Honda Civic manuals

Honda Civic Service Manual: Manual Transmission Removal and Installation (K24Z7)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Manual Transmission Removal and Installation (K24Z7)

2131K5

1. Steering Joint Cover

1.

Remove the steering joint cover (A).


2. Steering Column Lower Slide Shaft - Hold


1.

Set the steering column to the center tilt position, and to the center telescopic position.


2.

Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and the joint yoke (D) of the upper shaft to prevent the lower slider shaft from pulling out.


3. Steering Joint Bolt - Loosen

1.

Loosen the steering joint bolt (A).


4. Steering Wheel Hold


1.

Center the steering wheel spoke angle.


2.

Install a commercially available steering wheel holder tool (A).


5. Steering Joint - Disconnection


1.

Remove the steering joint bolt (A).


2.

Disconnect the steering joint (B) from the pinion shaft.


NOTE:

If the center guide (C) is in place and has not moved, leave it in place.

If the center guide has come off, discard it.


6. Wide - Hood Open Position

1.

Open the hood, and secure it with hood support rod (A) in the wide-open position (B).


7. Front Grille Cover

1.

Remove the front grille cover (A).


2.

If necessary, remove the front bumper upper duct (A).


8. Wiper Arm Assembly


NOTE: Set the wiper arms to the auto-stop position before removal.


1.

Remove the cowl top wiper covers (A).


2.

Remove the wiper arms (B).


9. Both Side Cowl Covers


1.

Remove the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


10. Center Cowl Cover


1.

Remove the center cowl cover (A).


2.

Disconnect the windshield washer tube (B).


3.

If necessary, remove the hood rear seal (C).


11. Under Cowl Panel

1.

Remove the under cowl panel (A).


12. Battery Terminal - Disconnection


1.

Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode.


2.

Disconnect and isolate the negative cable with the battery sensor (A) from the battery.


NOTE:

Always disconnect the negative side first.

To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal.

Do not disconnect the battery sensor from the negative terminal (C).


3.

Disconnect the positive cable (D) from the battery.


13. Air Cleaner Assembly


1.

Disconnect the intake air duct (A) and the intake air pipe (B).


2.

Remove the harness clamp (C).


3.

Remove the air cleaner (D).


14. Intake Air Duct

1.

Remove the intake air duct.


15. ECM Assembly

1.

Remove the cover (A).



2.

Disconnect ECM connectors A, B, and C.


NOTE: ECM connectors A, B, and C have symbols (A=□, B=△, C=○) embossed on them for identification.


3.

Remove the ECM (D).


16. Clutch Slave Cylinder


1.

Remove the clutch line bracket (A).


2.

Remove the slave cylinder (B).


3.

Carefully move the slave cylinder out of the way to avoid bending the clutch line.


NOTE:

Do not press the clutch pedal after the slave cylinder has been moved.

Do not disconnect the clutch line joints.


17. Shift Cable Bracket


1.

Remove the lock pins (A).


2.

Remove the shift cable bracket bolts (B).


3.

Disconnect the shift cables from the change lever assembly (C).


4.

Carefully remove both cables and the shift cable bracket (D) together to avoid bending the cables.


18. Transmission Peripheral Assembly Upper Side


1.

Disconnect the connectors (A).


2.

Remove the harness clamps (B).


3.

Remove the harness clamp (A).


4.

Remove transmission hanger C.


19. Engine Support Hanger

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1.

Attach the universal lifting eyelet to the cylinder head.



2.

Install the engine support hanger as shown.


3.

Attach the hook to the slotted hole in the universal lifting eyelet.


4.

Tighten the wing nut (A) by hand, and lift and support the engine/transmission.


NOTE: Be careful when working around the windshield.


20. Upper Transmission Housing Mounting Bolt

1.

Remove the upper transmission mounting bolts.


21. Transmission Mount Assembly


1.

Remove the ground cable terminal (A).


2.

Remove the transmission mount assembly (B).


22. Vehicle Lift

1.

Raise the vehicle on a lift, and make sure it is securely supported.


23. Splash Shield

1.

Remove the splash shield (A).


24. MTF Replacement (M/T)


1.

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


2.

Reinstall the drain plug with a new sealing washer.


25. Front Wheel

1.

Remove both front wheels.


26. Front Stabilizer Ball Joint, Both Damper Side - Disconnection


1.

Remove the flange nut (A) on both sides while holding the joint pin (B) with a hex wrench (C).


2.

Disconnect the stabilizer link (D) on both sides.


