Repair Procedure
REPAIR PROCEDURENOTE:
Some steps in this procedure are model-specific. If the vehicle you're working on isn't listed in a model-specific step, go to the next step.
1. Replace the fluid in the CVT with Honda Genuine CVT fluid, not ATF-Z1:
^ Refer to the CVT section of the appropriate service manual, or
^ Online, enter keyword CVT FLUID or ATF, and select CVT Fluid Replacement (CVT) or ATF Replacement (CVT) from the list.
NOTE:
^ Fuzzy metal particles on the drain plug magnet are normal. Remove the particles before you reinstall the plug.
^ To prevent contamination when you refill the CVT, clean the area around the fill hole, and use a clean funnel.
2. Raise the vehicle on a lift until the wheels are off the ground.
3. Start the engine, shift to D, and accelerate to 40 mph.
4. Release the accelerator pedal, and lightly apply the brakes until the wheels stop. Lower the vehicle.
5. Turn the ignition switch to LOCK (0), then check the CVT fluid level within 90 seconds; it should be between the upper and lower HOT marks. Add fluid if needed.
6. Set the parking brake, and block the front wheels.
7. Start the engine, and shift to D. Make sure the A/C is off.
8. With the brake pedal held firmly, press the accelerator pedal to the floor, and release it after 3 seconds. Do not move the shift lever during this step.
9. Shift to N, and release the brake pedal. Increase the engine speed to 3,000 rpm, and hold it for 15 seconds. This allows the start clutch to cool.
10. Repeat steps 8 and 9 with the shift lever in D, then repeat with the shift lever in R.
11. Test-drive the vehicle for 1 mile or more, accelerating from a stop several times. During the drive, calibrate the start clutch by turning on the headlights, and then decelerating from 40 to 20 mph without using the brakes.
^ If the judder is gone, return the vehicle to the customer.
^ If the judder is still there, repeat steps 1 thru 11. If the judder remains after you repeat steps 1 thru 10, go to step 12.
NOTE:
If you can't do the start clutch calibration during the test-drive, do it in the shop using the HDS or the SCS method. The start clutch on 2003 Civic Hybrids can be calibrated only with the driving method and the SCS method.
^ Refer to the CVT section of the appropriate service manual, or
^ Online, enter keyword START, and select CVT Start Clutch Pressure Control Calibration Procedures from the list.
12. Soak a new start clutch assembly in Honda Genuine CVT Fluid for at least 30 minutes prior to installation.
13. Remove the CVT from the vehicle:
^ Refer to Section 14 of the appropriate service manual, or
^ Online, enter keyword TRANS, and select CVT Transmission Removal from the list.
14. With clean shop towels, cover all of the openings in the CVT and anything else that might get damaged by water and cleaning chemicals (axle openings, breather, and electrical connectors). Clean all dirt and grease off the CVT before you disassemble it.
15. Place the CVT on a workbench with the flywheel housing upward.
NOTE:
^ Make sure to keep the CVT and your work surface clean.
^ Use lint-free towels and a clean, dedicated solvent tank to clean CVT parts.
^ If you don't keep everything clean, your repair may not be successful.
16. To avoid input shaft oil seal damage, remove the input shaft seal ring.
17. Civic GX and HX only: Remove the ATF passage line holder from the flywheel housing.
18. Remove the flywheel housing, the dowel pins, and the flywheel housing gasket.
NOTE:
The Civic GX, Civic HX, and Civic Hybrid CVT is shown. The Insight CVT is similar.
19. Remove the differential assembly from the transmission case.
NOTE:
The Civic GX, Civic HX, and Civic Hybrid CVT is shown. The Insight CVT is similar.
20. Remove the park pawl shaft, the park pawl, and the park pawl spring.
21. All models except Insight. Remove the ATF passage line assembly, and discard the two 0-rings.
22. Civic Hybrid only: Remove the final drive shaft, the secondary driven gear, and the thrust shim.
23. Remove the snap ring, the cotter retainer, and the cotters from the start clutch assembly.
24. Remove the start clutch assembly with the special tool.
NOTE:
Make sure the jaws of the special tool engage the park gear, not the start clutch assembly.
