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

4WD Transaxle

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BEFORE DISASSEMBLY



See Figures 1, 2 and 3

Cleanliness is an important factor in the overhaul of this information transaxle. Before opening up this unit, the entire outside of the transaxle assembly should be cleaned, preferably with a high pressure washer such as a car wash spray unit. Dirt entering the transaxle internal parts will negate all the time and effort spent on the overhaul. During inspection and reassembly all parts should be thoroughly cleaned with solvent then dried with compressed air. Wiping cloths and rags should not be used to dry parts.

Wheel bearing grease, long used to hold thrust washers and lube parts, should not be used. Lube seals with clean transaxle oil and use ordinary unmedicated petroleum jelly to hold the thrust washers and to ease the assembly of seals, since it will not leave a harmful residue as grease often will. Do not use solvent on neoprene seals, if they are to be reused, or thrust washers.

Before installing bolts into aluminum parts, always dip the threads into clean transaxle oil. Antiseize compound can also be used to prevent bolts from galling the aluminum and seizing. Always use a torque wrench to keep from stripping the threads. The internal snaprings should be expanded and the external rings should be compressed, if they are to be reused. This will help ensure proper seating when installed.



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Fig. Fig. 1: Exploded view of the transaxle components-4WD Wagon



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Fig. Fig. 2: Exploded view of the transaxle upper housing-4WD Wagon



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Fig. Fig. 3: Transaxle component key list

TRANSAXLE DISASSEMBLY



  1. Remove the Reverse idle shaft bolt, the super low shift lever bolt and the super low shift set ball screw.
  2.  
  3. Remove the bolts attaching the clutch case to the transaxle housing.
  4.  
  5. Remove the sealing bolt and the circlip holding the countershaft ball bearings.
  6.  
  7. Separate the clutch housing from the transaxle housing.
  8.  
  9. Remove the thrust shim, the dish spring and oil guide plate from the transaxle housing.
  10.  
  11. With the cover removed, a clearance inspection must be made before any further disassembly is done to the unit.
    1. Measure the clearance between the reverse shift fork and the 5th/Reverse shift piece pin.
    2.  
    3. The service limit is 0.02 in. (0.5mm). If the clearance is outside the limits, measure the width of the L-groove in the reverse shift fork. This clearance should be 0.28-0.29 in. (7.00-7.25mm). Replace the shift fork if the measurement exceeds the maximum.
    4.  
    5. Measure the clearance between the reverse idler gear and the reverse shift fork. The service limit is 0.072 in. (1.8mm).
    6.  
    7. If the clearance exceeds the service limit, measure the width of the reverse shift fork pawl groove opening. The opening measurement should be 0.52-0.53 in. (13.0-13.3mm). If the measurement is outside the limits, replace the shift fork with a new one.
    8.  

  12.  

COMPONENT DISASSEMBLY



Mainshaft/Countershaft

See Figures 4, 5, 6 and 7



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Fig. Fig. 4: Mainshaft and countershaft removal-4WD Wagon

REMOVAL
  1. Remove the revere idler shaft and reverse idler gear from the clutch housing.
  2.  
  3. Remove the following parts from the reverse shift holder assembly:
    1. 1st/2nd shift fork shaft.
    2.  
    3. Super-low shift piece bar.
    4.  
    5. Super-low shift lever.
    6.  
    7. Super-low shift piece.
    8.  
    9. 1st/2nd shift fork.
    10.  

  4.  
  5. Remove the following parts from the clutch housing:
    1. Special bolt (6mm).
    2.  
    3. Lock plate.
    4.  
    5. 5th/reverse shift fork shaft.
    6.  
    7. 3rd/4th shift fork.
    8.  
    9. Reverse shift fork.
    10.  

  6.  
  7. Remove the reverse shift holder assembly from the clutch housing.
  8.  
  9. Remove the following parts from the clutch housing and the Super-low/2nd shaft assembly:
    1. Ball bearing.
    2.  
    3. Spacer collar with flanges.
    4.  
    5. Super-low/2nd gear.
    6.  
    7. Synchronizer ring.
    8.  
    9. Super-low shift fork shaft assembly.
    10.  
    11. Needle bearing.
    12.  
    13. Thrust washer.
    14.  
    15. Super-low/1st shaft.
    16.  
    17. Spacer collar.
    18.  
    19. Super-low/1st gear.
    20.  
    21. Thrust needle bearing.
    22.  
    23. Thrust washer.
    24.  
    25. Spring washer
    26.  
    27. Space collar.
    28.  

