ACURA CSX 2006 Service Repair Manual

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Special Tools Required
13-45
A
D B
C
D A
B
C A
B C
A
B
 Inner driver handle, 40 mm 07746-0030100
 Inner bearing driver attachment, 30 mm 07746-0030300
NOTE: Refer to the Exploded View, as needed, during
this procedure. 1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2. Install the 1st gear distance collar (A), the needle bearing (B), and 1st gear (C) onto the countershaft
(D).
3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the
grooves (C) in 1st gear, then install the synchro
spring (D). 4. Install the 1st/2nd synchro hub (A) by aligning the
synchro ring fingers (B) with the grooves (C) in the
1st/2nd synchro hub.
5. Install the reverse gear (A) by aligning the slots of reverse gear and the 1st/2nd synchro hub (B). After
installing, check the operation of the 1st/2nd
synchro hub set.
NOTE: Make sure to align the slots in the 1st/2nd
synchro hub as shown.
(cont’d)
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13-46Manual Transmission
Countershaft Reassembly (cont’d)
C
D B
A
D
B
CA B
C A
D
C
07746-0030100 D
25,480 N
(2,600 kgf,
5,730 lbf) max.
A
B
6. Install the triple cone synchro assembly (A) with the
synchro spring (B) by aligning the synchro ring
fingers (C) with the grooves (D) in the 1st/2nd
synchro hub.
7. Install the distance collar (A) and the friction damper (B) by aligning the friction damper fingers
(C) with the grooves (D) in the 1st/2nd synchro hub. 8. Install the needle bearing (A).
9. Install 2nd gear (B) by aligning the synchro cone
fingers (C) with the grooves (D) in 2nd gear.
10. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 40 mm inner driver
handle (C) and a press (D).
NOTE: Do not exceed the maximum pressure.
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13-47
B
07746-0030100
C
25,480 N
(2,600 kgf,
5,730 lbf) max.
A
B
07746-0030100C
25,480 N
(2,600 kgf,
5,730 lbf) max.
A D
07746-0030100
A
E
07746-0030300
B
C
C
F
11. Press on 4th gear (A) using the 40 mm inner driver
handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.
12. Press on 5th gear (A) using the 40 mm inner driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure. 13. Install the distance collar (A) and the 35 mm shim
(B), and temporarily press on the used old ball
bearing (C) using the 40 mm inner driver handle (D),
the 30 mm inner bearing driver attachment (E), and
a press (F).
NOTE: Useanysizeof35mmshim,andnotesizeyou used. Measurements taken in the following steps
will determine the correct shim to use for final
assembly.
 Make sure to install the ball bearing as shown.
(cont’d)
08/08/21 14:45:46 61SNR030_130_0049
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Standard: 0.04 0.10 mm (0.0016 0.0039 in.)
35 mm ShimType Part Number Thickness
13-48Manual Transmission
Countershaft Reassembly (cont’d)
B
C A
14. Measure the clearance between the bearing (A) and
the 35 mm shim (B) with a feeler gauge (C). 15. If the measured clearance in step 14 is not within
the standard, select another suitable 35 mm shim
from the table, then go to next step to replace the
35 mm shim and the ball bearing with new one. If
the measured clearance in step 14 is within the
standard, go to next step to replace only the ball
bearing with new one.
A 23981- PPP-000 0.87 mm (0.034 in.)
AA 23981- PPP-900 0.91 mm (0.036 in.)
B 23982- PPP-000 0.95 mm (0.037 in.)
AB 23982- PPP-900 0.99 mm (0.039 in.)
C 23983- PPP-000 1.03 mm (0.041 in.)
AC 23983- PPP-900 1.07 mm (0.042 in.)
D 23984- PPP-000 1.11 mm (0.044 in.)
AD 23984- PPP-900 1.15 mm (0.045 in.)
E 23985- PPP-000 1.19 mm (0.047 in.)
AE 23985- PPP-900 1.23 mm (0.048 in.)
F 23986- PPP-000 1.27 mm (0.050 in.)
AF 23986- PPP-900 1.31 mm (0.052 in.)
G 23987- PPP-000 1.35 mm (0.053 in.)
AG 23987- PPP-900 1.39 mm (0.055 in.)
H 23988- PPP-000 1.43 mm (0.056 in.)
