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

L3 Series Transaxle

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BEFORE DISASSEMBLY



See Figure 1

Cleanliness is an important factor in the overhaul of the manual transaxle. Before opening up the 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 assembly-L3 series transaxle

TRANSAXLE DISASSEMBLY



See Figures 2 through 6

  1. Remove the reverse light switch.
  2.  



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Fig. Fig. 2: Remove these components from the transaxle case-L3 series transaxle

  1. Remove the cable bracket.
  2.  
  3. Remove the breather tube.
  4.  
  5. Remove the bolts attaching the transaxle housing to the clutch housing.
  6.  
  7. Remove the 32mm sealing bolt.
  8.  
  9. Reach into the hole and expand the countershaft ball bearing snapring, removing it from the groove.
  10.  
  11. Separate the transaxle housing from the clutch housing.
  12.  
  13. Remove the thrust shim and oil guide plate from the transaxle housing.
  14.  



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Fig. Fig. 3: Measure the shift fork clearance before removing the fork-L3 series transaxle

  1. Before removing the reverse shift fork, measure the clearance between the reverse shift fork and the shift piece pin. The specification is 0.002-0.020 in. (0.05-0.50mm). If not within specification, measure the width of the L-groove in the reverse shift fork. The maximum width is 0.285 in. (7.25mm). Replace the fork if the width exceeds the specification.
  2.  
  3. Measure the clearance between the reverse idler gear and the reverse shift fork. The specification is 0.020-0.071 in. (0.50-1.8mm). If not within specification, remove the fork and measure the distance between the shift fork pawls. The specification is 0.500-0.512 in. (12.7-13.0mm). Replace the shift fork if the pawl spread is too wide.
  4.  
  5. Remove the reverse shift fork if not already removed in the previous step. Remove the reverse idler shaft and reverse idler gear from the clutch housing.
  6.  
  7. Remove the interlock guide bolt from under the clutch housing.
  8.  



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Fig. Fig. 4: Removing the mainshaft and countershaft-L3 series transaxle



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Fig. Fig. 5: Removing the shift forks-L3 series transaxle

  1. Remove the mainshaft and countershaft assemblies together with the shift forks and shafts.
  2.  
  3. Remove the differential assembly.
  4.  
  5. Remove the plug bolt and 1st/2nd select spring. Remove the reverse lock cam and magnet.
  6.  
  7. Remove the shift arm B and shift arm C attaching bolts.
  8.  
  9. Remove the shift arm shaft, reverse selector spring, reverse return selector, shift arm C, interlock, shift arm B, steel ball, spring and spring collar. Inspect all parts for wear and damage, especially the shift rod detents.
  10.  
  11. Remove the shift am A attaching bolt, spring bolt, spring and steel ball.
  12.  
  13. Remove the shift rod and boot from the clutch housing.
  14.  



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Fig. Fig. 6: Removing the shift rod assembly-L3 series transaxle

  1. Remove shift arm A.
  2.  
  3. If damaged, remove the countershaft needle bearing and oil guide plate from the clutch housing using the adjustable bearing remover 07736-A01000A and a slide hammer.
  4.  
  5. Remove the mainshaft bearing and oil seal from the clutch housing.
  6.  
  7. Remove the differential oil seals.
  8.  

COMPONENT DISASSEMBLY AND ASSEMBLY



Shift Fork Shafts
DISASSEMBLY

Do not lose the spring loaded detent parts while disassembling the shift forks and shafts.

  1. Remove the roll pin from the shift piece.
  2.  
  3. Remove the 5th and 3rd/4th shift forks from the shaft.
  4.  
  5. Remove the shift piece from the shaft.
  6.  
  7. Remove the roll pin and remove the 1st/2nd shift fork from its shaft.
  8.  

INSPECTION
  1. Inspect the shift fork bores for scoring and excessive wear.
  2.  
  3. Inspect the shift fork pawls for cracks and wear.
  4.  
  5. Inspect the shafts for scoring, damage and excessive wear. Pay special attention to the detent groves.
  6.  
  7. Inspect the detent balls for wear and the springs for rust and deformation.
  8.  

ASSEMBLY
  1. Install the 1st/2nd shift fork on its shaft. Install the roll pin.
  2.  
  3. Install the shift piece on the shaft.
  4.  
  5. Install the 5th and 3rd/4th forks on the shaft.
  6.  
  7. Install the roll pin.
  8.  