  10.  
  11. Remove the mainshaft assembly, countershaft assembly and the Super-low/2nd shaft form the clutch housing.
  12.  
  13. Remove the bearing from the transfer shaft.
  14.  
  15. Remove the differential assembly from the clutch housing.
  16.  
  17. To remove the transfer shaft, remove the 2nd/4th selector rod from the clutch housing.
  18.  
  19. Remove the selector fork, selector sleeve and the transfer spacer collar from the clutch housing.
  20.  



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Fig. Fig. 5: Exploded view of the mainshaft assembly-4WD Wagon



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Fig. Fig. 6: Exploded view of the countershaft assembly-4WD Wagon



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Fig. Fig. 7: Transfer shaft removal-4WD Wagon

  1. Remove the selector shaft, needle bearings and the transfer driven gear from the transaxle side of the clutch housing.
  2.  
  3. To remove the differential oil seal, remove the circlip and remove the oil seal from the transaxle housing and from the clutch case.
  4.  
  5. The transfer shaft needle bearing can be removed from the clutch housing, the transfer shaft tapered bearing can be removed from the transaxle housing, along with the mainshaft bearing/oil seal from the clutch housing. The countershaft bearing should be removed from the clutch housing with the use of a slide hammer tool. As the components are removed from the major units, new components can be installed at that time.
  6.  
  7. Inspect the mainshaft and the countershaft for damage, excessive wear or broken teeth. Examine the splines for wear.
  8.  
  9. Examine the synchronizer units for worn teeth, roughness or wear, scoring galling or cracks.
  10.  
  11. To measure the clearance between the ring and the gear, hold the ring against the gear evenly while measuring the clearance with a feeler gauge. The service limit is 0.016 in. (0.4mm). If necessary, replace the unit.
  12.  
  13. To assemble the mainshaft, install the components in the following order on the mainshaft:
    1. Needle bearing
    2.  
    3. 3rd gear
    4.  
    5. Synchronizer assembly
    6.  
    7. 4th gear
    8.  
    9. Needle bearings
    10.  
    11. Spacer collar
    12.  
    13. Needle bearing
    14.  
    15. 5th gear
    16.  
    17. Synchronizer assembly
    18.  
    19. Ball bearing
    20.  

  14.  
  15. To measure the clearance of the components of the mainshaft, push down on the bearing race with a socket and measure the clearance between the 3rd and 2nd gears.
    1. The 3rd gear clearance service limit is 0.012 in. (0.3mm). If the measurement is out of specifications, measure the thickness of the 3rd gear, which should have a service limit of 1.292 in. (32.3mm). If this reading is within specifications, replace the synchronizer hub.
    2.  
    3. Measure the clearance between the 4th gear and the spacer collar and the 5th gear and the spacer collar. The service limit is 0.012 in. (0.3mm). If the measurement is out of specifications, measure each side of the spacer collar from the inside lip of the spacer lug. A service limit of 11.04 in. (26.0mm) is allowed.
    4.  
    5. If the measurement of the spacer collar is within specifications measure the thickness of the 4th and 5th gears. The 4th gear service limit thickness is 1.24 in. (31mm), while the 5th gear service limit is 1.212 in. (30.3mm). if the measurements are out of specifications, replace the gears. If the gears are within specifications, but the clearance is still out of specifications, replace the synchronizer hub.
    6.  

  16.  
  17. To determine the mainshaft shim selection, remove the thrust shim, the dish spring and the oil guide plate from the transaxle housing.
  18.  
  19. Install the 3rd/4th synchronizer hub, spacer collar, 5th synchronizer hub and the ball bearing on the mainshaft. Install the assembly into the transaxle case.
  20.  
  21. Measure the distance between the end of the transaxle case and the mainshaft.
    1. Use a straight edge and vernier caliper.
    2.  
    3. Measure at three locations and average the readings.
    4.  

