differential ACURA INTEGRA 1994 Service Repair Manual

Standards and Service Limits
Differential (Manual transmissionlSection 15
Differential (Automatic transmissionlSection 15
Steering - Section 17
' When using a new belt, adjust detlection or tension to new values. Run the engine lor 5 minutes then turn it off.Readiust detlection or tension to used belt values.
M€ASUREMENTSTANDARD INEW) SERVICE LIMIT
DifferentialPinion shaft contact area LD. 81881 engine818C1 engineCarrier'to-pinion clearance 81881 engineB18C t engineDriveshafvintermediate shaft contact area LD.81881 engine818C1 engineCarrier to driveshaft clearance 81881 engineBlSC'l engineCarrier-to-intermediate shatt clearanceB188l engine818C1 engine
18.000 - 18.016 (0.7087 - 0.7093)18.000 18.018 (0.7087 - 0.7094)0.0r3 0.045 (0.0005 - 0.0018)0.0'13 - 0.047 (0.0005 0.0019)
28.000 - 28.021 \1.1024-1.1032128.005 - 28.025 (1.1026 1.'1033)0.020 - 0.062 (0.0008 0.0024)0.045 , 0.086 {0.0018 - 0.0034)
0.050 - 0.087 (0.0020 0.0034)0.075 - 0.111 (0.0030 - 0.0044)
o. t aron,0.1 {0.006}
Differentialprnron gearEacklasht. D.Pinion geaFto-pinion shaft clearance
0.05 0.15 (0.002 0.006)'18.042 - 18.066 (0.7103 0.7113)0.055 - 0.095 (0.0022 0.0037)
Adjust
0.15 {0.006)
Sel ring-to-bearing outer race clearance 81881 engin€0 - 0.10 (0 0.004)Adjust
Differential taper roller bearing preloadStarting torque N.m {kgfcm, lbf.in) Bl8Cl engine2.1r - 3.04 {21.5 - 3 r.0, 13.0- 18.7)Adjust
MEASUREMENTSTANDARO INEWISERVICE LIM]T
Difterentialcarfl€rPinion shatt contact area l.D.Carrier-to-oinion clearanceDriveshafvintermediate shaft contact are l.D.Carrier-to-driveshatt clearance
18.000 - 18.018 {0.7087 - 0.7094)0.016 - 0.052 {0.0006 - 0.0020)28.00s 28.025 {1.1026 - 1.1033)0.025 - 0.066 (0.0010 - 0.0026)
0.1 {0.004)
0.12 (0.005)
Differentialprnron gearBacklasht.D.Pinion gear-to-pinion shaft clearance
0.05 - 0.15 (0.002 - 0.006)18.042 - 18.066 (0.7r03 - 0.7113)0.059 - 0.095 (0.0023 - 0.0037)
Adjust
0.15 (0.006)
Set ring-to-bearing outer race clearance0 - 0.r5 (0 - 0.006)Adjust
MEASUREMENTSTANDARD INEWI
Steering wheelRotational play at steering wheel circumferenceStaning losd at steering wheel circumferenceN {kgf, lbfl Engine running
0 - 10 {0 - 0.39)
34 \3.5,7.71
GearboxAngle of rack-guide-screw loosened from lockedposition20" i 5'
PurnpPump pressure with shut-off valve closedkPa (kgtlcm,, psi)6,400 7.400 165 75. 920 - 1. r00)
Power steeringtluidRecommended fluidFluid capacity For overhaulf (US qt, lmp q0 For fluid change
Honda power steering fluid V1.06 (1.12,0.98)
0.79 (0.83,0.70)
Power steeringbelt*Deflection with 98 N (1okgt,22lhfl
between pulleys11.5- 13.5 (0.45 0.53)with used belt8.0 - 10.010.31 0.39)with new belt
Belt tension N lkgf, lbl)Measured with belt tension gauge390 - 540 (40 - 55, 88 - 120) with used belt740 880175 90. 170 200) with new belt

