NHTSA ID Number: 10219641
Manufacturer Communication Number: A22-017
TSB/Document Date: 2022-09-14
Summary
Service bulletin - Customer complains that the manual transmission will not shift, the clutch is slipping, or the vehicle won’t move when in gear. Due to supplier production issues, the friction disc material may have prematurely worn.
•
Do not to damage the ball joint boot when installing the ball joint remover.
•
Refer to Ball Joint Removal in the service information or instructions on how to use the tool 07MAC-SL00202.
24.1. Remove the cotter pin.
24.2. Remove the nut.
24.3. Disconnect the tie-rod end ball joint from the knuckle using the ball joint tread protector and the ball joint
remover.
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25. Disconnect the lower stabilizer link ball joint from both sides:
25.1. Remove the flange nuts while holding the respective joint pin with a hex wrench.
25.2. Remove the stabilizer link.
26. Disconnect the lower arm ball joint from both sides:
26.1. Remove the flange nuts.
26.2. Disconnect the lower ball joint from the lower arm.
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27. Remove the lower arm mounting bolts from both sides.
28. Remove the intake air resonator.
29. Remove the torque rod mounting bolt.
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30. Remove the front sub frame:
30.1. Set the subframe adapter (P/N VSB02C000016) on a transmission jack, line up the slots in the arms with the
bolt holes on the corner of the jack base, then tighten the bolts.
30.2. Attach the subframe adapter to the front subframe.
30.3. Remove the front subframe.
31. Support the transmission with a transmission jack.
32. Remove the clutch cover.
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33. Disconnect the driveshaft inboard joint from both sides:
33.1. Pry the inboard joint using a pry bar.
NOTE: Be careful not to damage the oil seal or the end of the inboard joint with the pry bar.
33.2. Remove the driveshaft as an assembly.
NOTE: Do not pull on the driveshaft, or the inboard joint may come apart. Pull the inboard joint straight out to
avoid damaging the oil seal.
33.3. Drive the inboard joint off of the intermediate shaft using a drift punch and a hammer.
33.4. Remove the driveshaft as an assembly.
NOTE: Do not pull on the driveshaft, or the inboard joint may come apart. Pull the inboard joint straight out.
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34. Remove the intermediate shaft.
NOTE: Hold the intermediate shaft horizontal until it is clear of the differential to prevent damaging the oil seal.
35. Remove the lower transmission assembly mounting bolts.
36. Remove the transmission:
36.1. Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate.
36.2. Slowly lower the transmission about 150 mm (5.91 in).
36.3. Make sure that all hoses and harness are disconnected and free from the transmission.
36.4. Lower the transmission.
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37. Remove the pressure plate:
37.1. Install the ring gear holder attachment, the ring gear holder, the clutch alignment tool set, and the 21 mm
clutch alignment pilot.
37.2. Loosen the pressure plate mounting bolts in a crisscross pattern in several steps, then remove the pressure
plate.
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38. Remove the clutch disc, the clutch alignment tool set and the 21 mm clutch alignment pilot.
39. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the
flywheel, the ring gear holder attachment, and the ring gear holder.
40. Remove the release bearing:
40.1. Remove the release fork boot.
40.2. Remove the release fork from the clutch housing by squeezing the release fork set spring. Remove the
release bearing.
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41. Clean the new replacement pressure plate and flywheel with a clean lint-free towel and solvent, wipe off all the
corrosion preventative layers on the pressure plate and flywheel.
NOTE: Do not spray the flywheel with spray cleaners, doing so may cause damage to the dual mass flywheel
bearing.
42. Install the new flywheel:
42.1. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
42.2. Install the ring gear holder attachment and the ring gear holder.
42.3. Torque the flywheel mounting bolts in a crisscross pattern in several steps.
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43. Install the new clutch disc:
43.1. Apply super high temp urea grease (P/N 08798-9002) to the splines of the clutch disc.
NOTE: Wipe off any excess grease.
43.2. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc
slides freely on the mainshaft.
43.3. Install the clutch disc facing its surface marked with a T/M SIDE to the transmission side using the clutch
alignment tool set and the 21 mm clutch alignment pilot.
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44. Install the new pressure plate:
44.1. Install the pressure plate and the pressure plate mounting bolts finger-tight while aligning the point marks
across the pressure plate and the flywheel as shown.
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44.2. Torque the pressure plate mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent
warping the diaphragm spring. Make sure that there is not clearance between the pressure plate and the
flywheel.
Specified Torque: 26 N·m (2.7 kgf·m, 19 lbf·ft)
44.3. Remove the ring gear holder attachment, the ring gear holder, the clutch alignment tool set, and the 21 mm
clutch alignment pilot.
44.4. Make sure the diaphragm spring fingers are all the same height.
44.5. Do the release bearing inspection and replace it if necessary.
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45. Install the new release bearing:
45.1. Apply super high temp urea grease (P/N 08798-9002) to the release fork, the release fork bolt, the release
bearing, and the release bearing guide in the shaded areas.
NOTE:
•
The release bearing is packed with grease. Do not wash it in solvent.
•
Do not use silicone grease.
