Honda Civic/Del Sol 1996-2000

Manual Transaxle Assembly

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Fig. Exploded view of a Honda manual transaxle

REMOVAL & INSTALLATION



The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery.


WARNING
Use only genuine Honda manual transaxle fluid (MTF)-it is specially formulated for use in Honda transaxles. If Honda MTF is not available, API SG/SJ 10W-30 or 10W-40 motor oil may be used as a temporary lubricant. However, motor oil will cause increased transaxle wear and shifting effort. Refill the transaxle with Honda MTF as soon as possible.

  1. Disconnect the negative and positive battery cables.
  2.  
  3. Remove the resonator, the air cleaner box, and the air intake duct.
  4.  
  5. Disconnect the starter cables and the transaxle ground cable.
  6.  
  7. Disconnect the back-up light switch connection.
  8.  
  9. Move the upper radiator hose out of its bracket.
  10.  
  11. Disconnect the Vehicle Speed Sensor (VSS) connector.
  12.  
  13. Unbolt the clutch fluid line bracket. Unbolt and remove the slave cylinder. It isn't necessary to disconnect the clutch fluid line.
  14.  
  15. Raise and safely support the vehicle. Remove the front wheels.
  16.  
  17. Drain the transaxle fluid.
  18.  
  19. Remove the strut pinch bolt and fork bolt. Disconnect the lower ball joint from the steering knuckle using a ball joint remover.
  20.  
  21. Pry the halfshaft inboard joints out of the transaxle case. Swing the steering knuckles out to free the halfshafts from the transaxle.
  22.  
  23. Tie the halfshafts up and out of the way with wire so that the joints will not be stressed. Tie plastic bags over the inboard joints to prevent damage to the CV-boots and splined shafts.
  24.  
  25. Disconnect the shift rod and extension rod from the transaxle case. Drive the shift rod retaining pin out with a pin punch.
  26.  
  27. Disconnect and remove the front exhaust pipe.
  28.  
  29. Remove the engine-to-transaxle stiffener brackets and the clutch cover plate.
  30.  
  31. Attach a lifting chain to the engine and lift slightly to ease the tension on the mounts.
  32.  
  33. Remove the splash shield from underneath the vehicle.
  34.  
  35. Unbolt and remove the right-front mount/bracket assembly.
  36.  
  37. Place a jack under the transaxle to support its weight.
  38.  
  39. Remove the transaxle side mount and bracket.
  40.  
  41. Remove the starter's lower mounting bolt. Remove the upper three transaxle case bolts.
  42.  
  43. Remove the three rear transaxle mount bracket bolts. Next, remove the lower three transaxle case bolts.
  44.  
  45. Pull the transaxle away from the engine until it clears the mainshaft. Lower the transaxle out of the vehicle Be careful not to bend the clutch hydraulic line.
  46.  

To install:

Use new self-locking nuts and color-coded bolts when installing the transaxle and suspension components.

  1. Apply high temperature grease to the mainshaft splines, release fork contact points, and throw-out bearing. The manufacturer recommends part No. 08798-9002, Honda Super High temp Urea Grease.
  2.  
  3. Place the transaxle on a transaxle jack and raise it to the level of the engine.
  4.  
  5. Align the transaxle and engine. Be sure the transaxle case dowel pins are securely seated, and fit the transaxle onto the engine. Install the upper and lower transaxle case bolts and the 14mm rear mount bolts and washers. Only hand-tighten them at this time.
  6.  
  7. Raise the transaxle and install the side mount. Tighten the upper and lower transaxle case bolts to 47 ft. lbs. (64 Nm). Tighten the 14mm rear mount bracket bolts to 61 ft. lbs. (84 Nm).
  8.  
  9. First, tighten the transaxle side mount bracket nuts and bolt to 47 ft. lbs. (64 Nm). each. Next, tighten the mount bushing bolts to 47 ft. lbs. (64 Nm). Finally, tighten the through-bolt to 54 ft. lbs. (74 Nm).
  10.  
  11. Install the right-front mount/bracket assembly. Use three new 12mm bolt and washers, and tighten them to 47 ft. lbs. (64 Nm). Tighten the two 10mm bolts to 33 ft. lbs. (45 Nm).
  12.  
  13. Install the clutch cover.
  14.  
  15. Install the engine-to-transaxle stiffener brackets and tighten the 8mm bolts to 17 ft. lbs. (24 Nm). Tighten the 10mm bolts to 33 ft. lbs. (44 Nm).
  16.  
  17. Once the transaxle is bolted to the engine, and the transaxle mounts are securely tightened, the engine lifting chain may be removed.
  18.  
  19. Connect the shift rod with a new spring pin and clip. Then, fit the shift rod boot back into place. Connect the torque rod and tighten the bolt to 16 ft. lbs. (22 Nm).
  20.  
  21. Install the front exhaust pipe. Use new self-locking nuts and gaskets. Tighten the rear flange nuts to 16 ft. lbs. (22 Nm). Tighten the front flange nuts to 40 ft. lbs. (54 Nm) for D16Y8 and D16Y7 engines, or 25 ft. lbs. (33Nm) for all others.
  22.  
  23. Install new set rings on the inboard CV joint splines. Install the halfshafts into the transaxle case and intermediate shaft. The inboard joints must snap into place.
  24.  
  25. Connect the lower ball joint and damper fork. Install the front wheels.
  26.  
  27. Install the slave cylinder and clutch pipe stay. Coat the slave cylinder's tip with high temperature grease. Be sure it snaps into the release fork. Tighten the slave cylinder mounting bolts to 16 ft. lbs. (22 Nm).
  28.  
  29. Connect the VSS connector and back-up light switch connectors.
  30.  
  31. Install the wiring harness clamps and starter cables. Install the resonator, air cleaner box, and air intake duct. Fit the upper radiator hose back into its bracket.
  32.  
  33. Lower the vehicle and tighten the strut pinch bolts to 32 ft. lbs. (44 Nm). Tighten the fork bolts to 47 ft. lbs. (65 Nm). Tighten the ball joint castle nuts to 40 ft. lbs. (55 Nm), then tighten them only enough to install new cotter pins.
  34.  
  35. Turn the breather cap so that the arrow with the F mark points toward the front of the vehicle.
  36.  
  37. Refill the transaxle with the Honda MTF fluid.
  38.  
  39. Reconnect the positive and negative battery cables.
  40.  
  41. Bleed the clutch hydraulic system.
  42.  
  43. Check the clutch and transaxle for smooth operation.
  44.  
  45. Check and adjust the front wheel alignment.
  46.  

 
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