[":::,::-'
Eecause of its compact impeller design, the fuel pump is installed inside the fueltank, thereby saving space
ng the fuel line system.
FUEL PUMP
FUEL FILTER
FUEL PUMP BRACKET
FUEL PUMP CROSS SECTION lsido vi6rvl
IMPELLERS
CHECK VALVEPUMP CASING
The fuel oumo consists of a DC motor, a circumference flow pump, a relief valve for ptotecting the fuel lir
a check valve for retaining residual pressure, an inlet port, and a discharge port. The fuel pump assembly
the impellers (driven by the motor), the fuel pump casing {which forms the pumping chsmber), and the fuel p
OPERATION(1 ) When the engine is started. the PGi/t-Fl main relay actuates the fuel pump, and the motor turns togeth
impellers.
Differential pressure is generated by the numerous grooves around the impellers.
(2) Fuel entering the inlet porr flows inside the motor from the pumping chambe. and is forced through th
port via the check valve.
lf tuel flow is obstructed at the discharge side of the tuel line, the relief valve will open to bypass the
inlet port and prevent excessive fuel pressure.
(3) When the engine stops, the tuel pump stops automatically. However, a check valve closes by gravity t
residual pressure in the line, helping the engine to aestan more easily.
and simplify-
N lTop vi6w)
PORT
GROOVES
fuel line systems,
embly consists of
fuel pump cover.
together with the
rgh the discha.ge
ss the fuel to the
avitv to retain the
(cont'd)
PUMP COVER
FUEL PUMP ASSEMBLY CROSS SECTION
D|SCHARGE FORT ^ . tNLEr P
IMPELLER
11-109

Transaxle
Clutch
Manual Transmission ......................
Automatic Transmission ..................
Differential
Manual Transmission
81881 engine
818C1 engine
Automatic Transmission ...............
Driveshafts
12-1
13-1
14-1
15-1
15-9
15-19
16-1