  22.  
  23. Measure the distance between the end of the clutch housing and the bearing inner race. Again, average the readings.
  24.  
  25. Calculate the thickness of the shim to be added, as follows
    1. Add the measurement recorded in Step 21 and Step 22.
    2.  
    3. Subtract 0.04 in. (1.0mm), representing the height of the dish spring after installation and the remainder is the thickness of the shim needed. The shim needed would be 0.064 in. (1.60mm).
    4.  
    5. When making this measurement, if the inner race protrudes above the clutch housing, measure the height it protrudes and subtract this amount from the measurement. Then subtract the 0.04 in. (1.0mm) dish spring to compute the shim needed. The shim needed would be 0.064 in. (1.60mm).
    6.  
    7. Thickness of the shims vary from 0.044-0.086 in. (1.10mm to 2.15mm), available in thickness of 0.05mm increments, for a total of 22 different sizes.
    8.  

  26.  
  27. Check the thrust clearance as outlined in the following steps:
    1. Install the dish spring and shim selected in the transaxle housing.
    2.  
    3. Install the mainshaft into the clutch housing.
    4.  
    5. Place the transaxle cover housing over the mainshaft and onto the clutch housing.
    6.  
    7. Tighten the clutch and transaxle retaining bolts.
    8.  
    9. Reach through the 18mm sealing bolt hole and measure the clearance between the dish spring and the thrush shim at its opening.
    10.  
    11. The scale 0.012 in. (0.3mm) side should fit while the scale side 0.0196 in. (0.49mm) side should not of the special measuring tool, 07998SD9000A or its equivalent.
    12.  
    13. If the clearance is incorrect, the adjusting shims must be changed to correct the specifications.
    14.  

  28.  

Countershaft
CLEARANCE INSPECTION
  1. Assemble the gears, spacer collars, thrust washers, synchronizer hub and rings to the countershaft, in the following manner:
    1. Super-low gear
    2.  
    3. Selective thrust washer
    4.  
    5. Needle bearing
    6.  
    7. Low gear
    8.  
    9. Reverse gear and synchronizer assembly
    10.  
    11. 2nd gear
    12.  
    13. Spacer collar
    14.  
    15. Needle bearing
    16.  
    17. 3rd gear
    18.  
    19. 4th gear
    20.  
    21. 5th gear
    22.  
    23. Ball bearing
    24.  
    25. Lockwasher and locknut
    26.  

  2.  
  3. Tighten the countershaft locknut to a torque of 80 ft. lbs. (110 Nm).
  4.  

Place the countershaft assembly in a soft jawed vise before tightening the locknut.

  1. Measure and record the clearance between the Super-low gear and thrust washer. The service limit is 0.0072 in. (0.18mm).
  2.  
  3. If the clearance is out of specifications, select the appropriate thrust washer or spacer collar for the correct clearance.
  4.  
  5. Measure the clearance between the 2nd gear and 3rd gears. The service limit is 0.0072 in. (0.18mm).
  6.  
  7. If the clearance is out of specifications, select the appropriate thrust washer or collar for the correct clearance.
  8.  

Transfer Driven Gear
DISASSEMBLY

See Figures 8 and 9



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Fig. Fig. 8: Transfer driven gear assembly-4WD Wagon

  1. Slide the driven gear assembly into the clutch housing and secure with retaining bolts, if the unit had previously been removed.
  2.  
  3. Hold the companion flange with a flange holding tool and remove the locking nut with the proper socket.
  4.  
  5. Remove the tool and the companion flange. Remove the driven gear from the housing by tapping on the driven gear shaft.
  6.  
  7. Remove the inner driven gear bearing from the driven gear shaft, using a bearing puller tool.
  8.  
  9. Pry the oil seal from the transfer rear cover. Remove the bearing races from the transfer rear cover as required.
  10.  
  11. To reassemble, press the inner and outer bearing races into the housing.
  12.  
  13. To check the gear preload, special tools are needed. However, the following procedure can be used.
    1. Assemble the following components in the transfer rear cover, the new transfer spacer, the drive gear, companion flange the lockwasher and the locknut.
    2.  

  14.  

Install the lockwasher with the dished side towards the companion flange.