AH 23988- PPP-900 1.47 mm (0.058 in.)
J 23989- PPP-000 1.51 mm (0.060 in.)
AJ 23989- PPP-900 1.55 mm (0.061 in.)
K 23990- PPP-000 1.59 mm (0.063 in.)
AK 23990- PPP-900 1.63 mm (0.064 in.)
L 23991- PPP-000 1.67 mm (0.066 in.)
AL 23991- PPP-900 1.71 mm (0.067 in.)
M 23992- PPP-000 1.75 mm (0.069 in.)
AM 23992- PPP-900 1.79 mm (0.070 in.)
N 23993- PPP-000 1.83 mm (0.072 in.)
AN 23993- PPP-900 1.87 mm (0.074 in.)
P 23994- PPP-000 1.91 mm (0.075 in.)
AP 23994- PPP-900 1.95 mm (0.077 in.)
Q 23995- PPP-000 1.99 mm (0.078 in.)
08/08/21 14:45:46 61SNR030_130_0050
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13-49
C
07746-0030100
D
07746-0030300 E
B
A B
118N·m(12kgf·m,
87 lbf·ft)
A
16. Remove the ball bearing (see step 3 on page 13-42).
17. Remove the 35 mm shim.
18. Install the correct 35 mm shim (A), then press onnew ball bearing (B) using the 40 mm inner driver
handle (C), the 30 mm inner bearing driver
attachment (D), and a press (E).
NOTE: If necessary, replace the 35 mm shim with the correct one selected in step 15.
 Make sure to install the ball bearing as shown.
19. Check the clearance between the bearing and the 35 mm shim with a feeler gauge. 20. Securely clamp the countershaft assembly in a
bench vise with wood blocks (A).
21. Tighten new special bolt (B) (left-hand threads). NOTE: Apply MTF to the bolt threads and flange.
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13-5013-50 Manual Transmission
Synchro Sleeve and Hub Inspection
and Reassembly
Synchro Ring and Gear Inspection
DE
B
C A
A B GOOD
WORN
Example of synchro ring teeth
C
B A
WORN
GOOD A
Example of synchro sleeve teeth and gear teeth
1. Inspect the gear teeth on all synchro hubs and synchro sleeves for wear (r ounded off corners).
2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for free movement. Make
sure to match the three sets of longer teeth (C)
(120 degrees apart) on the synchro sleeve with the
three sets of deeper grooves (D) in the synchro hub.
NOTE: Do not install the synchro sleeve with its l onger
teeth in the 1st/2nd and 5th synchro hub slots (E)
because it will damage the spring ring.
 If replacement is required, always replace the synchro sleeve and the synchro hub as a set. 1. Inspect the synchro rings for scoring, cracks, and
damage (A).
2. Inspect the inside of each synchro ring (B) for wear. Inspect the teeth (C) on each synchro ring for wear
(rounded off).
3. Inspect the teeth (A) on each synchro sleeve and matching teeth on each gear for wear (rounded off).
08/08/21 14:45:47 61SNR030_130_0052
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Synchro Ring-to-Gear Clearance
Standard: 0.70 1.49 mm (0.028 0.059 in.)
Service Limit: 0.4 mm (0.016 in.)
Double Cone Synchro and Triple Cone Synchro-to-
Gear Clearance
Standard:
: Outer Synchro Ring (B) to Synchro Cone (C)0.70 1.19 mm (0.028 0.047 in.)
: Synchro Cone (C) to Gear (A) 0.50 1.04 mm (0.020 0.041 in.)
: Outer Synchro Ring (B) to Gear (A) 0.95 1.68 mm (0.037 0.066 in.)
Service Limit: : 0.3 mm (0.012 in.)
: 0.3 mm (0.012 in.)
: 0.6 mm (0.024 in.) Synchro ring-to-gear
Double cone synchro and triple cone
synchro-to-gear
13-51
D
B
C A
B
A
B
A
B
C A
4. Inspect the synchro teeth on gear for scoring,cracks, and damage (A).
5. Inspect the thrust surface (B) on each gear hub for wear.
6. Inspect the cone surface (C) on each gear hub for wear and roughness.
7. Inspect the teeth on all gears (D) for uneven wear, scoring, and cracks.
8. Coat the cone surface of each gear with MTF, and place its synchro ring on it. Rotate the synchro ring,
making sure that it does not slip.