12 N.m (1.2 kgim,9 lbnft)
15 N.m (1.5 kgnm, 11 lbf.ft)
15 N.m (1.5 kgf.m, 11 lbf.ft)
24 N.m (2.4 kgf.m, 17 lbf'ft)
27 N.m (2.8 kgnm,20 lbnft)
30 N.m (3.1 kgf.m, 22 lbf'ft)
Bolt Size
,l
{
@@69
@
@@@@@@@@6Dq0
o€xv0@
@0!@@@@al
61@
B
c
D
E
F
6x1.0mm
6x1.0mm
I x 1.0 mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.0 mm
i) BALL BEARINGe sroPPER R|NG9 TAPER RINGA NEEDLE EEARINGO SPACER.d SYNCHRO RINGt sYNcHRo SPR|NG!) 5TH/REVEFSE sYNcHRo SLEEVEO 5TH/REVERSE SYNCHRO HUB[0 sYrucxao nlrucii i) 5TH GEARO 38 x 43 x 26 mm NEEDLE BEARINGt3 SPACEE COLLARO 4TH GEAR.iB SYNCHRO FING.Ii9 SYNCHRO SPRING{, 3RD/,ITH SYNCHRO HUB
@ 3RD/4TH SYNCHBO SLEEVEt9 3RD GEARO MAINSHAFTO wasHER@) SPRING WASHER40 BALL BEARINGO 28 x 41 x ? mm OIL SEAL Replace.ad 35 x 56 x 8 mm OIL SEAL Replace.a0 14 x 20 mm OOWEL PIN@ OIL CHAMBER PLATE'A BEVERSE IDLEN GEAR SHAFT@ wasHER t-2).A REVERSE IDLER GEAFO REVERSE CHANGE HOLDER3A sTH/REVERSE SHIFT PIECEO 1ST/2ND SHIFT FORK04 3RD/.TH sHlFr FoRK@ 5TH/REVERSE SHIFT FORKO9' OIL GUTTER PLATE6' SNAP RING@ 72 mm THRUST SHIM) OIL GUIOE PLATEi!0 10 mm WASHER Replace..4i] REVERSE IDLER GEAR SHAFT BOLT54 N.m {5.5 kgt m, 40lblftl) TRANSMISSION HANGER B(3 BREATHER CAP@ TRANSMISSION HANGER A63 BACK.UP LIGHT SWITCH25 N.m (2.5 ksf.m, 18lbfftl@r 14 mrn waSHER Replace.67 16 mm SEALING BOLT29 N.m (3.0 kgl.m, 22 lbf ft)@ 32 mm SEALING BOLT25 N.m (2.5 kgf.m. 18lbt'ft|@ 40 x 62 x 9 mm OIL SEAL Replace.D STEEL BALL D. 5/16 inGl SPRING L. 30 mm {1.2 in}
@ 12 mm WASHER Replace.63) SET SCREW22 N.m 12.2 kgl.m, 16 lbt'ft,@ OIL ORAIN PLUG39 N.m {4.0 kgt.m, 29 lbf'ftl€9 WASHER Replace.@ oIL FILLER PLUG4,1N.m 14.5 kgJ m, 33 lblftl
*1:81881 engine*2:B18Cl engine
WASHER Beplace.TRANSMISSION HOUSING80 mm SHIM (*1)79.5 mm SHIM {*21THRUST SHIM {*2IT. 2.0 mm (0.079 in)BEARING OUTER RACE {*2}SHIFT PIECE SHAFTINTERLOCKSHIFT PIECESHIFT ARM HOLDERSELECT ARMSELECT RETURN SPRING10 mm SHIM10 mm WASHERLOCK COLLAR3 x 16 mm SPRING PIN Replace.8 mm SPRING WASHERCHANGE PIECESET SCREW22 N.m {2.2 kgf.m, 16 lbf.ft}SPRING L.25.6 mm {1.01 inlSTEEL BALL D. 5/16 inMAGNETCLUTCH HOUSING14 x 25 x 16 mm OIL SEAL Replace.SHIFT RODDIFFERENTIAL ASSEMBLYSee section 15BEARING OUTER RACE I*2ITHRUST SHIM I*2)T. 2.5 mm (0.098 in,SHIFT ROD BOOTOIL GUID€ PLATE33 x 60 x 20 mm NEEDLE BEARINGBEARING RETAINER PLATELOCK WASHER Replace.COUNTERSHAFTTHRUST SHIM37 x 42 x 25 mm NEEDLE BEARINGlST GEARFRICTION DAMPERSYNCHRO RINGSYNCHRO SPRINGlST/2ND SYNCHRO HUBREVERSE GEARDOUBLE CONE SYNCHRO I*2ISYNCHRO BING I*1)FRICTION DAMPERSPACER42 x 6? x 24 mm NEEDLE BEARING2ND GEAR3RD GEAR4TH GEAS5TH GEARNEEDLE BEARINGBALL BEARINGSPRING WASHERLOCKNUT Replace.108 - 0- 108 N.m(11.0 - 0* 11.0 kgt m,80- 0- 80lbf.ft)5 x 22 mm SPRING PIN Replace.00
13-9

Mainshaft, Gountershaft, Shift Fork
- Removal
1. Remove the mainshaft and the countershaft assem-
blies with the shift forks from the clutch housing.
NOTE: Tape the mainshaft spline belore removing
the mainshaft and the countershaft assemblies.
2 Remove the spring washer and the washer.
Remove the differential assembly from the clutch
housing.
OIFFERENTIAL
CLUTCH HOUSING
13-17
4. Remove the chamber plate.
CLUTCH HOUSING
CHAMBCR PLATE

