How to Remove Axles From a '91 Civic

The 1991 Honda civic base model hatchback or sedan came with a 1.5-liter four-cylinder engine and a five-speed manual transmission. Your Civic came with a front wheel drive configuration which means a constant velocity or CV shaft is used to transfer power from the transmission differential to the front wheels. The inboard and outboard CV joints allow the axle shaft to flex and move with the front suspension and wheels while steering without interrupting power flow between the transmission and the front wheels. Any time you remove the axle shaft the circlip and axle nut must be replaced.

Instructions

Draining the Transmission

1

Park the vehicle on a level surface and set the parking brake. Loosen the front wheel lug nuts with a lug wrench. Lift the front of the vehicle into the air and place jack stands under the front sub-frame rails. Lower the vehicle until it rests securely on the jack stands. Remove the front wheel lug nuts and remove the wheel from the vehicle.

2

Examine the passenger side of the transmission just above the fluid pan to locate the transmission drain plug; it has a 3/8-inch drive hole in the middle of it. Examine just to the rear of the passenger side axle to locate the 17 mm fill plug.

3

Remove the transmission fill plug with a 17 mm wrench and place it aside. Place the drive end of a 3/8-inch ratchet into the drain plug and rotate it counterclockwise until loose. Remove the drain plug by hand and allow the fluid to drain into the drain pan.

4

Clean the threads of the drain and fill plug with a wire brush. Remove the washer gaskets from both plugs and replace them with new washers. Apply thread sealant to the drain plug threads and install the drain plug into the transmission. Tighten the drain plug to 29 foot-pounds with a torque wrench.

Axle Removal

5

Straighten the spindle nut cotter pin legs with and remove it with pliers. Locate the staked portion of the nut and place the pointed chisel into the gap. Tap the chisel with a hammer until the nut is unlocked from the axle. Instruct a helper to enter the vehicle and apply the brakes. Set a 32 mm 3/4-inch drive socket over the spindle nut. Install the 3/4-inch drive breaker bar to the 32 mm socket and loosen the nut counterclockwise. Instruct the helper to release the brakes and exit the vehicle when the nut can be removed by hand.

6

Loosen and remove the damper fork pinch bolt with a socket and ratchet. Hold the damper fork bottom mounting bolt head with a wrench and rotate the nut counterclockwise with a socket and ratchet. Tap the bottom mounting bolt out of the damper for with a hammer. Remove the damper fork and set it aside.

7

Straighten the lower ball joint cotter pin legs and remove the cotter pin with pliers. Loosen and remove the lower ball joint castle nut with a socket and ratchet. Place a pry bar between the steering knuckle and lower control arm and pry downward on the control arm to separate the ball joint.

8

Remove the spindle nut and discard it. Pull outward on the steering knuckle and pull on the outboard CV joint tripod to separate the shaft from the wheel hub. Tap the end of the axle shaft with a brass punch and hammer lightly to help separate the shaft from the hub, if necessary.

9

Place a pry bar between the transmission case and inboard CV joint tripod. Pry outward on the joint enough to separate the axle circlip from the differential side gear. Remove the axle shaft from the transmission by hand and store it in a safe place, if you're not replacing it. Repeat this process for the opposite axle.

Axle Installation

10

Pry the original circlip from the CV shaft. Set one side of the circlip into the groove and work around the shaft until the circlip is fully installed. The circlip will be pre-installed with a new or re-manufactured replacement shaft.

11

Inspect both axle seals on the transmission for any wear or damage and replace as necessary. Wipe any residual transmission fluid off of the transmission seals.

12

Lay a small stack of shop rags over the lower control arm in a position that the axle shaft will sit safely. Slide the hub side of the axle shaft through the opening in the wheel well and set the outboard joint on the shop rags. Line up the splines of the axle shaft with the splines of the transmission and slide the axle shaft into the transmission. Apply enough force when installing the axle to seat the circlip in the groove of the differential side gears.

13

Pull outward on the steering knuckle assembly and guide the axle shaft into the wheel hub. Push the knuckle assembly towards the control arm. Pry downward on the control arm and guide the lower ball joint stud into the control arm. Install a new spindle nut to the axle shaft threads hand tight.

14

Install the lower ball joint castle nut and tighten to 40 foot-pounds with a torque wrench. Tighten the castle nut slightly to line up the grooves of the nut with the hole in the ball joint stud, if necessary. Slide a new cotter pin through the castle nut and ball joint stud. Bend the cotter pin legs in opposite directions around the castle nut with pliers.

15

Set the damper fork into position and install the lower mounting bolt and nut. Install the upper damper fork pinch bolt. Hold the lower mounting bolt head steady and tighten the lower mounting nut to 47 foot-pounds. Tighten the damper fork pinch bolt to 27 foot-pounds with a torque wrench.

16

Instruct a helper to enter the vehicle and apply the brakes. Tighten the new spindle nut to 137 foot-pounds. Instruct the helper to exit the vehicle. Locate the grove in the end of the new axle shaft and place the pointed chisel on the edge of the nut directly above it. Tap the chisel with a hammer to stake the nut. Install the wheel and tire to the vehicle and install the lug nuts hand tight.

Filling the Transmission

17

Install the transmission funnel through the fill hole of the transmission. Add fresh Honda manual transmission fluid a half quart at a time until fluid begins to leak from the fill plug hole. Remove the transmission funnel.

18

Apply thread sealant to the threads of the fill plug and install the fill plug to the transmission. Tighten the fill plug to 33 foot-pounds. Remove the drain pan from under the transmission and store the used fluid in a safe place until it can be disposed of properly.

19

Lift the front of the vehicle off the jack stands and remove the jack stands. Lower the vehicle to the ground. Tighten the lug nuts to 80 foot-pounds. Drive the vehicle to a local repair shop to have the front end alignment checked and adjusted as necessary.