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Honda Civic Service Manual: M/T Mainshaft Assembly Clearance Inspection (K24Z7)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / M/T Mainshaft Assembly Clearance 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).


Inspection

1. Mainshaft Assembly Clearance Inspection


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 exceeds the service limit, go to step 3.

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


Standard:

0.06-0.16 mm
(0.003-0.006 in)

Service Limit:

0.16 mm
(0.006 in)


3.

Measure the thickness of 3rd gear.


If the thickness is less than the service limit, replace 3rd gear.

If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.


Standard:

23.92-23.97 mm
(0.9417-0.9437 in)

Service Limit:

23.92 mm
(0.9417 in)


4.

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
(0.0063 in)


5.

Measure the length of the 4th/5th gear distance collar as shown.


If the length is not within the standard, replace the 4th/5th gear distance collar.

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


Standard:

24.03-24.08 mm
(0.9461-0.9480 in)


6.

Measure the thickness of 4th gear.


If the thickness is less than the service limit, replace 4th gear.

If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.


Standard:

23.92-23.97 mm
(0.9417-0.9437 in)

Service Limit:

23.92 mm
(0.9417 in)


7.

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
(0.0063 in)


8.

Measure the length of the 4th/5th gear distance collar as shown.


If the length is not within the standard, replace the 4th/5th gear distance collar.

If the length is within the standard, go to step 9.


Standard:

24.03-24.08 mm
(0.9461-0.9480 in)


9.

Measure the thickness of 5th gear.


If the thickness is less than the service limit, replace 5th gear.

If the thickness is within the service limit, replace the 5th/6th synchro hub and the 5th/6th synchro sleeve as a set.


Standard:

23.92-23.97 mm
(0.9417-0.9437 in)

Service Limit:

23.92 mm
(0.9417 in)


10.

Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 11.


Standard:

0.15-0.25 mm
(0.006-0.009 in)

Service Limit:

0.25 mm
(0.009 in)


11.

Measure the length of the 6th gear distance collar.


If the length is not within the standard, replace the 6th gear distance collar.

If the length is within standard, go to step 12.


Standard:

24.03-24.08 mm
(0.9461-0.9480 in)


12.

Measure the thickness of 6th gear.


If the thickness is less than the service limit, replace 6th gear.

If the thickness is within the service limit, replace the 5th/6th synchro hub and the 5th/6th synchro sleeve as a set.


Standard:

23.83-23.88 mm
(0.9382-0.9402 in)

Service Limit:

23.83 mm
(0.9382 in)


Installation

1. 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.


2. 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).


3. Baffle Plate

1.

Install the baffle plate (A).


4. Reverse Shift Fork

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1.

Install the reverse shift fork (A).


5. 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).


6. 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).


7. 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.


8. 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.


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