•
Replace the release fork bolt if necessary.
45.1. Set the release fork set spring.
45.2. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft
while inserting the release fork through the hole in the clutch housing.
45.3. Align the detent of the release fork with the release fork bolt, then press the detent of the release fork over the
release fork bolt squarely.
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45.4. Install the release fork boot. Make sure the boot seals around the release fork and clutch housing.
45.5. Move the release fork right and left to make sure that it fits properly against the release bearing and that the
release bearing slides smoothly. Wipe off any excess grease.
46. Install the transmission:
46.1. Make sure the two dowel pins are undamaged and installed in prescribed holes on the clutch housing as
shown. Replace the dowel pins if they are damaged.
46.2. Place the transmission on the transmission jack and raise it to the engine level.
46.3. Align the transmission mainshaft and the clutch pressure plate.
46.4. Move the transmission inward until there is no clearance between the transmission housing and the engine
block.
NOTE: Do not use the lower transmission bolts to move the transmission housing closer to the engine block
.
46.5. Install the lower transmission assembly mounting bolts.
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47. Install the intermediate shaft:
NOTE: Do not wash the rubber parts with solvent.
47.1. Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent, then dry them
with compressed air.
47.2. Hold the intermediate shaft horizontal when installing it into the differential to prevent damaging the oil seal.
48. Connect the inboard driveshaft joints on both sides.
Right Driveshaft:
48.1. Apply 0.5–1.0 g (0.018–0.035 oz) of UM246 (P/N 41211-PY5-305) to the whole splined surface of the right
driveshaft.
48.2. After applying grease, remove the grease from the splined grooves at intervals of 2–3 splines and from the set
ring groove so that air can bleed from the intermediate shaft.
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Left Driveshaft:
48.1. Clean the areas where the driveshaft contacts the differential thoroughly with solvent, then dry them
compressed air.
NOTE: Do not wash the rubber parts with solvent.
48.2. Replace the set ring.
48.3. Insert the inboard end of each driveshaft into the differential or the intermediate shaft until the set ring locks in
the groove.
NOTE: Insert the driveshaft horizontally to prevent damaging the oil seal.
48.4. Apply about 3 g (0.11 oz) of moly 60 paste (P/N 08734-0001) to the contact area of the outboard joint and the
front wheel bearing. Repeat for the other side.
NOTE: The paste helps prevent noise and vibration.
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48.5. Install the outboard joints into the respective knuckle hub.
48.6. Install the spindle nut.
NOTE:
•
Use a new spindle nut during reassembly.
•
Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut.
•
Tighten the spindle nut to the specified torque during reassembly.
48.7. Stake the spindle nut.
49. Install the clutch cover.
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50. Install the intake air resonator.
51. Install the front subframe:
NOTE:
•
Align the front subframe with the subframe alignment pin.
•
Align the front subframe in the following sequence.
51.1. Lift the front subframe up to the body, and loosely install the new subframe mounting bolts and the new front
subframe rear stay mounting bolts.
51.2. Insert the subframe alignment pin through the positioning hole on the right rear subframe, and into the
positioning hole on the body, then loosely tighten the subframe right rear mounting bolt.
51.3. Insert the subframe alignment pin through the positioning hole on the left rear subframe, and into the
positioning hole on the body, then loosely tighten the subframe left rear mounting bolt.
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51.4. Tighten the subframe mounting bolts to the specified torque in the numbered sequence as shown. Use the
subframe alignment pin when tightening the rear side subframe mounting bolts.
51.5. Check all of the subframe mounting bolts, and retighten if necessary.
51.6. Tighten the front subframe rear stay mounting bolts to the specified torque.
52. Loosely install the torque rod mounting bolt.
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53. Install the front brace A or B depending on trim level:
NOTE:
•
Before installing the front brace, be sure the collar bolt can be screwed/unscrewed lightly by hand, and then
screw them into the space adjuster fully by hand. Do not tighten them with any tools.
•
Before installing the front brace, screw the special bolt into the collar bolts, and check that they turn together. If
they do not turn together, replace the bolts.
•
After setting the front brace in the body, install all of the mounting bolts, but do not tighten them. First tighten the
bolt. Next, tighten the bolt. Then tighten the bolts. As you tighten the bolts, the collar bolts screw out of the
space adjuster until they contact the body. Continue tightening the bolts to the specified torque.
Front Brace A
53.1. Install the inner bolts.
53.2. Install the outer bolts.
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Front Brace B
53.1. Install the bolts.
54. Install the lower arm bolts on both sides.
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55. Connect the lower arm ball joints on both sides.
NOTE:
•
Use the new flange nuts.
•
Tighten the flange nuts in the sequence shown.
55.1. Insert the lower ball joint into the lower arm. Install the flange nuts.
56. Connect the lower stabilizer link ball joints on both sides:
56.1. Install the stabilizer link.
56.2. Install the new flange nuts, then tighten them to the specified torque while holding the respective joint pin with
a hex wrench.
