Honda Civic/CRX/del Sol 1984-1995 Repair Guide

Transaxle

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REMOVAL & INSTALLATION



1984-87 Models

See Figures 1 through 12

The Civic 4WD Wagon transaxle must be removed with the engine. For removal procedures please refer to Engine Removal & Installation in Engine & Engine Rebuilding . Once the engine/transaxle assembly is removed from the vehicle, then the transaxle can be separated with the transfer case from the engine.



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Fig. Fig. 1: Disconnect the shift rod and lever-1984-87 models except Wagon



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Fig. Fig. 2: Removing the front transaxle mount-1984-87 models except Wagon



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Fig. Fig. 3: Removing the engine torque bracket-1984-87 models except Wagon



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Fig. Fig. 4: Removing the rear transaxle mount-1984-87 models except Wagon

Make sure jack stands are in proper position. Apply the parking brake and block the rear wheels.

  1. Disconnect the battery negative and positive cables.
  2.  
  3. Unlock the steering and place the transaxle in neutral.
  4.  
  5. Disconnect all wires in the engine compartment necessary for the removal, including:
    1. black/white wire from the starter solenoid.
    2.  
    3. temperature gauge sending unit wire.
    4.  
    5. ignition timing thermo-sensor wire.
    6.  
    7. back-up light switch.
    8.  
    9. distributor wiring.
    10.  
    11. transaxle ground cable.
    12.  

  6.  
  7. Unclip and remove the speedometer cable at the transaxle. Do not disassemble the speedometer gear holder!
  8.  
  9. Remove the clutch slave cylinder with the hydraulic line attached, or disconnect the clutch cable at the release arm.
  10.  
  11. Remove the side and top starter mounting bolts. Loosen the front wheel lug nuts.
  12.  
  13. Apply the parking brake and block the rear wheels. Raise and support the front end of the vehicle. Remove the front wheels.
  14.  
  15. Attach a suitable chain hoist to the rear of the engine then raise the engine slightly to take the weight off of the mounts. Drain the transaxle, then reinstall the drain plug and washer.
  16.  



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Fig. Fig. 5: Unbolting the transaxle drain plug-1984-87 style CRX shown



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Fig. Fig. 6: Drain the transaxle into a suitable container-warm transaxle oil will drain much faster

  1. Remove the splash shields from the underside.
  2.  



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Fig. Fig. 7: Unbolting a splash shield to facilitate transaxle removal-1984-87 style CRX shown



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Fig. Fig. 8: Removing the right-side splash shield-1984-87 style CRX shown

  1. Remove the stabilizer bar.
  2.  
  3. Disconnect the left and right lower ball joints and tie rod ends, using a ball joint separator.
  4.  


CAUTION
Use caution when separating the ball joints. Place a floor jack under the lower control arm securely at the ball joint. Otherwise, the lower control arm may jump suddenly away from the steering knuckle as the ball joint is removed!

  1. Turn the right steering knuckle out as far as it will go. Place a prybar against the inboard CV-joint. Pry the right axle out of the transaxle about 1/2 inch (12mm). This will force the spring clip out of the groove inside the differential gear splines. Pull it out the rest of the way. Repeat this procedure on the other side.
  2.  
  3. Disconnect the shift lever torque rod from the clutch housing.
  4.  
  5. Slide the pin retainer back and drive out the spring pin using a pin punch, then disconnect the shift rod. Remove the bolt from the shift rod clevis, if so equipped.
  6.  
  7. Place a transaxle jack under the transaxle and raise the jack securely against the transaxle to take up the weight.
  8.  
  9. Remove the engine torque rods and brackets. Remove the bolts from the front transaxle mount. Remove the transaxle housing bolts from the engine torque bracket.
  10.  



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Fig. Fig. 9: Unbolting the front transaxle mount-1984-87 style CRX shown



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Fig. Fig. 10: The front transaxle mount in-hand. The mount is simply a molded piece of heavy-duty rubber designed to take up vibration and torsional forces under power

  1. Remove the remaining starter mounting bolts and take out the starter.
  2.  
  3. Remove the remaining transaxle mounting bolts and the upper bolt from the engine damper bracket. Remove the clutch housing bolts from the rear transaxle mounting bracket. Remove the one remaining bolt from the engine.
  4.  
  5. Start backing the transaxle away from the engine and remove the two lower damper bolts.
  6.  
  7. Pull the transaxle clear of the engine and lower the jack.
  8.  



