Honda Civic Service Manual: M/T Reverse Shift Fork Clearance 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.

Measure the clearance between the reverse idler gear (A) and the reverse shift fork (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 2.

2.

Measure the width of the reverse shift fork.

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).