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57. Connect the lower stabilizer link ball joints on both sides:
57.1. Wipe off any grease contamination from the ball joints tapered section and threads.
57.2. Connect the tie-rod ball joints to the knuckle.
57.3. Install the nuts and tighten them to the specified torque.
57.4. Install new cotter pins.
NOTE: Bend the cotter pin as shown.
58. Connect the EPS subharness.
59. Install exhaust pipe A.
NOTE: Use new gaskets and new self-locking nuts when reassembling.
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60. Loosely install the transmission mount and install the ground cable.
61. Install the upper transmission assembly mounting bolts.
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62. Remove the engine support hanger:
62.1. Remove the engine support hanger.
62.2. Remove the universal lifting eyelet.
62.3. Install the front damper caps.
63. Engine and transmission mount tightening procedures:
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64. Install the intake manifold bracket.
65. Install the change wire bracket:
65.1. Install the change wire bracket with the change wires.
NOTE:
•
Do not wipe off the grease of the change wire ends.
•
Tighten the bolts in the numbered sequence shown to the specified torque.
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65.2. Install the lock pins.
65.3. Connect the connector.
66. Install the engine wire harness (engine side) on both sides:
66.1. Install the harness brackets and the harness covers.
66.2. Install the ground cables.
66.3. Connect the connectors, and make sure they are fully seated.
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67. Install the engine wire harness (transmission side), bracket and connect the connector.
68. Install the slave cylinder:
68.1. Install the clutch line brackets.
NOTE: Be careful not to bend the clutch line.
68.2. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the push rod of the slave cylinder.
68.3. Install the slave cylinder.
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69. Install the intake air duct E & F.
NOTE: Make sure the end of hose band is aligned with the mark on the hose band after the parts are installed.
70. Install the 12 Volt battery:
70.1. Install the harness holder.
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70.2. Install the PCM Harness Bracket.
70.3. Install the battery base.
NOTE: tighten the mounting bolts in the numbered sequence shown.
70.4. Install the battery box.
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70.5. Install the 12 volt battery insulator, the 12 volt battery and the 12 volt battery setting plate.
70.6. Clean the 12 volt battery terminals, connect the positive terminal to the 12 volt battery. Then, connect the
negative terminal to the 12 volt battery.
NOTE:
•
Always connect the positive side first.
•
Do not hold the connector when conecting the negative terminal.
70.7. Apply multipurpose grease to the terminals to prevent corrosion.
70.8. Close the cover.
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70.9. Install the baffle plate.
71. Install the Front Grille Cover.
72. Connect the Steering Joint:
72.1. Set the rack in the straight ahead driving position.
72.2. Cut the wire.
72.3. Slip the lower end of the steering joint onto the pinion shaft.
NOTE:
•
Pinion shaft with center guide: Install the steering joint by aligning the center guide.
•
Pinion shaft without center guide: Position the steering column by aligning the gap within the angle.
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72.4. Align the bolt hole on the steering joint with the groove around the pinion shaft.
72.5. Loosely install the steering joint bolt.
72.6. Be sure that the joint bolt is securely in the groove in the pinion shaft.
72.7. Pull on the steering joint to make sure that the steering joint is fully seated.
72.8. Tighten the steering joint bolt to the specified torque.
72.9. Install the steering joint cover.
NOTE: Check the steering joint cover for damage and cracks. If the steering joint cover is cracked, replace the
steering joint cover.
73. Refill the transmission:
73.1. Remove the oil check bolt.
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73.2. Remove the filler plug.
73.3. Refill the MTF through the filler plug hole on the transmission, until the MTF overflows from the oil check bolt
hole. Always use Honda Manual Transmission Fluid (MTF).
Fluid Capacity:
2.0 L (2.1 US qt)
73.4. After the fluid stops overflowing, install the oil check bolt with a new 6 mm sealing washer.
73.5. Clean any dirt and oil from the sealing surface of the filler plug and the transmission housing.
73.6. Apply liquid gasket (P/N 08718-0003, 08718-0004, or 08718-0009) to the threads of the filler plug. Install the
filler plug within 5 minutes of applying the liquid gasket.
73.7. Install the filler plug.
NOTE: If the Maintenance Minder required to replace the MTF, reset the Maintenance Minder with the gauge
(see "Resetting the Maintenance Minder"). If the Maintenance Minder did not require to replace the MTF, reset
the Maintenance Minder with the HDS (see "Resetting the Individual Maintenance Items").
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74. Install the engine undercover.
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75. Install the PCM:
75.1. Connect connectors to the PCM.
75.2. Tighten the bolts.
76. Install the front wheels.
77. Check that the transmission shifts into all gears smoothly.
78. Check Wheel Alignment, Refer to 2016-2021 Civic Wheel Alignment in service information.
79. Check VSA Sensor Neutral Position:
79.1. Connect iHDS
NOTE: Do not press the brake pedal during this procedure.
79.2. Set the steering wheel in the straight-ahead position.
79.3. Select the ADJUSTMENT from the ABS/TCS/VSA menu with the HDS, then select ALL SENSOR, and follow
the screen prompts.
80. Test drive vehicle.
END
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TSB/Document ID: A22-017
Replacement Service Bulletin Number:
MFR Communication Date: 2022-09-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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