Removal and installation of a manual transmission (Honda Civic 6)

Removal

1. Disconnect the negative cable from the battery.

Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!

2. Remove the resonator, air intake sleeve and air cleaner housing (see Chapter Power and exhaust systems).

3. Disconnect the starter wiring and unscrew the upper bolt securing the latter (see Chapter Engine electrical equipment).



4. Disconnect the gearbox ground bus, the wiring of the reverse light switch sensor (see Checking and replacing the reverse light switch sensor) and speed sensor (see accompanying illustration).

5. Loosen the hub nuts securing the drive shafts (see Chapter Clutch and drive shafts). Loosen the front wheel nuts. Jack up the car and place it on supports. Remove the front wheels.

6. If equipped, remove the crankcase guard.

7. Remove the exhaust system crank section that runs under the gearbox (see Chapter Power and exhaust systems).

8. Drain the transmission oil (see Chapter Routine maintenance).



9. Disconnect the shift drive rod and the gear shift lever reaction rod from the gearbox (see Removal and installation the gear shift rod).

10. Remove the union nut connecting the hydraulic hose of the clutch drive to the pressure hydraulic line. Remove the pressure line and the clutch slave cylinder with the push rod (see Chapter Clutch and drive shafts).

Caution! Try not to bend or twist the pressure line. Do not depress the clutch pedal with the slave cylinder removed.

11. Remove the drive shafts (see Chapter Clutch and drive shafts).



12. If equipped, remove the powertrain stiffener (see accompanying illustration).

13. Remove the mounting bolts and access cover from the clutch dome.

14. Loosen the distributor mounting bolt. Attach the slings to the cylinder head and hang the engine on winches, relieving the load on the gearbox supports.

15. If equipped, remove the splash shield.

16. Support the transmission with a jack (if possible special), securing it to the head of the latter with a safety chain.

Note: Special transmission attachments are available for the floor jack head. Raise the gearbox, completely relieving its supports.

17. Loosen the nuts and bolts securing the right support of the manual transmission (see accompanying illustration).



18. Remove the four upper bolts securing the gearbox to the engine (see accompanying illustration).



19. Loosen the bolts of the brackets for fastening the hydraulic lines of the clutch drive (see accompanying illustration).



20. Remove the lower rear transmission-to-engine mounting bolt located directly above the right drive shaft.



21. Remove the lower transmission-to-engine mounting bolt and the support bracket bolts (see accompanying illustration).

22. Finally, make sure that all lines and wiring are disconnected, then, moving the jack, carefully separate the manual transmission from the engine.

23. Having completely released the primary shaft of the manual transmission from the clutch assembly, remove the transmission from under the vehicle.

24. After removing the gearbox, access to the clutch components is opened, the condition of which, taking advantage of the opportunity, should be checked immediately. Usually, when removing the manual transmission, it is customary to replace the clutch (see Chapter Clutch and drive shafts).

Installation

1. If removed, reinstall the clutch components (see Chapter Clutch and drive shafts).

2. Make sure the two guide pins are in place. Secure the transmission to the jack as you did during disassembly and carefully slide it under the car, lifting it into its normal position. Carefully engage the input shaft with the splines of the driven disk hub. Do not force it under any circumstances – if the input shaft does not engage the hub, adjust the angle of the gearbox and turn the shaft slightly to ensure the splines are correctly aligned.



3. Screw in the bolts securing the manual transmission to the engine, as well as the bolts of the rear bracket. Tighten the fasteners to the required torque.

4. Screw in the three upper bolts securing the gearbox to the engine, as well as the lower bolt securing the starter. Tighten the fasteners to the required torque.

5. Raise the gearbox slightly on the jack, install the bolt and nuts securing the right assembly support bracket. Tighten the fasteners to the required torque.

6. Install the front locking bracket and tighten its mounting bolts to the required torque.

7. If so equipped, install the splash shield. Tighten the fasteners to the required torque.

8. Disconnect the lifting rigging and screw the distributor mounting bolt back into place.

9. Install the clutch dome inspection hole cover. If equipped, install the powertrain stiffeners. Tighten the fasteners to the required torque.

10. Further installation is carried out in the reverse order of dismantling.

11. Fill the gearbox with the required amount of transmission oil of the required grade (see Chapter Routine maintenance).

12. Bleed the clutch hydraulic system

13. Perform road tests of the vehicle, checking the correct operation of the manual transmission. Inspect the power unit for signs of fluid leaks.