Mainshaft Assembly
CHECKING CLEARANCES

See Figures 7 and 8

Before disassembling the mainshaft assembly, perform the following measurements. If any measurement is not within specifications, disassemble the mainshaft assembly and replace parts as required.

If all measurements are within specifications, there is no reason to disassemble the mainshaft assembly, providing there is no damage to any of its components.



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Fig. Fig. 7: Mainshaft thrust shim selection chart-L3 series transaxle



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Fig. Fig. 8: Measuring the mainshaft thrust-L3 series transaxle

  1. Push down on the bearing race with a suitable socket and measure the clearance between 2nd and 3rd gears. The specification is 0.002-0.013 in. (0.06-0.33mm). If not within specifications, disassemble the mainshaft and check the thickness of 3rd gear. If the thickness of 3rd gear is within specification, replace the 3rd gear synchro hub.
  2.  
  3. Measure the clearance between 4th gear and the spacer collar. The specification is 0.002-0.012 in. (0.06-0.31mm). If not within specifications, disassemble the mainshaft and inspect 4th gear and the spacer collar. If the 4th gear portion of the spacer collar is within specification, check the thickness of 4th gear. If the thickness of 4th gear is within specification, replace the 4th gear synchro hub.
  4.  
  5. If the vehicle is a five-speed, measure the clearance between 5th gear and the spacer collar. The specification is 0.002-0.012 in. (0.06-0.30mm). If not within specifications, disassemble the mainshaft and inspect 5th gear and the spacer collar. If 5th gear portion of the spacer collar is within specification, check the thickness of 5th gear. If the thickness of 5th gear is within specification, replace the 4th gear synchro hub.
  6.  

DISASSEMBLY
  1. Remove the ball bearing from the end of the mainshaft.
  2.  
  3. Remove the 5th synchro hub, sleeve, spring and ring, if equipped.
  4.  
  5. Remove 5th gear, if equipped.
  6.  
  7. Remove the needle bearing (five-speed) or collar (four-speed), spacer collar and the needle bearing.
  8.  
  9. Remove 4th gear.
  10.  
  11. Remove the 3rd/4th synchro ring, spring, hub, sleeve, ring and spring.
  12.  
  13. Remove 3rd gear and the needle bearing.
  14.  

INSPECTION
  1. Inspect the needle bearings for wear or damage.
  2.  
  3. Inspect the inside of the synchro rings for wear.
  4.  
  5. Install each hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
  6.  
  7. Inspect the synchro ring teeth and matching teeth on the gears for wear in the form of rounding.
  8.  
  9. Inspect the gear hub thrust and cone surfaces for wear.
  10.  
  11. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
  12.  
  13. Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is 0.016-0.046 in. (0.40-1.18mm). Remove the ring from the gear.
  14.  
  15. Inspect the splines and gear teeth on the mainshaft for damage or excessive wear.
  16.  
  17. Inspect the oil passages for clogging.
  18.  
  19. If the clearance between 2nd and 3rd gears was not within specification, measure the thickness of 3rd gear from the flat side to the top of the coned side. The specification is 1.187-1.192 in. (30.15-30.27mm). If the reading is not within specification, replace the gear; if it is within specification, replace the synchro hub.
  20.  
  21. If the clearance between 4th gear and the spacer collar was not within specification, measure the length of the 4th gear half of the spacer collar. The specification is 1.080-1.081 in. (27.41-27.46mm). If the reading is not within specification, replace the spacer collar; if it is not within specification, measure the thickness of 4th gear from the flat side to the top of the coned side. The specification is 1.183-1.188 in. (30.05-30.17mm). If the reading is not within specification, replace the gear; if it is within specification, replace the synchro hub.
  22.  
  23. If the clearance between 5th gear and the spacer collar was not within specification, measure the length of the 5th gear half of the spacer collar. The specification is 0.926-0.928 in. (23.51-23.56mm). If the reading is not within specification, replace the spacer collar; if it is not within specification, measure the thickness of 5th gear from the flat side to the top of the coned side. The specification is 1.116-1.121 in. (28.35-28.47mm). If the reading is not within specification, replace the gear; if it is within specification, replace the synchro hub.
  24.  
  25. Measure the outer diameter of the ball bearing contact area above the 5th gear synchro hub splines. The specification is 0.863-0.866 in. (21.93-22.00mm).
  26.  
  27. Measure the outer diameter of the 5th gear needle bearing contact area. The specification is 1.060-1.063 in. (26.93-27.00mm).
  28.  
  29. Measure the outer diameter of the 4th gear needle bearing contact area. The specification is 1.336-1.339 in. (33.93-34.00mm).
  30.  
  31. Measure the outer diameter of the ball bearing contact area below 1st gear. The specification is 1.020-1.023 in. (25.92-29.00mm).
  32.  
  33. Inspect the mainshaft for runout. The maximum allowable runout is 0.0020 in. (0.05mm). Replace the mainshaft if any measurement is not within specifications.
  34.  