9. Measure the clearance between each gear (A) and its synchro ring (B) all around the gear. Hold the
synchro ring against the gear evenly while
measuring the clearance. If the clearance is less
than the service limit, replace the synchro ring and
gear.
08/08/21 14:45:48 61SNR030_130_0053
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Special Tools Required
13-52
Manual Transmission
Mainshaft Bearing and Oil Seal Replacement
C
07736-A01000B
D
B
A
A A
07749-0010000
B
07746-0010300
A
07JAD-PL90100
 Oil seal driver, 65 mm 07JAD-PL90100
 Adjustable bearing puller, 20 40 mm 07736-A01000B
 Bearing driver attachment, 42 x 47 mm 07746-0010300
 Driver handle, 15 x 135L 07749-0010000
 Slide hammer, 3/8’’-16 UNF commercially available 1. Remove the ball bearing (A) from the clutch housing (B) using the 20 40 mm adjustable
bearing puller (C) and a commercially available
3/8’’ - 16 UNF slide hammer (D).
2. Remove the oil seal (A) from the clutch housing. Be careful when removing the oil seal so the clutch
housing is not damaged. 3. Drive in new oil seal from the transmission side
using the 15 x 135L driver handle (A) and the
42 x 47 mm bearing driver attachment (B).
4. Drive in new ball bearing from the transmission side using the 65 mm oil seal driver (A).
08/08/21 14:45:49 61SNR030_130_0054
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Special Tools Required
13-53
Countershaft Bearing Replacement
A
B
A
B
07736-A01000B D
C D
07JAD-PL90100
A
C
B
B
6x1.0mm
12 N·m
(1.2 kgf·m, 8.7 lbf·ft) A
 Oil seal driver, 65 mm 07JAD-PL90100
 Adjustable bearing puller, 20 40 mm 07736-A01000B
 Slide hammer, 3/8’’-16 UNF commercially available
1. Remove the bearing set plate (A) from the clutch housing (B).
2. Remove the needle bearing (A) using the 20 40 mm adjustable bearing puller (B) and a
commercially available 3/8’’-16 UNF slide hammer
(D), then remove oil guide plate C. 3. Position oil guide plate C and new needle bearing
(A) in the bore of the clutch housing (B).
4. Install the needle bearing using the 65 mm oil seal driver (D).
5. Install the bearing set plate (A) with the bolts (B).
08/08/21 14:45:50 61SNR030_130_0055
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Special Tools Required
13-54
Manual Transmission
Mainshaft Thrust Clearance Adjustment
A
M B
B
A
C C
A
07GAJ-PG20110
B
07GAJ-PG20130 D
 Catch adapter 07GAJ-PG20110
 Base adapter 07GAJ-PG20130
NOTE:
 Take measurement at normal room temperature.
 Clean all the parts thoroughly before installation.
1. Remove the 72 mm shim (A) and oil guide plate M from the transmission housing (B).
2. Thoroughly clean the 28 mm spring washer (A) and the 28 mm washer (B) before installing them on the
clutch housings side ball bearing (C).
NOTE: Install the spring washer in the direction
shown.
3. Assemble all of the mainshaft components. NOTE: Refer to the Exploded View, as needed,
during the assembly (see page 13-36). 4. Install the mainshaft assembly into the clutch
housing.
5. Place the transmission housing over the mainshaft and onto the clutch housing.
6. Tighten the clutch and transmission housings with several 8 mm bolts.
NOTE: It is not necessary to use sealing agent
between the housing for this procedure.
7. Lightly tap on the mainshaft with a plastic hammer.
8. Attach the catch adapter (A) and the base adapter (B) to the mainshaft as follows:
 Back out the catch adapter bolt (C), and loosen the two hex bolts (D).
 Fit the catch adapter over the mainshaft so its lip is towards the transmission.
 Align the catch adapter lip around the groove at the inside of the mainshaft splines, then tighten
the hex bolts.
9. Fully seat the mainshaft by tapping its end with a plastic hammer.
10. Thread the catch adapter bolt in until it just contacts thewidesurfaceofthebaseadapter.
08/08/21 14:45:50 61SNR030_130_0056
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