Transmission
;
ReassemblV
1. lnstallthe new oil seal.
2. Set the change Piece.
3. lnstall the shift rod.
4 Installthe steel ball, the spring, and the set screw.
5. lnstall the change piece attaching bolt.
6. Install the shift rod boots.
8x1.0mm30 N.m 13.1 kg{ m.
SET SCREW12 x'1.0 mm22 N.m {2.2 kg{.m, 16lbl.ft}
SPRINGL. 25.6 mm22 tbl.ltl
Installthe oil chamber Piate.
SHIFT ROD
6x1.0mm12 N.m (1.2 kgt'm,9lbtft)
9.
10.
8. Install the differential assembly.
DIFFERENTIALASSEMBLY
Set the spring washer and the washer.
Install the mainshaft, the countershaft, and the shift
fork assemblies.
NOTE: Align the finger ot the interlock with the
groove in the shift fork shaft.
MAINSHAFT
COUNTERSHAFT
SHIFT FORKS
(cont'd)
13-41

MAINSHAFT4TH GEAR
MAINSHAFT 3RD GEARSUB.SHAFT 4TH GEAR
lST,HOLD CLUTCHMAINSHAFT2ND GEARTOROUECONVERTER
SUB-SHAFT 1ST GEAR
SUB.SHAFT2ND CLUTCHSTARTERNING GEAR
LOCK-UPCLUTCH
4TH CLUTCHMAINSHAFT 1STGEAR
DRIVE PLATE
1ST CLUTCH
MAINSHAFT
ONE-WAY CLUTCH
PARKING GEAR
,I ST GEAR
COUNTERSHAFT REVERSE GEAR
REVERSE SELECTOR
REVERSE SELECTOR HU8
COUNTERSHAFT 4TH GEAR
COUNTERSHAFT 2ND GEAR
COUNTERSHAFT 3RD GEAR
DIFFERENTIAL
FINAL DRIVEN GEAR
3RD CLUTCH
14-7

PROBABLE CAUSE
1Shitt cable broken/out of adiustment.
Throttle cable too short.
Throttle cable too long.
Wrong type ATF.
ldle rpm too low/high.
o.Oil pump worn or binding.
7.Pressure regulator stuck.
8.l st clutch detective.
9.2nd clutch detective.
10.3rd clutch defective.
114th clutch defective.
12.1 st'hold clutch defective.
13.Mainshatt worn/damaged.
14.Modulator valve stuck.
Throttle valve B stuck.
lo.ATF strainer clogged.
Toroue converter def ective.
18.Torque converter check valve stuck.'I 9.1-2 shift valve stuck.
2-3 shift valve stuck.
213-4 shift valve stuck.
Servo control valve stuck.
23.Clutch Dressure control (CPC) valve stuck.
2-3 orifice control valve stuck.
Orifice control valve stuck.
26.3-2 kick-down valve stuck.
27.4-3 kick-down valve stuck.
24.4th exhaust valve stuck.
29.1st accumulator detective.
30.2nd accumulator detective.
313rd accumulator defective.
4th accumulator defective.
1 st-hold accumulator defective.
Servo valve stuck.
35.Lock-up timing B valve stuck.
36.Lock-up shift valve stuck.
37.Lock-uo control valve stuck.
38.Shift fork benr.
39.Reverse gears worn/damaged (3 gears).
40.Reverse selectot worn.
413rd gears worn/damaged (2 gears).
Final qears worn/damaged (2 gearsl.
43.Differential Dinion shatt worn.
44.Feedpipe O-ring broken.
45.4th qears worn/damaged (2 gearsl
Gear clearance incorrect.
47.Clutch clearance incorrect.
48.One-way (sprag) clutch defective.
49.Sealinq rings/quide worn.
50.Axle-inboard joint clip missing.