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Fig. Fig. 11: A strong cross bar and tie-strap suspended on pads between the front fenders can be used in lieu of an engine hoist to support the transaxle/engine during transaxle removal



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Fig. Fig. 12: The transaxle is here being pulled away from the engine-note the support strap securing the transaxle

To install:
  1. To ease installation, fabricate two 14mm diameter dowel pins and install them in the clutch housing.
  2.  
  3. Raise the transaxle and slide it onto the dowels. Slide the transaxle onto position aligning the mainshaft splines with the clutch plate.
  4.  
  5. Attach the damper lower bolts when the positioning allows. Tighten both bolts until the clutch housing is seated against the block.
  6.  
  7. Install two lower mounting bolts and tighten them to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the front and rear torque rod brackets. Tighten the front torque rod bolts to 54 ft. lbs., the front bracket bolts to 33 ft. lbs. (45 Nm), the rear torque rod bolts to 54 ft. lbs., and the rear bracket bolts to 47 ft. lbs. (65 Nm).
  10.  
  11. Remove the transaxle jack.
  12.  
  13. Install the starter and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  14.  
  15. Turn the right steering knuckle out far enough to fit the CV-joint end into the transaxle. Use new 26mm spring clips on both axles. Repeat procedure for the other side.
  16.  


WARNING
Make sure that the axles bottom fully so that you feel the spring clip engage the differential.

  1. Install the lower ball joints. Tighten the nuts to 32 ft. lbs. (43.4 Nm)
  2.  
  3. Install the tie rods. Tighten the nuts to 32 ft. lbs. (43.4 Nm).
  4.  
  5. Connect the shift linkage.
  6.  
  7. Connect the shift lever torque rod to the clutch housing and tighten the bolt to 7 ft. lbs. (9.5 Nm).
  8.  
  9. Install the stabilizer bar.
  10.  
  11. Install the lower shields.
  12.  
  13. Install the front wheels and tighten the lug nuts to specification.
  14.  
  15. Install the remaining starter bolts and tighten to 33 ft. lbs. (45 Nm).
  16.  
  17. Install the clutch slave cylinder or install the clutch cable at the release arm.
  18.  
  19. Install the speedometer cable holder using a new O-ring coated with clean engine oil.
  20.  
  21. Connect all engine compartment wiring.
  22.  
  23. Fill the transaxle with SAE 10W-40 engine oil.
  24.  

1988-91 Models

See Figures 13, 14, 15 and 16



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Fig. Fig. 13: Disconnect the components before removing the transaxle



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Fig. Fig. 14: Disconnect the halfshafts and header pipe before removing the transaxle



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Fig. Fig. 15: Removing the transaxle from the vehicle



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Fig. Fig. 16: Transaxle removal-4WD Wagon

Make sure jack stands are in proper position. Apply the parking brake and block the rear wheels.