27. Ball Joint - Removal

Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint connection to disconnect it.


1.

Install a hex nut (A) or the ball joint thread protector.


NOTE: When using a hex nut, make sure the nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint pin.


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2.

Apply grease to the ball joint remover on the areas shown (A).


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3.

Install the ball joint remover as shown.


NOTE:

Fasten the safety chain (A) securely to a suspension arm or the subframe (B).

Making sure not to damage the ball joint boot.


4.

Tighten the pressure bolt until the ball joint pin pops loose from the ball joint connecting hole.


NOTE: Do not use pneumatic or electric tools on the pressure bolt.


5.

Remove the ball joint remover.


6.

Remove the hex nut or the ball joint thread protector.


7.

Pull the ball joint out of the ball joint connecting hole.


28. Tie-Rod End Ball Joint - Disconnection, Both Side

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1.

Remove the cotter pin (A) from the tie-rod end ball joint.


2.

Remove the nut (B).


3.

Disconnect the tie-rod end ball joint.


NOTE: Be careful not to damage the ball joint boot when installing the remover.


29. Lower Arm Joint - Disconnection, Both Knuckle Side


1.

Remove the flange bolt and the self-locking nuts on both sides.


2.

Separate the lower arm using a pry bar on both sides.


30. Driveshaft Front Both Inboard Side



Left driveshaft


1.

Pry the inboard joint (A) from the differential using a pry bar.


NOTE:

Do not pull on the driveshaft (B), or the inboard joint may come apart. Pull the inboard joint straight out to avoid damaging the oil seal.

Be careful not to damage the oil seal or the end of the inboard joint with the pry bar.


2.

Remove the set ring (C).




Right driveshaft


3.

Drive the inboard joint (A) off of the intermediate shaft using a drift punch and a hammer.


NOTE: Do not pull on the driveshaft (B), or the inboard joint may come apart.


4.

Remove the set ring (C).


31. Intermediate Shaft Assembly

1.

Remove the crankshaft position (CKP) sensor cover (A).


2.

Remove the flange bolt (A) and the dowel bolts (B).


3.

Remove the intermediate shaft (A) from the differential.


NOTE: Hold the intermediate shaft horizontal until it is clear of the differential to prevent damaging the oil seal (B).


32. Subframe Support


1.

Attach the subframe adapter to the front subframe by looping the belt (A) over the front of the front subframe (B), then secure the belt with its stop (C).


2.

Raise the jack and line up the slots in the subframe adapter arms with the bolt holes on the jack base, then securely attach them with four bolts.


33. Lower Torque Rod - Disconnection

1.

Remove the lower torque rod mounting bolts.


34. Front Subframe Assembly

1.

Loosen the mid-stiffener mounting bolt (A) on both sides.


2.

Disconnect the EPS connectors.


3.

Lower the front subframe.


35. Transmission Jack Support

1.

Support the transmission with a transmission jack.


36. Manual Transmission Assembly

1.

Remove the clutch cover (A).


Front side


Rear side


2.

Remove the lower transmission mounting bolts.


3.

Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate.


4.

Slowly lower the transmission about 150 mm (5.91 in).


5.

Check once again that all hoses and harness are disconnected and free from the transmission.


6.

Lower the transmission.


37. Release Fork


1.

Remove the release fork boot (A).


2.

Remove the release fork (B) from the clutch housing by squeezing the release fork set spring (C) with pliers.


3.

Remove the release bearing (D).


4.

Check the play of the release bearing by spinning it by hand. If there is excessive play or noise, replace the release bearing.


NOTE: The release bearing is packed with grease. Do not wash it in solvent.


1. Release Fork

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1.

Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.


NOTE: Do not use silicone grease.


2.

Set the release fork set spring (E).


NOTE: Replace the release fork bolt if necessary.



3.

With the release fork (A) slid between the release bearing pawls (B), install the release bearing on the mainshaft while inserting the release fork through the hole (C) in the clutch housing.


4.

Align the detent (D) of the release fork with the release fork bolt (E).


5.

Press the detent of the release fork over the release fork bolt squarely.


6.

Install the release fork boot (F).


7.

Make sure the boot seals around the release fork and the clutch housing.


8.

Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly.


NOTE: Wipe off any excess grease.


2. Manual Transmission Assembly


1.

Make sure the two dowel pins (A) are undamaged and installed in prescribed holes on the engine block as shown. Replace the dowel pins if they are damaged.


2.

