Honda Civic Service Manual: A/T Countershaft Disassembly, Reassembly, and Inspection (A/T)

1.

Remove the transmission range switch cover (A).

1.

Disconnect the connector (A).

2.

Remove the transmission range switch (B).

1.

Remove the transmission range switch subharness (A).

2.

Remove the clamp brackets (B).

1.

Remove the ATF warmer bracket (A).

1.

Remove the end cover (A), the dowel pins (B), the O-rings (C), and the end cover gasket (D).

1.

Remove the input shaft (mainshaft) speed sensor (A) with the O-ring (B).

1.

Remove the output shaft (countershaft) speed sensor (A) with the O-ring (B).

1.

Remove A/T clutch pressure control solenoid valve A with the ATF joint pipes (B), the O-rings (C), the 35 mm ATF pipe (D), and the gasket (E).

1.

Remove A/T clutch pressure control solenoid valves B and C with the ATF joint pipes (A), the O-rings (D), the 50 mm ATF pipe (E), and the gasket (F).

1.

Remove the shift solenoid valve cover (A) with the dowel pins (B), the gasket (C), and the clamp bracket (D).

1.

Disconnect the connectors.

1.

Remove the 6 x 199 mm ATF pipe (A).

2.

Remove the 8 x 192.5 mm ATF pipe (B).

3.

Remove the 8 x 180.5 mm ATF pipes (C).

4.

Remove the ATF lubrication pipe (D).

1.

Install the mainshaft holder onto the mainshaft.

2.

Engage the park pawl with the park gear.

3.

Using a chisel, cut the lock tab (A) of the locknut (B).

NOTE: Keep all of the chiseled particles out of the transmission.

4.

Remove the locknuts (A) and the conical spring washers (B) from each shaft.

NOTE:

5.

Remove the mainshaft holder.

6.

Remove the park pawl (A), the park pawl spring (B), the park pawl shaft (C), and the stop shaft (D).

7.

Pry down the lock tab of the lock washer (E).

8.

Remove the lock bolt (F) and the lock washer.

9.

Remove the park lever (G), the park lever stop (H), and the park lever spring (I).

10.

Remove the snap ring (A) securing the idler gear to the idler gear shaft.

11.

Install a puller (A) with two 6 x 1.0 mm bolts (B) on the idler gear shaft idler gear (C).

12.

Set a spacer (D) between the puller and the idler gear shaft (E).

13.

Remove the idler gear shaft idler gear.

14.

Install a puller (A) with two 6 x 1.0 mm bolts (B) on the mainshaft idler gear (C).

15.

Set a spacer (D) between the puller and the mainshaft (E).

16.

Remove the mainshaft idler gear.

17.

Place a spacer (A) on the countershaft (B).

18.

Set a commercially available bearing puller (C) on the park gear (D).

19.

Remove the park gear.

20.

Install a puller (A) with two 6 x 1.0 mm bolts (B) on the secondary shaft idler gear (C).

21.

Set a spacer (D) between the puller and the secondary shaft (E).

22.

Remove the secondary shaft idler gear.

1.

Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C).

NOTE: Do not squeeze the end of the selector control shaft tips together when turning the control shaft.

2.

Install the housing puller over the countershaft.

NOTE: If the top arm of your housing puller is too short, replace it with 205 mm housing puller arm 07SAC-P0Z0101.

3.

Remove the transmission housing mounting bolts (D).

4.

Remove the transmission housing (E) using the housing puller.

1.

Remove the countershaft reverse gear (A).

2.

Remove the needle bearing (B).

1.

Pry down the lock tab of the lock washer (A).

2.

Remove the lock bolt (B) and the lock washer.

3.

Remove the reverse shift fork (C) with the reverse selector (D) together.

1.

Remove the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly (C) together.

1.

Place 4th-5th gear (A) on a press, and set a spacer (B) between the countershaft and the press to prevent damaging the countershaft.

NOTE: Some reverse selector hubs are not press-fitted, and can be removed without using a press.