  1. Disconnect the positive and negative battery cables from the battery.
  2.  
  3. Remove the three mount bolts and loosen the one bolt located at the side of the battery base.
  4.  
  5. Remove the intake hose band at the throttle body.
  6.  
  7. Remove the air cleaner case complete with the intake hose. Disconnect the starter and transaxle ground cables.
  8.  
  9. Disconnect the speedometer, but be sure not to disassemble the speedometer gear holder.
  10.  
  11. Disconnect the back-up light switch connector and the clutch cable release arm.
  12.  
  13. Drain the transaxle fluid into a suitable drain pan. Disconnect the connectors and remove the mount bolts.
  14.  
  15. Remove the distributor assembly for additional access.
  16.  
  17. Remove the starter mounting bolts and remove the starter assembly. Remove the engine splash shield and the right wheel well splash shield.
  18.  
  19. Remove the header pipe. Remove the cotter pin and the lower arm ball joint nut. Separate the ball joint and lower arm.
  20.  
  21. Remove the bolts and nut, then remove the right radius rod. Remove the right and left halfshafts. Remove the header pipe bracket. Remove the shift lever torque rod and shift rod from the clutch housing.
  22.  
  23. On 4WD vehicles, remove the driveshaft and the intermediate shaft. Remove the cable bracket and the side transaxle mount from the transaxle housing and body.
  24.  
  25. Install a bolt at the cylinder head and attach a suitable chain hoist to the bolt and the other end to the engine hanger plate. Lift the engine slightly to unload the mounts or place a suitable transaxle jack under the transaxle and raise it just enough to take the weights off of the mounts.
  26.  
  27. Remove the front transaxle mounting bolts. Remove the rear transaxle mounting bolts. Remove the side transaxle mount. Remove the five remaining transaxle mounting bolts and pull the transaxle assembly far enough away from the engine to clear the 14mm dowel pins.
  28.  
  29. Separate the mainshaft from the clutch pressure plate and remove the transaxle by lowering the jack.
  30.  

To install:
  1. Make sure the two 14mm dowel pins are installed in the clutch housing.
  2.  
  3. Raise the transaxle into position with the transaxle jack. Loosely install all of the transaxle mount bolts, then tighten to 43 ft. lbs. (60 Nm).
  4.  
  5. Install the engine side mount bolt and tighten to 50 ft. lbs. (68 Nm).
  6.  
  7. Install the transaxle-to-rear transaxle mount bracket. Tighten the bolts to 40 ft. lbs. (55 Nm).
  8.  
  9. Install the transaxle-to-front transaxle mount and tighten the bolts to 29 ft. lbs. (40 Nm).
  10.  
  11. Install the transaxle-to-side transaxle mount and tighten the bolts to 43 ft. lbs. (60 Nm).
  12.  
  13. Install the starter and tighten the starter bolts to 33 ft. lbs. (45 Nm).
  14.  
  15. Remove the transaxle jack and the chain hoist and bolts.
  16.  
  17. Install the shift lever torque rod and shift rod. After reassembly, slide the retainer back into place after driving in the spring pin.
  18.  
  19. Install the header pipe bracket and tighten the bolts to 16 ft. lbs. (22 Nm).
  20.  
  21. On 4WD vehicles, install the cable bracket to the rear transaxle mount bracket. Install the select and shift cables. Install the intermediate shaft and the driveshaft.
  22.  
  23. Install a new set ring on the end of each halfshaft. Install the right and left halfshafts. Turn the right steering knuckle fully outward and slide the axle into the differential, until the spring clip is felt to engage the differential side gear.
  24.  
  25. Install the damper fork and radius rod. Tighten the radius rod nut to 39 ft. lbs. (44 Nm).
  26.  
  27. Install the ball joints to the lower arm. Tighten the stud nuts to 40 ft. lbs. (55 Nm) and install a new cotter pin.
  28.  
  29. Install the splash shields and exhaust header pipe.
  30.  
  31. Install the distributor if removed.
  32.  
  33. Connect the speedometer cable and connect the clutch cable to the release arm.
  34.  
  35. Connect the back-up light switch connector.
  36.  
  37. Install the three bolts located at the side of the battery base and tighten the intake hose band of the throttle body.
  38.  
  39. Fill the transaxle with the proper type and quantity of oil (refer to Routine Maintenance ).
  40.  
  41. Connect the starter and transaxle ground cable.
  42.  
  43. Install the air cleaner case and intake hose.
  44.  
  45. Connect the battery cables, start the engine and check the ignition timing.
  46.  

1992-95 Models

See Figures 17, 18, 19, 20 and 21



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Fig. Fig. 17: Various components to be removed to enable transaxle removal-1992-95



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Fig. Fig. 18: Mounts and brackets to be disconnected for transaxle removal-1992-95



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Fig. Fig. 19: Various bolts and components to re-attach for transaxle installation-1992-95



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Fig. Fig. 20: Mount bolts, torque figures and chain hoist attachment-1992-95



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Fig. Fig. 21: Linkage and components to attach for transaxle installation-1992-95

Make sure jack stands are in proper position. Apply the parking brake and block the rear wheels.