    1. Temporarily install the driven gear assembly and the retaining bolts in the transfer case.
    2.  
    3. To measure the preload, tighten the locknut to the specified torque of 87 ft. lbs. (120 Nm), using the flange holder tool and the proper socket and wrench combination.
    4.  
    5. Remove the driven gear assembly from the transfer case and position the assembly in a vise with protective jaws. Measure the preload.
    6.  
    7. Measure the preload by first turning the companion flange several times to assure normal bearing to race contact. Rotate the shaft assembly with the appropriate torque wrench.
    8.  
    9. The preload should be 7.0-9.5 inch lbs. (0.8-1.1 Nm). Replace the transfer spacer with a new spacer and readjust. Do not attempt to adjust the preload by loosening the locknut.
    10.  
    11. If the preload is less than 7.0 inch lbs. (0.8 Nm), adjust by tightening the locknut a little at a time until the proper preload is achieved.
    12.  
    13. Replace the transfer spacer with a new one if the preload is still outside the specified limits when the locknut is tightened to 166 ft. lbs. (230 Nm).

      Click image to see an enlarged view

      Fig. Fig. 9: Installing the transfer gear housing, apply sealant to the dotted line area-4WD Wagon

    14.  


ASSEMBLY
  1. Apply sealant to the clutch case mating surfaces of the transfer case.
  2.  

The transaxle uses no gaskets between the major housing, depending upon sealant to prevent fluid leakages.

  1. Install the transfer case.
  2.  
  3. Install the following parts, the transfer thrust shim, the drive gear, the drive gear thrust shim and the left side cover.
  4.  
  5. Assemble the following parts: the driven gear thrust shim, the driven gear assembly and the driven gear assembly bolts.
  6.  
  7. Measure the total bearing preload by rotating the companion flange several times to assure normal bearing to race contact. Place the selector lever in the 2WD position and measure the preload with an appropriate torque wrench.
  8.  
  9. The total bearing preload should be 6.1-8.75 inch lbs. (0.7-1.0 Nm). This preload is greater than the preload on the driven gear assembly when tested alone. Example: If the preload of the driven assembly alone was 7.9 inch lbs. (0.9 Nm), the total bearing preload should be between 14-16 inch lbs. (1.6-1.9 Nm).
  10.  
  11. If the preload is outside of the specifications, adjust it by replacing the transfer thrust shim.
    1. If the total bearing preload is less than specifications, reduce the size of the transfer thrust shim.
    2.  
    3. If the total bearing preload is more than specifications, increase the size of the transfer thrust shim.
    4.  

  12.  

BACKLASH INSPECTION

See Figure 10



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Fig. Fig. 10: Backlash can be checked by a dial indicator

  1. Shift the selector lever to the 2WD position.
  2.  
  3. With the drive shaft disconnected, check the backlash at the companion flange with the use of a dial indicator mounted to the transaxle case.
  4.  
  5. Measure the backlash, turn the companion flange 180° and remeasure. The standard measurement is 0.004-0.006 in. (0.10-0.15mm).
  6.  
  7. If the backlash is out of specifications, the driven gear thrust washer must be changed. Proper tooth contact must be retained after the backlash adjustment has been completed.
  8.  
  9. To check for proper tooth contact, remove the driven gear assembly from the transfer case and paint the driven gear teeth evenly with Prussian Blue or equivalent.
  10.  
  11. Reinstall the driven gear assembly back into the transfer case and tighten the bolts evenly to 20 ft. lbs. (26 Nm).
  12.  
  13. With the selector lever in 2WD, rotate the companion flange one full turn in both directions.
  14.  
  15. Remove the driven gear assembly from the transfer case and note the gear impressions on the gear. The correct tooth contact should be in the center of the tooth face and even between the top of the tooth and the bottom of the tooth.
  16.  
  17. The checking and adjustment of the driven gear assembly must be continued until the proper tooth contact is obtained.
    1. If the tooth pattern shows toe contact, use a thicker drive gear thrust shim and increase the thickness of the transfer thrust shim and increase the thickness of the transfer thrust shim and equal amount.
    2.  
    3. If the pattern of the teeth shows heel contact, too much back lash is indicated. To correct this condition, reduce the thickness of the drive gear thrust shim. The thickness of the transfer thrust shim must also be reduced by the amount by which the drive gear thrust washer shim is reduced.
    4.  
    5. The driven gear thrust shim will have to be changed also to compensate for the change in backlash.
    6.  
    7. To correct face contact (contact too near the tooth edge), use a thicker driven gear thrust shim to move the drive gear away from the drive gear. The backlash should remain within limits.
    8.  
    9. To correct flank contact (contact too near the bottom of the tooth), move the driven gear in towards the drive gear by using a thinner shim for the driven gear, while retaining the correct backlash.
    10.  

