Repair Procedure

NOTE:
Make sure the work surface and the CVT are completely clean. Use lint-free towels, and use a dedicated, clean solvent tank for cleaning the CVT parts. If you do not keep everything very clean, the repair may not be successful.





1. Soak the new start clutch assembly in Honda ATF-Z1 for at least 30 minutes.

2. Remove the transmission from the vehicle. See page 14-304 of the 1996-00 Civic Service Manual.

3. Cover with clean shop towels all of the openings in the transmission and anything else that might get damaged by water and cleaning chemicals (axle openings, breather, and electrical connectors). Clean all the dirt and grease off of the transmission before you start disassembly.

4. Place the transmission on a work bench with the flywheel housing facing upward.





5. Remove the ATF passage line holder from the flywheel housing.





6. Remove the flywheel housing (20 bolts).





7. Remove the differential assembly from the transmission case.

8. Remove the ATF passage line assembly.

9. Remove the park pawl shaft, then remove the park pawl and spring.

10. Remove the park rod holder.





11. Remove the snap ring, the cotter retainer, and the cotters from the start clutch assembly.





12. Remove the start clutch assembly with the special tool.





13. Remove the start clutch assembly from the hub. Clean the hub and then lubricate it with ATF-Z1 and then install the new start clutch assembly from the kit.





14. Lubricate the 0-rings with ATF-Z1. Replace the three 0-rings on the driven pulley shaft with new ones from the kit.

15. Place the new start clutch assembly on the driven pulley shaft.





16. Seat the start clutch assembly by aligning the tip of the special tool with the shaft hole and then pushing down the handle.





17. While holding the handle down, push down the bottom part of the tool, on the bottom, until it contacts the seating surface of the start clutch assembly.





18. Use a 19 mm wrench to hold the upper hexagonal section of the special tool. Use an adjustable wrench to tighten the lower hexagonal section until the gear seats.

19. Remove the special tool.





20. Assemble the cotters into the channel in the driven pulley shaft, then measure the clearance between the cotter and the start clutch guide. Measure the clearance at three locations, and then average them. Is the average clearance 0 to 0.13 mm?

^ Yes - Go to step 22.

^ No - Go to step 21.





21. Select the appropriate cotter from the table shown, and adjust the clearance.

22. Install the cotter retainer and the snap ring.





23. Assemble the park pawl, the spring, the shaft, and the park rod holder.

24. Install the ATF passage line assembly with two new 0-rings.

25. Install the differential assembly.

26. Install the flywheel housing with a new gasket. Torque the bolts to 29 N.m (22 lb-ft). Install a new 0-ring onto the ATF passage line holder assembly, and install the assembly into the flywheel housing.





27. Remove the ATF pan (14 bolts). Remove the two dowel pins so they don't fall out and get lost.

28. Remove the ATF strainer (two bolts) and the solenoid harness connector (one bolt).





29. Remove the lower main valve body (eight bolts). Remove the three long dowel pins that locate the lower main valve body assembly. Note the locations of the dowel pins.





30. Place the lower main valve body on the bag the replacement solenoid came in. Disconnect the 2P connector from the start clutch control solenoid. Remove the start clutch control solenoid (four bolts). Note the locations of the dowel pins, the filter, and the separator plate, then remove them. Discard the start clutch control solenoid.





31. Install the two dowel pins and the filter into the valve body. Install the separator plate onto the valve body. Install the new start clutch control solenoid, making sure you do not pinch the harness. Connect the 2P connector (the connector with the PNK/BLK and YEL wires) to the start clutch control solenoid. Torque all four bolts to 8 N.m (5.9 lb-ft).

32. Install new 0-rings from the repair kit onto the solenoid harness connector and the ATF strainer.

33. Install the three long dowel pins into the lower main valve body, then install the lower main valve body into the transmission case (eight bolts). Torque the bolts to 12 N.m (8.7 lb-ft).

34. Install the ATF strainer (two bolts) and the solenoid harness connector (one bolt). Torque the bolts to 12 N.m (8.7 lb-ft).

35. Install the ATF pan with a new gasket from the repair kit. Torque the bolts to 12 N.m (8.7 lb-ft).

36. Reinstall the transmission into the vehicle. Fill it with 6.8 quarts of Honda ATF-Z1 fluid.

37. Disconnect the two PCM connectors, loosen the lower and right side mounting bolts, remove the left side mounting bolt, and remove the PCM. See page 11-83 of the 1996-00 Civic Service Manual.

35. Install the new PCM in the reverse order of removal.

39. Perform the Start Clutch Calibration Procedure for '97-00 Models on page 14-293 of the 1996-00 Civic Service Manual. Follow the 1997-00 Model procedure for both years; the new PCM has the auto learning mode.

40. Check the fluid level, and refill as needed.