ASSEMBLY

If the selective mainshaft shims located above the oil guide plate in the transaxle housing are to be changed, do not assemble the mainshaft until that procedure is completed.

  1. Install the needle bearing and 3rd gear.
  2.  
  3. Install the 3rd/4th synchro spring, ring, sleeve, hub spring and ring.
  4.  
  5. Install 4th gear.
  6.  
  7. Install the first needle bearing, spacer collar and second needle bearing (five-speed) or collar (four-speed).
  8.  
  9. Install 5th gear, if equipped.
  10.  
  11. Install the 5th synchro ring, spring, sleeve and hub, if equipped.
  12.  
  13. Install the ball bearing.
  14.  

MAINSHAFT SHIM SELECTION
  1. If they have not already been removed, remove the thrust shim(s), and oil guide plate from the transaxle housing.
  2.  
  3. Install the 3rd/4th synchro hub, spacer collar, 5th synchro hub (five-speed) or collar (four-speed) and ball bearing on the mainshaft. Make sure the clutch side ball bearing is not installed on the mainshaft. Install the assembly in the transaxle case.
  4.  
  5. Measure the distance between the end of the transaxle case and the top of mainshaft 1st gear. Make the measurement at three places, average the results and record the final answer.
  6.  
  7. Install the clutch housing side bearing (without the spring washer) into the mainshaft and install the clutch housing on the transaxle housing temporarily. Measure the distance between the end of the clutch housing and the bearing inner race. Make the measurement at three places, average the results and record the final answer.
  8.  
  9. To select the proper shim(s), use the following formula: Step 3 + Step 4-0.95 = shim thickness. Select a shim or combination of shims that is equal to or close to the answer to the formula.
  10.  

Do not use more than 2 thrust shims.

CHECKING THRUST CLEARANCE
  1. Install the selected shim(s) in the transaxle case.
  2.  
  3. Install the spring washer on the mainshaft, concave side facing mainshaft 1st gear.
  4.  
  5. Install the mainshaft in the clutch housing.
  6.  
  7. Clean all dirt from the mating surfaces of the transaxle and clutch housings and install the transaxle housing to the clutch housing with several bolts spaced evenly around the housing.
  8.  
  9. Tap the mainshaft with a plastic hammer.
  10.  
  11. Install the collar and shaft holder of the mainshaft thrust clearance inspection tool 07GAJ-PG20101 to the mainshaft and tighten the three Allen bolts into the groove below the splines. Make sure they are positioned correctly and not digging into the splines. First, turn the bolt on the thinnest side of the tool just enough to keep the tool away from the splines. Then turn the remaining bolts equally to secure the tool off center.
  12.  
  13. Position a dial indicator so the pin rests on the outer circumference of the tip of the mainshaft.
  14.  
  15. Turn the bolt clockwise and read the clearance.
  16.  

Do not turn the bolt more than 60° after the needle of the dial indicator has stopped increasing.

  1. The clearance specification is 0.0043-0.0071 in. (0.11-0.18mm). If the clearance is not within specifications, repeat the entire procedure. Do not continue until the correct clearance has been obtained.
  2.  
  3. When the correct clearance has been obtained, disassemble the transaxle and assemble the mainshaft completely.
  4.  

Countershaft Assembly
DISASSEMBLY
  1. Remove the locknut and lockwasher.
  2.  
  3. Remove the ball bearing.
  4.  
  5. Remove the first needle bearing, 5th gear (five-speed) or collar (four-speed), 4th, 3rd and 2nd gears, the friction damper and the second needle bearing.
  6.  
  7. Remove the spacer collar.
  8.  
  9. Remove the first synchro ring, first spring, reverse gear, hub, spring and ring.
  10.  
  11. Remove 1st gear, the friction damper and the needle bearing.
  12.  