2.

Support the bottom of the countershaft with one hand, then press the countershaft out of the press-fitted reverse selector hub (C) with 4th-5th gear, and remove the countershaft while holding the underside the countershaft. The countershaft will drop down after pressing it out of the press-fitted reverse selector hub.

3.

Remove the needle bearing (A), the snap ring (B), the 33 x 45 x 7.8 mm collar (C), and the 29 mm cotters (D).

4.

Remove the 33.2 x 40 x 51.8 mm collar (A), 3rd gear (B), 2nd gear (C), and 1st gear (D).

1.

Inspect the needle bearing for galling and rough movement.

2.

Inspect the splines for excessive wear and damage.

3.

Check the shaft bearing surface for scoring and excessive wear.

1.

Install 1st gear (A), 2nd gear (B), 3rd gear (C), and the 33.2 x 40 x 51.8 mm collar (D).

2.

Install the 29 mm cotters (A), the 33 x 45 x 7.8 mm collar (B), the snap ring (C), the needle bearing (D), 4th-5th gear (E), and the reverse selector hub (F).

3.

Press the press-fitted reverse selector hub (A) in place using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.

NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using a press.

1.

Assemble the mainshaft, the countershaft, and the secondary shaft.

2.

Join the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly (C) together, and install them.

1.

Install the reverse shift fork (A) with the reverse selector (B) together.

2.

Install the lock bolt (C) using a new lock washer (D).

3.

Bend the lock tab (E) of the lock washer against the bolt head.

1.

Install the needle bearing (A).

2.

Install the countershaft reverse gear (B).

1.

Install the three dowel pins (A) and a new gasket (B).

2.

Align the spring pin (C) of the selector control shaft (D) with the transmission housing groove (E).

NOTE: Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together, it will cause a faulty shift position signal or position due to the play between the selector control shaft and the transmission range switch.

3.

Place the transmission housing (F) on the torque converter housing (G).

NOTE: Do not install the input shaft (mainshaft) speed sensor and the output shaft (countershaft) speed sensor before installing the transmission housing.

4.

Wrap the tip of a screwdriver with tape so the reverse idler gear teeth do not get damaged. Engage the reverse idler gear (H) with the reverse gears (I) by rotating the idler gear using the screwdriver.

5.

Make sure the transmission housing is securely seated so there is no clearance between the transmission housing and the torque converter housing.

6.

Install and tighten the transmission housing mounting bolts in at least two steps, in a crisscross pattern.

1.

Install the mainshaft holder onto the mainshaft.

2.

Lubricate the following parts with ATF:

3.

Install the mainshaft idler gear (A), the old conical spring washer (B), and the old locknut (C), and tighten the locknut to 216 N·m (22.0 kgf·m, 159 lbf·ft).

NOTE:

4.

Lubricate the following parts with ATF:

5.

Install the secondary shaft idler gear (A).

NOTE: Do not tap the idler gear to install.

6.

Install the idler gear shaft idler gear (B).

NOTE: Do not tap the idler gear to install.

7.

Set the gear installer set on the idler gear shaft and the idler gear.

8.

Tighten the installer nut to install the idler gear part-way.

NOTE: The installer nut has left-hand threads.

9.

Install the old conical spring washer (A) and the old locknut (B), and tighten the locknut to 225 N·m (23.0 kgf·m, 166 lbf·ft).

NOTE:

10.

Retighten the installer nut to seat the idler gear in the idler gear shaft until it stops.

11.

Remove the gear installer set.

12.

Install a new snap ring (A).

13.

Check that the snap ring is seated securely into the groove.

14.

Lubricate the following parts with ATF:

15.

Install the park gear (A), the old conical spring washer (B), and the old locknut (C).

16.

Install the park lever spring (D), the park lever (E), and the park lever stop (F).

17.

Install the lock bolt (G) using a new lock washer (H).

NOTE: Do not bend the lock tab of the lock washer until inspect the park lever stop.

18.