Place the transmission on the transmission jack, and raise it to the engine level.


3.

Align the transmission mainshaft and the clutch pressure plate.


4.

Move the transmission inward until there is no clearance between the transmission housing and the engine block.


Front side

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Rear side

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5.

Install the lower transmission mounting bolts.


6.

Install the clutch cover (A).


3. Subframe Support

1.

Using the subframe adapter, raise the front subframe up to the body.


4. Front Subframe Assembly

1.

Loosely install the new front subframe mounting bolts (A).


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2.

Insert the subframe alignment pin (B) through the positioning hole (C) on the right front subframe, and into the positioning hole (D) on the body, then loosely tighten the subframe right front mounting bolt.


3.

Insert the subframe alignment pin through the positioning slot on the left front subframe, and into the positioning hole on the body, then loosely tighten the subframe left front mounting bolt.


4.

Tighten the subframe mounting bolts to the specified torque values starting with the right front subframe mounting bolt. Use the subframe alignment pin when tightening the front side subframe mounting bolts.


5.

Check all of the subframe mounting bolts, and retighten if necessary.


NOTE: Tighten the bolts in the sequence shown.


6.

Remove the transmission jack and the subframe adapter.


7.

Connect the EPS connectors.


8.

Tighten the new mid-stiffener mounting bolt on both sides.


5. Lower Torque Rod - Reconnection

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1.

Install the new lower torque rod mounting bolts.


6. Intermediate Shaft Assembly


1.

Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent.


NOTE: Do not wash the rubber parts with solvent.


2.

Dry the areas where the intermediate shaft contacts the differential thoroughly with compressed air.


3.

Insert the intermediate shaft (A) into the differential correctly.


NOTE: Insert the intermediate shaft carefully to prevent damaging the oil seal (B).


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4.

Install the flange bolt (A) and the dowel bolts (B).


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5.

Install the crankshaft position (CKP) sensor cover (A).


7. Driveshaft Front Both Inboard Side



Left driveshaft


1.

Install a new set ring (A).


2.

Clean the area where the driveshaft contact the differential thoroughly with solvent.


NOTE: Do not wash the rubber parts with solvent.


3.

Dry the area where the driveshaft contact the differential thoroughly with compressed air.


4.

Insert the inboard end (B) of the driveshaft into the differential (C) until the set ring (D) lock in the groove (E).


NOTE: Insert the driveshaft horizontally to prevent damaging the oil seal.





Right driveshaft


5.

Install a new set ring (A).


6.

Apply 0.5-1.0 g (0.018-0.035 oz) of super high temp urea grease (P/N 08798-9002) to the whole splined surface (B) of the right driveshaft.


7.

After applying grease, remove the grease from the splined grooves at intervals of 2-3 splines and from the set ring groove (C) so that air can bleed from the intermediate shaft.


8.

Insert the inboard end (D) of the driveshaft into the intermediate shaft (E) until the set ring (F) lock in the groove (G).


8. Lower Arm Joint - Reconnection, Both Knuckle Side

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1.

Connect the lower arm (A) to the knuckle on both sides using new flange bolt and new self-locking nuts.


2.

After lightly tightening all three fasteners, tighten them to the specified torque in the following order; the nut on the front (B), the nut on the rear (C), then the bolt (D).


9. Tie-Rod End Ball Joint - Connection, Both Side


1.

Wipe off any grease contamination from the ball joint tapered section and threads.


2.

Connect the tie-rod ball joint (A) to the knuckle.


3.

Install the nut (B).


4.

Install a new cotter pin (C).


NOTE: Bend the cotter pin as shown.


10. Front Stabilizer Ball Joint, Both Damper Side - Reconnection

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1.

Connect the stabilizer link (A) on both sides.


2.

Install a new flange nut (B) on both sides while holding the joint pin (C) with a hex wrench (D).


11. Front Wheel

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1.

Install both front wheels.


NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.


12. MTF Replacement (M/T)



1.

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


2.

Refill the transmission with MTF to the proper level (C). Always use Honda Manual Transmission Fluid (MTF).


Manual Transmission Fluid Capacity

Except K24Z7 engine:

 

1.4 L (1.5 US qt) at fluid change

 

1.6 L (1.7 US qt) at overhaul

K24Z7 engine:

 

1.9 L (2.0 US qt) at fluid change

 

2.0 L (2.1 US qt) at overhaul


3.

Reinstall the filler plug with a new sealing washer.


13. Splash Shield

1.

Install the splash shield (A).


