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Honda Civic Service Manual: M/T Shift Fork Clearance Inspection (K24Z7)

Honda Civic Service Manual / Powertrain / Transmission/Transaxle / Manual / Transmission Assembly / M/T Shift Fork Clearance Inspection (K24Z7)

Removal

1. M/T Change Lever Assembly


1.

Remove the interlock bolt (A).

2.

Remove any old liquid gasket from the interlock bolt.

3.

Remove the change lever assembly (B).

4.

Remove the 8 x 14 mm dowel pins (C).

2. Back-Up Light Switch


1.

Remove the back-up light switch (A).

2.

Remove any old liquid gasket.

3. Output Shaft (Countershaft) Speed Sensor

1.

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

4. Transmission Housing

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 10 mm flange bolt (A) and the sealing washer (B).

3.

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).


4.

Remove the 32 mm sealing cap (A).

5.

While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

6.

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

7.

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

Inspection

1. Shift Fork Clearance Inspection

1.

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.

Standard (New):

0.35－0.65 mm
(0.014－0.025 in)

Service Limit:

0.65 mm
(0.025 in)

2.

Measure the thickness of the shift fork fingers.

If the thickness is not within the standard, replace the shift fork.

If the thickness is within the standard, replace the synchro sleeve and the synchro hub as a set.

If one arm of the shift fork shows more wear than others, the fork may be bent and needs to be replaced.

Standard:

7.4－7.6 mm
(0.291－0.299 in)

3.

Measure the clearance between each shift fork (A) and the shift arm (B). If the clearance exceeds the service limit, go to step 4.

Standard:

0.2－0.5 mm
(0.008－0.019 in)

Service Limit:

0.5 mm
(0.019 in)

4.

Measure the width of the shift arm.

If the width is not within the standard, replace the shift arm.

If the width is within the standard, replace the shift fork or the reverse shift piece.

Standard:

16.9－17.0 mm
(0.665－0.669 in)

Installation

1. Transmission Housing


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:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.


3.

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

4.

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

5.

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.

6.

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 (C) after setting in the 72 mm snap ring.


7.

Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension as installed: 3.3－6.0 mm (0.130－0.236 in)

8.

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:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

9.

Install the 8 mm flange bolts finger-tight with transmission hanger A, transmission hanger B, and the harness bracket (C).

10.

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

Specified Torque:

8 x 1.25 mm
27 N·m (2.8 kgf·m, 20 lbf·ft)


11.

Install the 10 mm flange bolt (A) with new sealing washer (B).

12.

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

2. Output Shaft (Countershaft) Speed Sensor


1.

Apply MTF to a new O-ring (A).

2.

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

3. Back-Up Light Switch


1.

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).

2.

Install the back-up light switch.

4. M/T Change Lever Assembly

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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:

If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.

If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.


3.

Install the 8 x 14 mm dowel pins (A).

4.

Install the change lever assembly (B).

5.

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).

6.

Install the interlock bolt.

M/T Reverse Shift Fork Clearance Inspection (R18Z1 M/T)
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M/T Shift Fork Disassembly and Reassembly (K24Z7)
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