NOTES
A.See flushing procedure, page l4-168 and 169.
B.Set idle rpm in gear to specitied idle speed. lf still no good, adiust motor mounts as outlined in engine
section of service manual.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the clutch pack is seized or is excessively worn, inspect the other clutches Jor wear, and check the
orifice control valves and throttle valves for free movement.
E.It throttle valve B is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed, the transmission will not upshift. lI stuck open, the transmission
has no lst gear.
H.lf the 2-3 orifice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear.
lf the clutch Dressure control valve is stuck closed, the transmission will not shilt out of 1st gear.
K.improper alignment or main valve body and torque converter housing may cause oil pump seizure. The
symptoms ale mostly an rpm-related ticking noise or a high-pitched squeak.
L.ll the ATF strainer is ctogged with panicles of steel or aluminum, inspect the oil pump and ditferential
pinion shaft. lt both are OK and no cause lor the contamination is found, replace the torque converter.
M.lf the 1st clutch feedpipe guide in the right side cover is scored by the mainshaft, inspect the ball bear-
ing for excessive movement in the transmission housing. lf OK. replace the right side cover as it is dent-
ed. The O-ring under the guide is probably worn.
N.ReDlace the mainshstt if the bushing for the 4th feedpipe is loose or damaged.
It the 4th feedpipe is damaged or out ot tound, replace the right side cover'
Replace the subjshaft it thtbushing for the 1st-hold Jeedpipe is loose or damaged.
lf the 1st-hold feedpipe is damaged or out of round, replace it.
Replace the mainshaft if the bushing lor the 1st feedpipe is loose or damaged.
lf the lst feedpipe is damaged or out ot round, replace it.
o.A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position
while the wheels rotate in reverse, such as rocking the car in snow.
P.InsDect the frame for collision damage.
o.Inspect for damage or wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamters of countershaft 4th and reverse gear.
3. Shift fork for scutt marks in center.
4. Differential Dinion shaJt for wear under pinion gears.
5. Bottom of 3rd clutch for switl marks.
Replace items 1 , 2, 3 and 4 it worn or damaged. lf transmission makes clicking, grinding or.whirring
noise, atso replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to
1,2,3ot4.lf ditiersntial Dinion shaft is worn, overhaul differential assembly, and replace ATF strainel, and thoroughly
clean transmission, tlush torque convertet, cooler and lines.
lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and tinal
driven gear.
R.Be wry careful not to dsmage the torque converter housing when replacing the main ballbearing. You
may al;o damage the oil pump when you torque down the main valve body. This will result in oil pump
seizure it not detected. Use proper tools.
qInstall the main seal tlush with the torque converter housing, lf you push it into the torque converter
housing until it bottoms out. it will block the oil return passage and result in damage.
T,Harsh do\/vnshiJt"\./l,'hen coasting to a stop with zero th.ottle may be caused by a bent-in throttle valve
retainer/cam stopper. Throttle cable adjustment may clear this problem.
ifuitle cable adjustment is essential for proper operation of the transmission. Not only does it affect
the shift points if misad,usted, but also the shift quality and lock-up clutch operation'
A cable adjusted too long will result in throttle pressure being too low for the amount of engine torque
input into ihe trsnsmission and may cause clutch slippage. A cable adjusted too short will result in too
hi;h throttle pressure which may cause harsh shitts, erratic shrfts and torque con
14-89

1 2. Pry the right driveshaft out of the differential and pry
the lett driveshatt out of the intermediate shaft.
'13. Pull on the inboard joint and remove the right and
left driveshafts (see section 16).
'14. Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with
clean engine oil.
PLASTIC BAG
Disconnect the heated oxygen sensor (HO2S) con-
necror.
Remove the exhaust pipe A.16.
SELF-LOCKINGNUTReplace.
Replace.
14-101
17. Remove the intermediate shaft.
Remove the shift cable cover, then remove the shift
cable by removing the control lever.
CAUTION: Take care not to bend the shift control
cabls whilo removing it.
18.
SHIFT CABLE
LOCKWASHER CONTROLLEVERReplace.
(cont'dl