  18.  
  19. When the tooth contact and backlash is correct, apply a coating of sealant to the mating surfaces of the clutch and transfer cases. No gaskets are used.
  20.  
  21. Install the thrust shim and the O-ring on the driven gear assembly and install the assembly into the transfer case opening. Tighten the bolts to 20 ft. lbs. (26 Nm). Slide the drive gear thrust shim and drive gear onto the transfer shaft.
  22.  
  23. Place the transfer thrust shim and O-ring on the left side cover and install the cover on the transfer case. Tighten the bolts to 33 ft. lbs. (45 Nm). Remeasure the total bearing preload after the assembly, which should be 6.1-7.9 inch lbs. (0.7-1.0 Nm).
  24.  

TRANSAXLE ASSEMBLY



See Figures 11, 12, 13 and 14

  1. Install the guide plate, dish spring and mainshaft thrust shim in the transaxle housing.
  2.  

Use the correct thrust shim for the mainshaft for the proper thrust clearance.

  1. Install the oil gutter and collect plates in the transaxle housing.
  2.  
  3. Install the transfer shaft assembly and the 2nd/4th selector rod.
  4.  
  5. Install the differential assembly in the clutch housing.
  6.  
  7. Install the bearing on the transfer shaft.
  8.  
  9. Install the super-low/2nd shaft, countershaft assembly and the mainshaft assembly in the clutch housing.
  10.  
  11. Install the super-low shift piece and the shift fork on the super-low shift fork shaft.
  12.  
  13. Assemble the super-low shift fork shaft assembly with the following components:
    1. Ball bearing
    2.  
    3. Flanged spacer collar
    4.  
    5. Super-low/2nd gear
    6.  
    7. Synchronizer hub assembly
    8.  
    9. Needle bearing
    10.  

  14.  
  15. Install the following components into the clutch housing:
    1. Spacer collar
    2.  
    3. Lock washer
    4.  
    5. Thrust washer
    6.  
    7. Thrust needle bearing
    8.  
    9. Super-low/1st gear
    10.  
    11. Needle bearing
    12.  
    13. Spacer collar
    14.  
    15. Super-low/1st shaft
    16.  
    17. Thrust washerAlign the lug on the end of the super-low/1st shaft with the groove in the clutch case. Install the lockwasher with the dished end facing upward.
    18.  

  16.  
  17. Install the reverse shift holder assembly into the clutch housing.
  18.  
  19. Install the reverse shift fork, the 3rd/4th shift fork and the 5th shift fork onto the mainshaft.
  20.  



Click image to see an enlarged view

Fig. Fig. 11: Installing the differential assembly-4WD Wagon



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Fig. Fig. 12: Installing the mainshaft, countershaft and super-low 2nd gear shaft-4WD Wagon

  1. Slide the 5th/Reverse shift fork shaft down through each shift fork.
  2.  

Install the fork shaft with the detent hole facing the countershaft.

  1. Install the 1st/2nd shift fork, the super-low shift piece and the super-low shift lever.
  2.  
  3. Slide the 1st/2nd shift fork shaft through the shift pieces and the shift lever.
  4.  
  5. Install the super-low shift piece bar in the reverse shift holder assembly.
  6.  
  7. Install the reverse idler gear and idler gear shaft in the clutch housing.
  8.  

Install the reverse idler shaft with the threads facing towards the outside.

  1. Apply sealant to the transaxle mating surfaces and install the dowel pins.
  2.  
  3. Install the transaxle housing over the clutch housing and carefully line-up the shafts.
  4.  
  5. Tighten the retaining bolts to 20 ft. lbs. (26 Nm).
  6.  



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Fig. Fig. 13: Installing the transaxle housing, apply sealant around the case edge as shown-4WD Wagon



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Fig. Fig. 14: Transaxle housing bolt torque sequence-4WD Wagon

  1. Install the reverse idler shaft retaining bolt and washer. Install the detent ball, spring, washer and super-low shift detent ball screw. Install the super-low shift lever bolt.
  2.  
  3. Install the circlip in the bore of the transaxle housing.
  4.  
  5. Install the oil seal into the transaxle housing and the oil seal in the clutch housing.
  6.  
  7. Fill with oil and install in the vehicle.
  8.  

 
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