ACURA CSX 2006 Service Repair Manual

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13-123
D
B
C A
A
C
B
D B
D
C A
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.
(cont’d)
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DYNOMITE -2009-

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13-124Manual Transmission
Countershaft Reassembly (cont’d)
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 B
07746-0030100
A D
25,480 N
(2,600 kgf,
5,730 lbf) max.
C
07746-0030300
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. Press on 6th gear (A) using the 40 mm inner driver
handle (B), the 30 mm inner bearing driver
attachment (C), and a press (D).
NOTE: Do not exceed the maximum pressure.
08/08/21 14:48:36 61SNR030_130_0126
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Standard: 0.04 0.10 mm (0.0016 0.0039 in.) 35 mm Shim
Type Part Number Thickness
13-125
A E
B C
07746-0030100
D
07746-0030300
B
C A
14. Install the 35 mm shim (A), and temporary press on
the old ball bearing (B) using the 40 mm inner
driver handle (C), the 30 mm inner bearing driver
attachment (D), and a press (E).
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.
15. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C). 16. If the measured clearance in step 15 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. If the measured
clearance in step 15 is within the standard, go to
next step to replace only the ball bearing.
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.)
(cont’d)
08/08/21 14:48:36 61SNR030_130_0127
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13-126Manual Transmission
Countershaft Reassembly (cont’d)
A
E
B C
07746-0030100
D
07746-0030300 B
118 N·m
(12kgf·m,87lbf·ft)
A
17. Remove 6th gear and the ball bearing (see step 3on page 13-119).
18. Remove the 35 mm shim.
19. Repeat step 13 to install 6th gear.
20. Install the correct 35 mm shim (A), then press on new ball bearing (B) using the 40 mm inner driver
handle (C), the 30 mm inner bearing driver
attachment (D), and a press (E), then recheck the
clearance.
NOTE: If necessary, replace the 35 mm shim with the correct one selected in step 16.
 Make sure to install the ball bearing as shown.
21. Check the clearance between the bearing and the 35 mm shim with a feeler gauge. 22. Securely clamp the countershaft assembly in a
bench vise with wood blocks (A).
23. Tighten new special bolt (B) (left-hand threads). NOTE: Apply MTF to the bolt threads and flange.
08/08/21 14:48:37 61SNR030_130_0128
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13-12713-127
Synchro Sleeve and Hub Inspection
and Reassembly Synchro Ring and Gear Inspection
B
A
E
C
D
A
B GOOD
WORN
Example of synchro ring teeth
C
B A
WORN
GOOD
Example of synchro sleeve teeth and gear teeth
A
1. Inspect the gear teeth on all synchro hubs and
synchro sleeves for rounded off corners, which
indicate wear.
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/6th 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 ring 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).
(cont’d)
08/08/21 14:48:37 61SNR030_130_0129
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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
13-128
Manual Transmission
Synchro Ring and Gear Inspection (cont’d)
D
B
C A
B
A
B
A
B
A
C
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 14:48:38 61SNR030_130_0130
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Special Tools Required
13-129
Mainshaft Bearing and Oil Seal Replacement
C
07736-A01000B
A
B
D
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 14:48:39 61SNR030_130_0131
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Special Tools Required
13-130
Manual Transmission
Countershaft Bearing Replacement
A
B
C
B
07736-A01000B
A D
D
07JAD-PL90100 A
B C
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).
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Special Tools Required
13-131
Mainshaft Thrust Clearance Adjustment
A
M B
B
A
C A
07GAJ-PG20110
B
07GAJ-PG20130 D
C
 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 housing 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 13-113). 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.
(cont’d)
08/08/21 14:48:41 61SNR030_130_0133
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Standard: 0.11 0.17 mm (0.004 0.007 in.)
(Example)
Measure reading: 1.93 mm (0.076 in.)
1.93 0.14 = 1.79 mm (0.070 in.) 72 mm Shim
Type Part Number Thickness
13-132Manual Transmission
Mainshaft Thrust Clearance Adjustment (cont’d)
A
07GAJ-PG20130 B
07GAJ-PG20110
11. Zero a dial gauge (A) on the end of the mainshaft.
12. Turn the catch adapter bolt (B) clockwise; stop
turning when the dial gauge has reached its
maximum movement. The reading on the dial
gauge is the amount of mainshaft thrust clearance.
NOTE: Do not turn the catch adapter bolt exceeds
60 degrees after the needle of the dial gauge stops
moving. Applying more pressure with the catch
adapter bolt could damage the transmission.
13. If the reading is within the standard, the clearance is correct. If the reading is not within the standard,
select the appropriate shim needed from the table,
and recheck the thrust clearance.
Subtract the total clearance measurement from the
middle of the clearance standard 0.14 mm
(0.0056 in.)
Select the shim closest to the amount calculated.
For this example, the 1.80 mm (0.071 in.) shim is
best.
14. With oil guide plate M and the appropriate size shim installed in the transmission housing, check
the thrust clearance again to make sure the
clearance is within the standard. A 23931-P21-000 0.60 mm (0.024 in.)
B 23932-P21-000 0.63 mm (0.025 in.)
C 23933-P21-000 0.66 mm (0.026 in.)
D 23934-P21-000 0.69 mm (0.027 in.) E 23935-P21-000 0.72 mm (0.028 in.)F 23936-P21-000 0.75 mm (0.030 in.)
G 23937-P21-000 0.78 mm (0.031 in.) H 23938-P21-000 0.81 mm (0.032 in.) I 23939-P21-000 0.84 mm (0.033 in.)
J 23940-P21-000 0.87 mm (0.034 in.)
K 23941-P21-000 0.90 mm (0.035 in.) L 23942-P21-000 0.93 mm (0.037 in.)
M 23943-P21-000 0.96 mm (0.038 in.) N 23944-P21-000 0.99 mm (0.039 in.)
O 23945-P21-000 1.02 mm (0.040 in.) P 23946-P21-000 1.05 mm (0.041 in.)
Q 23947-P21-000 1.08 mm (0.043 in.) R 23948-P21-000 1.11 mm (0.044 in.)
S 23949-P21-000 1.14 mm (0.045 in.)T 23950-P21-000 1.17 mm (0.046 in.)
U 23951-P21-000 1.20 mm (0.047 in.) V 23952-P21-000 1.23 mm (0.048 in.)
W 23953-P21-000 1.26 mm (0.050 in.) X 23954-P21-000 1.29 mm (0.051 in.)Y 23955-P21-000 1.32 mm (0.052 in.) Z 23956-P21-000 1.35 mm (0.053 in.)
AA 23957-P21-000 1.38 mm (0.054 in.) AB 23958-P21-000 1.41 mm (0.056 in.)
AC 23959-P21-000 1.44 mm (0.057 in.)
AD 23960-P21-000 1.47 mm (0.058 in.) AE 23961-P21-000 1.50 mm (0.059 in.)AF 23962-P21-000 1.53 mm (0.060 in.)
AG 23963-P21-000 1.56 mm (0.061 in.) AH 23964-P21-000 1.59 mm (0.063 in.) AI 23965-P21-000 1.62 mm (0.064 in.)
AJ 23966-P21-000 1.65 mm (0.065 in.)
AK 23967-P21-000 1.68 mm (0.066 in.) AL 23968-P21-000 1.71 mm (0.067 in.)
AM 23969-P21-000 1.74 mm (0.069 in.) AN 23970-P21-000 1.77 mm (0.070 in.)
AO 23971-P21-000 1.80 mm (0.071 in.) (cont’d)
08/08/21 14:48:41 61SNR030_130_0134
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