14. Lower The Vehicle On The Lift

1.

Lower the vehicle on the lift.


15. Steering Joint - Reconnection


1.

Set the rack in the straight ahead driving position.


2.

Slip the lower end of the steering joint (A) onto the pinion shaft (B).


NOTE:

Pinion shaft with center guide: Install the steering joint by aligning the center guide (C).

Pinion shaft without center guide: Position the steering column by aligning the gap (D) within the angle.



3.

Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft.


4.

Loosely install the steering joint bolt (C).


5.

Be sure that the joint bolt is securely in the groove in the pinion shaft.


6.

Pull on the steering joint to make sure that the steering joint is fully seated.


16. Steering Wheel Release

1.

Remove the steering wheel holder tool (A).


17. Steering Joint Bolt - Tighten

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1.

Tighten the steering joint bolt (A) to the specified torque.


18. Steering Column Lower Slide Shaft - Release

1.

Cut the wire (A).


19. Steering Joint Cover

1.

Install the steering joint cover (A) in the sequence shown.


20. Transmission Mount Assembly

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1.

Install the transmission mount assembly (A) using new bolts and new nuts.


2.

Install the ground cable terminal (B).


21. Upper Transmission Housing Mounting Bolt

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1.

Install the upper transmission mounting bolts.


22. Engine Support Hanger

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1.

Remove the engine support hanger.


2.

Remove the universal lifting eyelet.


23. Transmission Peripheral Assembly Upper Side

1.

Install transmission hanger C.


2.

Install the harness clamp (A).



3.

Connect the connectors (A).


4.

Install the harness clamps (B).


24. Shift Cable Bracket

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1.

Apply a light coat of silicone grease (P/N 08C30- B0234M) to the shift cable ends (A).


NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.


2.

Connect the shift cable ends to the change lever assembly (B).


3.

Install the shift cable bracket (C).


4.

Install the lock pins (D).


25. Clutch Slave Cylinder

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1.

Apply a light coat of super high temp urea grease (P/N 08798-9002) to the push rod (A) of the slave cylinder (B).


2.

Install the slave cylinder.


3.

Install the clutch line bracket (C).


NOTE: Be careful not to bend the clutch line.


26. ECM Assembly


1.

Connect ECM connectors A, B, and C.


NOTE: ECM connectors A, B, and C have symbols (A=□, B=△, C=○) embossed on them for identification.


2.

Install the ECM (D).


3.

Install the cover (A).


27. Intake Air Duct

1.

Install the intake air duct.


28. Air Cleaner Assembly


1.

Install the air cleaner (A).


2.

Install the harness clamp (B).


3.

Connect the intake air pipe (C) and the intake air duct (D).


29. Battery Terminal - Reconnection


NOTE: If the battery performs abnormally, test the battery.


1.

Clean the battery terminals.


2.

Connect the positive cable (A) to the battery.


NOTE: Always connect the positive side first.


3.

Connect the negative cable and the battery sensor (B) to the battery.


NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal.


4.

Apply multipurpose grease to the terminals to prevent corrosion.


30. Under Cowl Panel

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1.

Install the under cowl panel (A).


31. Center Cowl Cover


1.

If necessary, install the hood rear seal (A).


2.

Connect the windshield washer tube (B).


3.

Install the center cowl cover (C).


32. Both Side Cowl Covers


1.

Install the side cowl cover (A).


2.

The left side is shown; repeat on the right side.


33. Wiper Arm Assembly

1.122


NOTE: Set the wiper arms to the auto-stop position before installation.


1.

Install the wiper arms (A).


2.

Install the cowl top wiper covers (B).


34. Front Grille Cover

1.

Install the front bumper upper duct (A).


2.

Install the front grille cover (A).


35. Manual Transmission After Install - Check

1.

Check the shift lever operation.


2.

Check the clutch operation.


36. Pre-Alignment Checks

For proper inspection and adjustment of the wheel alignment, do these checks:


1.

Release the parking brake to avoid an incorrect measurement.


2.

Make sure the suspension is not modified.


3.

Make sure the fuel tank is full, and that the tire repair kit, the spare tire, the jack, and the tools are in place on the vehicle.


4.

Check the tire size and tire pressure according to tire information.


37. Caster - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.


1.

Check the caster angle.


