorted. 6. All Removed Parts - In
  • Page 343Transmission Mount Removal and Installation NOTE: How to read the torque specifications. 1. Engine Undercover Plate - Remove 2. Air Cleaner - Remove 3. 12 Volt Battery - Remove 4. 12 Volt Battery Base - Remove cardiagn.com 1. Remove the harness holder (A). 2. Loosen the bolts (B). 3. Remove the 12 v
  • Page 3441. Remove the harness holder (A). 2. CVT: Remove the harness clamp (B). cardiagn.com 6. Intake Air Duct E - Remove (CVT) 7. PCM - Remove 8. Transmission - Support 1. Lift and support the transmission with a jack and a wood block under the transmission. 9. Transmission Mount - Remove
  • Page 345M/T 1. Remove the ground cable (A). 2. Remove the transmission mount (B). NOTE (M/T): Do not remove the bolt (C) from the transmission mount. If the bolt is removed, the transmission mount must be replaced as an assembly. cardiagn.com CVT 10.All Removed Parts - Install 1. Install the parts in the re
  • Page 346cardiagn.co
  • Page 347Transmission Mount Removal and Installation NOTE: Where icon is shown, click for further information. Do the mounts tightening procedure before tightening all of the mounts' bolts and nuts. 1 cardiagn.com
  • Page 348cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) 2
  • Page 349cardiagn.com Torque: N·m (kgf·m, lbf·ft) 3
  • Page 350cardiagn.com Detailed information, notes, and precautions Torque: N·m (kgf·m, lbf·ft) Replace 1. Engine Undercover Plate - Remove
  • Page 3512. Air Cleaner - Remove cardiagn.com
  • Page 3523. 12 Volt Battery - Remove 4. PCM Assembly - Remove 5. 12 Volt Battery Base - Remove Note for installation Tighten the mounting bolts in the numbered sequence shown. When installing the 12 volt battery base, tighten the mounting bolts in the following numbered sequence. → → → If disassemble the 12
  • Page 353NOTE: Do not remove the bolt (A) from the transmission mount. If the bolt is removed, the transmission mount must be replaced as an assembly. cardiagn.com 10.All Removed Parts - Install 1. Install the parts in the reverse order of removal.
  • Page 354Transmission Mount Removal and Installation 1. Engine Undercover Plate - Remove 2. Air Cleaner - Remove 3. 12 Volt Battery - Remove 4. 12 Volt Battery Base - Remove 1. Remove the harness holder (A). cardiagn.com 2. Loosen the bolts (B). 3. Remove the 12 volt battery base (C). NOTE: When installing t
  • Page 3551. Remove the harness holder (A). 2. CVT: Remove the harness clamp (B). cardiagn.com 6. PCM - Remove 7. Transmission - Support 1. Lift and support the transmission with a jack and a wood block under the transmission. 8. Transmission Mount - Remove M/T 1. Remove the ground cable (A). 2. Remove the tr
  • Page 356CVT cardiagn.com 9. All Removed Parts - Install 1. Install the parts in the reverse order of removal. NOTE: Do the mounts tightening procedure before tightening all of the mounts' bolts and nuts.