Install the park pawl shaft (I), the park pawl spring (J), the park pawl (K), and the stop shaft (L).

19.

Lift the park pawl up, and engage it with the park gear, and tighten the locknut to 225 N·m (23.0 kgf·m, 166 lbf·ft).

NOTE:

20.

Remove the old locknuts and the old conical spring washers from the mainshaft, the countershaft, and the secondary shaft.

21.

Lubricate the following parts with ATF:

22.

Install new conical spring washers (A) with facing stamped mark side up in the direction shown.

23.

Install a new mainshaft locknut (B), a new countershaft locknut (C), and a new secondary shaft locknut (D).

24.

Tighten the mainshaft locknut to 155 N·m (15.8 kgf·m, 114 lbf·ft).
Tighten the countershaft and secondary shaft locknuts to 167 N·m (17.0 kgf·m, 123 lbf·ft).

NOTE:

25.

Remove the mainshaft holder.

26.

Stake the locknuts into the shafts to a depth (A) of 0.7－1.3 mm (0.027－0.051 in) using a 3.5 mm punch (B).

27.

Set the park lever in the P position.

28.

Measure the distance (A) between the park pawl shaft center (B) and the extension line (C) connected centers of the park lever roller pin (D) and the control shaft (E) in the vertical direction from the extension line.

Standard: 46.8－47.8 mm (1.843－1.882 in)

31.

Bend the lock tab (A) of the lock washer against the bolt head.

1.

Install the 6 x 199 mm ATF pipe (A).

2.

Install the 8 x 192.5 mm ATF pipe (B).

3.

Install the 8 x 180.5 mm ATF pipes (C).

4.

Install the ATF lubrication pipe (D).

1.

Connect the shift solenoid valve connectors:

1.

Install the shift solenoid valve cover (A) with the dowel pins (B), a new gasket (C), and the clamp bracket (D).

1.

Clean the mounting surfaces and the fluid passages of the solenoid valve body and the transmission housing.

2.

Install a new gasket (A) with the blue side down and the white side up on the transmission housing.

3.

Install the 50 mm ATF pipe (D) and the ATF joint pipes (E).

4.

Install new O-rings (F) over the ATF joint pipes.

5.

Install A/T clutch pressure control solenoid valves B and C.

1.

Clean the mounting surfaces and the fluid passages of the solenoid valve body and the transmission housing.

2.

Install a new gasket (B) with the blue side down and the white side up on the transmission housing.

3.

Install the 35 mm ATF pipe (C) and the ATF joint pipes (D).

4.

Install new O-rings (E) over the ATF joint pipes.

5.

Install A/T clutch pressure control solenoid valve A.

1.

Install the output shaft (countershaft) speed sensor (A) using a new O-ring (B).

1.

Install the input shaft (mainshaft) speed sensor (A) using a new O-ring (B).

1.

Install the dowel pins (A) and a new gasket (B).

2.

Install new O-rings (C) over the ATF pipes.

3.

Install the end cover (D).

1.

Install the ATF warmer bracket (A).

1.

Install the clamp brackets (A).

2.

Install the transmission range switch subharness (B).

1.

Make sure the selector control shaft is in the N position. If necessary, move the selector control shaft to the N position.

NOTE: Do not use the selector control shaft to adjust the shift position. If the selector control shaft tips are squeezed together it will cause a faulty signal or position due to play between the selector control shaft and switch.

2.

Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.079 in) feeler gauge blade (D) in the cutouts to hold the switch in the N position.

NOTE: Be sure to use a 2.0 mm (0.079 in) blade or equivalent to hold the switch in the N position.

3.

Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position with the 2.0 mm (0.079 in) blade (C).

4.

Tighten the bolts on the transmission range switch (A) while you continue holding the N position.

NOTE: Do not move the transmission range switch when tightening the bolts.

5.

Remove the feeler gauge (B).

6.

Check the connector (C) for corrosion, dirt, or oil, and clean or repair if necessary, then connect the connector securely.

1.

Install the transmission range switch cover (A).