USA and Canada models

Caster angle:

 

Except Si:

5 ° 19 ’±30 ’

 

Si (Without 18 inch wheel):

5 ° 22 ’±30 ’

 

Si (With 18 inch wheel):

5 ° 15 ’±30 ’


Mexico models

Caster angle:

 

Without 18 inch wheel:

5 ° 10 ’±30 ’

 

With 18 inch wheel:

5 ° 6 ’±30 ’


If the measurement is within specifications, measure the front camber angle.

If the measurement is not within specifications, check for bent or damaged suspension components.


38. Camber - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.


1.

Check the camber angle.


USA and Canada models

Camber angle:

 

Except Si:

   

Front:

0 ° 00 ’±30 ’

   

Rear:

-0 ° 45 ’±45 ’

 

Si (Without 18 inch wheel):

   

Front:

-0 ° 04 ’±30 ’

   

Rear:

-0 ° 52 ’±45 ’

 

Si (With 18 inch wheel):

   

Front:

-0 ° 18 ’±30 ’

   

Rear:

-0 ° 45 ’±45 ’

(Maximum difference between the front right and left side: 0 ° 45 ’)


Mexico models

Camber angle:

 

Front:

0 ° 20 ’±30 ’

 

Rear:

-0 ° 22 ’±45 ’

(Maximum difference between the front right and left side: 0 ° 45 ’)


If the measurement is within specification, measure the toe-in.

If the measurement for the front camber is not within the specification, go to front camber adjustment.

If the measurement for the rear camber is not within the specification, check for bent or damaged suspension components.


39. Front Toe - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.


1.

Set the steering column to the middle tilt position and telescopic positions.


2.

Center the steering wheel spokes, and install a steering wheel holder tool.


3.

Check the toe with the wheels pointed straight ahead.


Front toe-in: 0±2 mm (0±0.08 in)

If adjustment is required, go to the front toe adjustment.

If no adjustment is required, remove the alignment equipment.


40. Turning Angle - Inspection


Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.


Except '12 models


1.

Turn the wheel right and left while applying the brake, and measure the turning angle of both wheels.


USA and Canada models

Turning angle:

 

Except Si:

   

Inward:

38 ° 30 ’±2 °

   

Outward (reference):

30 ° 47 ’±1 °

 

Si (Without 18 inch wheel):

   

Inward:

38 ° 22 ’±2 °

   

Outward (reference):

30 ° 41 ’±1 °

 

Si (With 18 inch wheel):

   

Inward:

36 ° 33 ’±2 °

   

Outward (reference):

29 ° 53 ’±1 °


Mexico models

Turning angle:

 

Without 18 inch wheel:

   

Inward:

39 ° 12 ’±2 °

   

Outward (reference):

31 ° 14 ’±1 °

 

With 18 inch wheel:

   

Inward:

36 ° 58 ’±2 °

   

Outward (reference):

30 ° 16 ’±1 °


2.

If the measurement is not within the specifications, even up both sides of the tie-rod threaded section length while adjusting the front toe.


3.

If it is correct, but the turning angle is not within the specifications, check for bent or damaged suspension components.



'12 models


1.

Turn the wheel right and left while applying the brake, and measure the turning angle of both wheels.


USA and Canada models

Turning angle:

 

Except Si:

   

Inward:

38 ° 43 ’±2 °

   

Outward (reference):

30 ° 55 ’±1 °

 

Si:

   

Inward:

38 ° 36 ’±2 °

   

Outward (reference):

30 ° 49 ’±1 °


Mexico models

Turning angle:

 

Inward:

39 ° 15 ’±2 °

 

Outward (reference):

31 ° 21 ’±1 °


2.

If the measurement is not within the specifications, even up both sides of the tie-rod threaded section length while adjusting the front toe.


3.

If it is correct, but the turning angle is not within the specifications, check for bent or damaged suspension components.


41. HDS DLC - Connection


1.

Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.


2.

Turn the ignition switch to ON (II).


3.

Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.


42. VSA Sensor Neutral Position - Memorization

1.

Park the vehicle on a flat and level surface, with the steering wheel in the straight ahead position.


2.

Select VSA ADJUSTMENT, then select ALL SENSORS with the HDS, and follow the screen prompts.


NOTE: See the HDS Help menu for specific instructions.


43. Steering Angle Sensor Neutral Position - Clear

1.

Select EPS ADJUSTMENT, then select EPS STEERING ANGLE SENSOR VALUE CLEAR and follow the screen prompts on the HDS.


NOTE: See the HDS Help menu for specific instructions.


44. Maintenance Minder Reset

1.

After doing all procedures, select the individual maintenance item you wish to reset with the HDS..


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