Honda Civic Service Manual: M/T Mainshaft Disassembly, Reassembly, and Inspection (R18Z1 M/T)

1.

Remove the change lever assembly (A).

2.

Remove the 8 x 10 mm dowel pins (B).

1.

Remove the back-up light switch (A) and the 18 mm sealing washer (B).

1.

Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).

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 8 mm flange bolts in a crisscross pattern in several steps.

3.

Remove the 32 mm sealing cap (A).

4.

While expanding the 69 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

5.

Release the snap ring pliers, and remove the transmission housing.

6.

Remove the 14 x 20 mm dowel pins (D).

1.

Remove the reverse shift fork (A).

1.

Remove the reverse idler gear (A) and the reverse idler gear shaft (B).

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 26 mm washer (E).

4.

Remove the 36 mm spring washer (F).

1.

Support the tapered cone ring (A) on the bearing separator.

2.

Press the mainshaft out of the angular ball bearing (B).

3.

Support 5th gear (A) on the bearing separator.

4.

Press the mainshaft out of the 5th synchro hub (B) and 5th gear.

1.

Support 3rd gear (A) on the bearing separator.

2.

Press the mainshaft out of the 3rd/4th synchro hub (B) and 3rd gear.

1.

Inspect the gear and bearing contact areas for wear and damage.

2.

Measure the mainshaft at points A, B, C, D, and E. If any part of the mainshaft is less than the service limit, replace it.

3.

Inspect the runout by supporting both ends of the mainshaft.

4.

Rotate the mainshaft two complete turns while measuring with a dial gauge. If the runout exceeds the standard, replace the mainshaft.

1.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

2.

Install the needle bearing (A).

3.

Install 3rd gear (B).

4.

Install the synchro ring (C) with the synchro spring (D).

5.

Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 3rd/4th synchro hub.

NOTE: Make sure to install the 3rd/4th synchro hub in the direction shown.

6.

Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle, the 35 mm I.D. bearing driver attachment and a press.

7.

Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub.

8.

Check the operation of the 3rd/4th synchro hub set.

9.

Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 3rd/4th synchro hub.

10.

Install 4th gear (E) onto the synchro ring.

1.

Install the 4th/5th gear distance collar (A) with the needle bearings (B).

2.

Install 5th gear (C).

3.

Install the synchro ring (D) with the synchro spring (E) onto 5th gear.

4.

Install the 5th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th synchro hub.

5.

Press on the 5th synchro hub (A) using the 40 mm I.D. driver handle, the 35 mm I.D. bearing driver attachment and the press.

6.

Install the 5th synchro sleeve (A) by aligning the slots of the 5th synchro sleeve and the 5th synchro hub (B).

NOTE: Make sure to align the slots in the 5th synchro hub as shown.

7.

Check the operation of the 5th synchro hub set.

8.

Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 5th synchro hub.

9.

Install the MBS distance collar (E).

10.

Install the tapered cone ring (F).

11.

Install a new angular ball bearing (G).

12.

Press on the angular ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.

1.

Install the 36 mm spring washer (A).

NOTE: Be sure to install the spring washer in the direction shown.

2.

Install the 26 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.

1.

Install the reverse idler gear (A) and the reverse idler gear shaft (B).

1.

Install the reverse shift fork (A).

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:

3.

Install the 14 x 20 mm dowel pins (A).

4.

Set the tapered cone ring pawl (B) faces the 5th shift fork (C).

5.

Place the transmission housing on the clutch housing, making sure to line up the shafts.

6.

While expanding the 69 mm snap ring (D) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring.

7.

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 (E) after setting in the 69 mm snap ring.

8.

Make sure the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension as installed: 3.3－6.5 mm (0.130－0.256 in)

9.

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:

10.

Install the 8 mm flange bolts finger-tight.

11.

Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

12.

Install the steel balls, the detent ball springs, and the detent bolts (A) with new 12 mm sealing washers (B).

1.

Install the output shaft (countershaft) speed sensor (A) with a new O-ring (B) and the plain washer (C).

1.

Install the back-up light switch (A) with a new 18 mm sealing washer (B).

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:

3.

Install the 8 x 10 mm dowel pins (A).

4.

Install the change lever assembly (B).