Honda Civic Service Manual: M/T Shift Fork Clearance Inspection (K24Z7)
Removal
1. |
M/T Change Lever Assembly |
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1.
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Remove the interlock bolt (A).
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2.
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Remove any old liquid gasket from the interlock bolt.
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3.
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Remove the change lever assembly (B).
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4.
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Remove the 8 x 14 mm dowel pins (C).
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1.
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Remove the back-up light switch (A).
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2.
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Remove any old liquid gasket.
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3. |
Output Shaft (Countershaft) Speed Sensor |
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1.
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Remove the output shaft (countershaft) speed sensor (A), the
plain washer (B), and the O-ring (C).
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1.
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Remove the detent bolts (A), the 12 mm sealing washers (B), the
detent ball springs (C), and the steel balls (D).
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2.
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Remove the 10 mm flange bolt (A) and the sealing washer (B).
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3.
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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).
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4.
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Remove the 32 mm sealing cap (A).
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5.
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While expanding the 72 mm snap ring (B) on the countershaft ball
bearing with snap ring pliers, lift the transmission housing (C).
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6.
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Release the snap ring pliers, and remove the transmission housing.
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7.
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Remove the 14 x 20 mm dowel pins (D).
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Inspection
1. |
Shift Fork Clearance Inspection |
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1.
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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.
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Standard (New):
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0.35-0.65 mm
(0.014-0.025 in)
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Service Limit:
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0.65 mm
(0.025 in)
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2.
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Measure the thickness of the shift fork fingers.
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If the thickness is not within the standard,
replace the shift fork.
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If the thickness is within the standard, replace
the synchro sleeve and the synchro hub as a set.
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If one arm of the shift fork shows more wear
than others, the fork may be bent and needs to be
replaced.
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Standard:
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7.4-7.6 mm
(0.291-0.299 in)
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3.
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Measure the clearance between each shift fork (A) and the shift
arm (B). If the clearance exceeds the service limit, go to step
4.
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Standard:
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0.2-0.5 mm
(0.008-0.019 in)
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Service Limit:
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0.5 mm
(0.019 in)
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4.
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Measure the width of the shift arm.
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If the width is not within the standard, replace
the shift arm.
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If the width is within the standard, replace
the shift fork or the reverse shift piece.
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Standard:
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16.9-17.0 mm
(0.665-0.669 in)
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Installation
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1.
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Clean any dirt or oil from the mating surface of the transmission
housing and the clutch housing.
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2.
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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.
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NOTE:
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If you apply liquid gasket P/N 08718-0012, the
component must be installed within 4 minutes.
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If too much time has passed after applying the
liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket.
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3.
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Install the 14 x 20 mm dowel pins (A).
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4.
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Place the transmission housing on the clutch housing, making
sure to line up the shafts.
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5.
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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.
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6.
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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.
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NOTE: Install the 32 mm sealing cap (C) after setting in the
72 mm snap ring.
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7.
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Make sure the 72 mm snap ring (A) is securely seated in the groove
of the countershaft bearing.
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Dimension
as installed:
3.3-6.0 mm (0.130-0.236 in)
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8.
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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.
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NOTE:
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If you apply liquid gasket P/N 08718-0012, the
component must be installed within 4 minutes.
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If too much time has passed after applying the
liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket.
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9.
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Install the 8 mm flange bolts finger-tight with transmission
hanger A, transmission hanger B, and the harness bracket (C).
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10.
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Tighten the 8 mm flange bolts in a crisscross pattern in several
steps.
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Specified Torque:
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8 x 1.25 mm
27 N·m (2.8 kgf·m, 20 lbf·ft)
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11.
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Install the 10 mm flange bolt (A) with new sealing washer (B).
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12.
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Install the steel balls, the detent ball springs, and the detent
bolts (A) with new 12 mm sealing washers (B).
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2. |
Output Shaft (Countershaft) Speed Sensor |
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1.
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Apply MTF to a new O-ring (A).
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2.
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Install the output shaft (countershaft) speed sensor (B) with
the O-ring and the plain washer (C).
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1.
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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).
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2.
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Install the back-up light switch.
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4. |
M/T Change Lever Assembly |
iukn
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1.
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Clean any dirt or oil from the mating surface of the change lever
assembly and the transmission housing.
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2.
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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.
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NOTE:
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If you apply liquid gasket P/N 08718-0012, the
component must be installed within 4 minutes.
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If too much time has passed after applying the
liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket.
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3.
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Install the 8 x 14 mm dowel pins (A).
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4.
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Install the change lever assembly (B).
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5.
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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).
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6.
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Install the interlock bolt.
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Removal
1.
M/T Change Lever Assembly
1.
Remove the change lever assembly (A).
...
View
NOTE: Prior to reassembling, clean all parts in solvent, dry them, and
apply MTF to any contact surfaces.
1.
M/T Shift Fork Exploded View
...
See also:
Honda Civic Owners Manual. Fuel Economy and CO2 Emissions
Improving Fuel Economy and Reducing CO2 Emissions
Achieving fuel economy and reducing CO2 emissions is dependent on several
factors, including driving conditions, load weight, idling time, driving habits,
and
vehicle condition. Depending on these and other factors, you may not achieve the
rate ...