WARNING
Use fender covers to avoid damaging painted surfaces.

  1. Disconnect the positive and negative battery cables from the battery.
  2.  
  3. Remove the resonator, intake air duct, and air cleaner assembly.
  4.  
  5. Drain the transaxle oil.
  6.  
  7. Disconnect the starter motor cables, transaxle ground wire, and remove the wire harness clamp.
  8.  
  9. Disconnect the Vehicle Speed Sensor (VSS) and back up light switch connector.
  10.  
  11. Remove the clutch pipe bracket and slave cylinder.
  12.  
  13. Remove the transaxle halfshafts and coat the precision finished surfaces with clean grease. Tie sturdy plastic bags over the halfshaft ends.
  14.  
  15. Remove exhaust pipe A (header pipe).
  16.  
  17. Remove the shift rod and extension rod.
  18.  
  19. For D16Z6 engines, remove the front and rear engine stiffeners.
  20.  
  21. Remove the clutch cover.
  22.  
  23. Install a bolt at the cylinder head and attach a suitable chain hoist to the bolt and the other end to the engine hanger plate. Lift the engine slightly to unload the mounts or place a suitable transaxle jack under the transaxle and raise it just enough to take the weights off of the mounts.
  24.  
  25. Remove the splash gaurds and front stopper bracket.
  26.  
  27. Place a jack under the transaxle.
  28.  
  29. Remove the transaxle mount.
  30.  
  31. Remove the three upper transaxle mounting bolts and the lower starter mounting bolt.
  32.  
  33. Remove the transaxle rear mount bracket bolts and the transaxle mounting bolts. Pull away the transaxle from the engine until it clears the mainshaft, then lower the transaxle using the transmission jack.
  34.  

To install:
  1. Make sure the two dowel pins are installed in the clutch housing.
  2.  
  3. Apply Super High Temp Urea Grease (Honda part No. 080798-9002 or suitable aftermarket equivalent) as shown in the accompanying drawing, then install the release fork, release bearing and release fork boot.
  4.  
  5. Raise the transaxle into position with the transaxle jack. Loosely install the transaxle mount bolts and rear mount bracket bolts. Then tighten the mount bolts to 47 ft. lbs. (65 Nm) and tighten new rear mount bolts to 61 ft. lbs. (85 Nm).
  6.  
  7. Place the three upper transaxle mounting bolts in position, then tighten to 47 ft. lbs. (65 Nm. Install the lower starter mounting bolts in position and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the engine side mount bolt and tighten to 54 ft. lbs. (75 Nm).
  10.  
  11. Install the front stopper bracket and install the splash gaurd.
  12.  
  13. Install the distributor mounting bolt.
  14.  
  15. Install the clutch cover.
  16.  
  17. For D16Z6 engines, install the front and rear engine stiffeners as shown in the drawing.
  18.  
  19. Install the shift rod, spring pin and clip making sure the boot is installed on the shift rod and the hole is facing down.
  20.  
  21. Install the extension rod.
  22.  
  23. Install exhaust pipe A (header pipe), and tighten the bolts to 16 ft. lbs. (22 Nm).
  24.  
  25. Install the halfshafts using new set rings.
  26.  
  27. Install the ball joint onto the lower arm.
  28.  
  29. Install the clutch slave cylinder and then the clutch pipe stay.
  30.  
  31. Plug in the Vehicle Speed Sensor connector, transaxle ground, back-up light switch connector, transaxle ground wire and starter motor cables. Make sure that the crimped side of the ring is facing out.
  32.  
  33. Install the resonator, air cleaner asembly and air intake duct.
  34.  
  35. Turn the breather cap so that the "F" mark points at an angle of 30° towards the front of the car.
  36.  
  37. Refill the transaxle with oil, connect the battery cables and check for proper clutch and shifting function.
  38.  
  39. Check ignition timing and adjust.
  40.  
  41. Check front wheel alignment.
  42.  

 
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