INSPECTION
  1. Inspect the needle bearings for wear or damage.
  2.  
  3. Inspect the inside of the synchro rings for wear.
  4.  
  5. Install the hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
  6.  
  7. Inspect the synchro ring teeth and matching teeth on the gears for wear in the form of rounding.
  8.  
  9. Inspect the gear hub thrust and cone surfaces for wear.
  10.  
  11. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
  12.  
  13. Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is 0.016-0.047 in. (0.40-1.16mm). Remove the ring from the gear.
  14.  
  15. Inspect the oil passages in the countershaft for clogging.
  16.  
  17. Measure the outer diameter of the countershaft needle bearing contact area. The specification is 1.180-1.182 in. (29.95-30.02mm).
  18.  
  19. Measure the outer diameter of the 1st gear needle bearing contact area below the splines. The specification is 1.415-1.417 in. (35.93-36.00mm).
  20.  
  21. Measure the outer diameter of the ball bearing surface near the threaded end of the shaft. The specification is 0.982-0.984 in. (24.94-25.00mm).
  22.  
  23. Measure the runout of the countershaft. The maximum allowable runout is 0.0020 in. (0.05mm). Replace the countershaft if any measurement is not within specification.
  24.  

ASSEMBLY
  1. Install the needle bearing, friction damper and 1st gear.
  2.  
  3. Install the synchro ring, spring, hub, reverse gear, spring and ring.
  4.  
  5. Install the spacer collar.
  6.  
  7. Install the needle bearing, the friction damper, 2nd, 3rd, 4th gear and 5th gear (five-speed) or collar (four-speed) and the other needle bearing.
  8.  
  9. Install the ball bearing.
  10.  
  11. Install the lockwasher and locknut. Tighten the locknut to 80 ft. lbs. (110 Nm), loosen it, then retorque it to the 80 ft. lbs. (110 Nm).
  12.  

TRANSAXLE ASSEMBLY



See Figures 9 and 10

  1. Install the new differential seals.
  2.  
  3. Install a new mainshaft bearing oil seal and install the bearing if it was removed.
  4.  
  5. Install the oil guide plate and countershaft needle bearing, if they were removed.
  6.  
  7. Install the shift rod with new boot. Place shift arm A in the clutch housing, then push the shift rod through the shift arm.
  8.  
  9. Install the steel ball, spring, bolt and new shift arm A attaching bolts. Tighten the attaching bolts to 21 ft. lbs. (29 Nm).
  10.  
  11. Install the spring collar, spring and steel ball.
  12.  
  13. Install shift arm B into the interlock.
  14.  
  15. Install the interlock assembly and shift arm C into the clutch housing. Install the shift arm shaft into the clutch housing, aligning the shift arm shaft holes with the holes in the shift arms B and C.
  16.  
  17. Install the reverse lock cam and magnet.
  18.  
  19. Install the differential assembly.
  20.  
  21. Install the spring washer to the bottom of the mainshaft with the concave side facing up and install the mainshaft, countershaft and shift forks together as assembly. Install the tab of the interlock assembly into the notches of the shift fork as the mainshaft and countershaft assemblies are lowered into the clutch housing.
  22.  
  23. Install a new shift arm B attaching bolt and tighten to 21 ft. lbs. (29 Nm).
  24.  
  25. Install the 1st/2nd selector spring and plug bolt and tighten to 40 ft. lbs. (55 Nm).
  26.  
  27. Apply a light coating of sealant, part number 08718-550000, or equivalent to the interlock guide bolt and install in the proper hole under the clutch housing. Tighten the guide bolt to 29 ft. lbs. (41 Nm).
  28.  



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Fig. Fig. 9: Installing the mainshaft and countershaft-L3 series transaxle



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Fig. Fig. 10: Asembling the transaxle case-L3 series transaxle

  1. Install the reverse idler gear and idler gear shaft in the clutch housing.
  2.  
  3. Install the reverse shift holder.
  4.  
  5. Install the oil guide plate and selected shim(s) into the transaxle housing.
  6.  
  7. Thoroughly clean and dry the mating surfaces of the transaxle and clutch housings. Apply sealant, (part number 08718-550000, or equivalent) to the mating surface of the clutch housing.
  8.  
  9. Install the transaxle housing to the clutch housing, being careful to line up the shafts.
  10.  
  11. Install the snapring to the countershaft ball bearing through the hole at the top of the transxle housing.
  12.  
  13. Tighten the bolts in the proper sequence to 21 ft. lbs. (29 Nm).
  14.  
  15. Apply a light coating of sealant, (part number 08718-550000, or equivalent) to the 32mm sealing bolt and install.
  16.  
  17. Connect the breather tube. Install the cable bracket.
  18.  
  19. Install the reverse light switch.
  20.  

 
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