25. Remove the hub from the start clutch assembly. Discard the start clutch assembly.
26. All models except Civic GX: Clean the hub, lubricate it with CVT fluid, then install a new seal ring on it.
27. Civic GX only: Discard the hub, lubricate a new hub with CVT fluid, then install a new seal ring on it.
28. Insert the hub into the new start clutch, making sure the hub fully engages all of the clutch discs.
NOTE:
If the hub is not engaged with all of the clutch discs the start clutch will bind.
29. Use CVT fluid to lubricate the new 0-rings for the driven pulley shaft, then install the 0-rings on the shaft.
30. Place the new start clutch assembly and hub onto the driven pulley shaft.
NOTE:
Make sure to hold the gear engaged into the clutch assembly when you install the clutch assembly and hub onto the driven pulley shaft.
31. Seat the start clutch assembly by aligning the tip of the special tool with the shaft hole and then pushing down the handle.
32. While holding the handle down, push down the bottom part of the tool until it contacts the seating surface of the start clutch assembly.
33. Hold the upper hex section of the special tool with a 19 mm wrench, then use an adjustable wrench to tighten the tool's lower nut until the start clutch assembly seats.
34. Remove the special tool.
35. Reach under the start clutch to confirm that the clutch end plate can move up and down slightly (less than 1 mm).
36. Assemble the cotters into the channel in the driven pulley shaft, then measure the clearance between the cotters and the start clutch guide. Measure the clearance at three locations.
^ If the average clearance is 0 to 0.13 mm, go to step 38.
^ If the average clearance is more than 0.13 mm, go to step 37.
37. Remove the cotters, and measure their thicknesses. Then adjust the clearance by selecting additional cotters from the table above.
38. Install the cotter retainer and a new snap ring.
39. Remove the CVT case magnets, clean them, then reinstall them.
40. Civic Hybrid only: Reinstall the final drive shaft, the secondary driven gear, and the thrust shim.
41. Reinstall the park pawl shaft, the park pawl, and the park pawl spring.
NOTE:
The Civic GX, Civic HX, and Civic Hybrid CVT is shown. The Insight CVT is similar.
42. All models except Insight. Reinstall the ATF passage line assembly with two new 0-rings.
43. Reinstall the differential assembly.
44. Reinstall the flywheel housing dowel pins, then reinstall the flywheel housing with a new gasket. Torque the housing bolts to the correct spec below.
^ All models except Insight. Torque the housing bolts to 29 Nm (22 lb-ft).
^ Insight only: Torque the housing bolts to 27 Nm (20 lb-ft).
NOTE:
Do not reuse the old gasket or apply any gasket sealer.
45. Civic GX and HX only: Reinstall the ATF passage line holder to the flywheel housing with a new 0-ring.
46. Make sure the input shaft seal is not damaged, then install a new input shaft seal ring. Apply super high-temp urea grease to the input shaft splines.
47. Reinstall the CVT:
^ Refer to the CVT section of the appropriate service manual, or
^ Online, enter keyword TRANS, and select Transmission Installation from the list.
48. Fill the CVT with the correct amount of Honda Genuine CVT Fluid:
^ Civic GX and HX: 6 quarts
^ Civic Hybrid: 5.3 quarts
^ Insight: 5.8 quarts
49. Civic Hybrid and Insight only: Make sure the IMA battery level gauge shows at least three-quarters charged. If you need to increase the IMA charge, do this:
^ Insight only: Remove the EPS (electronic power steering) fuse from the under-hood fuse/relay box.
^ Start the engine, and run it at 3,500 rpm until the battery level gauge shows at least three-quarters charged.
^ Insight only: Reinstall the EPS fuse.
50. With the engine fully warmed up, test-drive the vehicle to make sure the judder is gone. During the drive, calibrate the start clutch by turning on the headlights, and decelerating from 40 to 20 mph without using the brakes.
51. When you are finished with your test-drive, turn the ignition switch to LOCK (0), then check the CVT fluid level within 90 seconds; it should be between the upper and lower HOT marks. Add fluid if needed.