ACURA NSX 1991 Service Repair Manual

Maintenance
Transmissio n Oi l
NOTE : Chec k th e oi l a t norma l operatin g temperatur e
(th e coolin g fa n come s on) , engin e OFF , an d th e ca r o n
leve l ground .
1 . Remov e th e oi l fille r plug , the n chec k th e leve l an d
conditio n o f th e oil .
WASHE R
Replace . Prope
r Level .
OI L FILLE R PLU G
4 5 N- m (4. 5 kg-m , 3 3 Ib-ft )
2. Th e oi l leve l mus t b e u p t o th e fill hole . I f i t i s belo w
th e hole , ad d oi l unti l i t run s out , the n reinstal l th e
oi l fille r plug .
3 . I f th e transmissio n oi l i s dirty , remov e th e drai n plu g
an d drai n th e oil .
4. Reinstal l th e drai n plu g wit h a ne w washer , an d
refil l th e transmissio n oi l t o th e prope r level .
5 . Reinstal l th e oi l fille r plu g wit h a ne w washer .
NOTE : Th e drai n plu g washe r shoul d b e replace d
a t ever y oi l change .
Oi l Capacity
2. 7 (2. 9 U S qt , 2. 4 Im p qt ) a t oi l change .
2.8 (3. 0 U S qt , 2. 5 Im p qt ) a t overhaul .
Use onl y SAE10W-3 0 or 10W-40 , API Servic e SF
or S G grade .
DRAIN PLU G
4 0 N- m (4. 0 kg-m , 2 9 Ib-ft )
WASHE R Replace .
Back-up Ligh t Switch ,
Neutral Positio n Switc h
Replacemen t
NOTE: T o chec k th e switch , se e sectio n 23 .
1 . Disconnec t th e connector , the n remov e th e switc h
connecto r fro m th e connecto r clamp .
2 . Remov e th e switch .
3. Appl y liqui d gaske t (P/ N 08718-0001 ) t o th e
switc h threads , the n instal l th e switch .
BACK-U P LIGH T SWITC H
2 5 N- m (2. 5 kg-m , 1 8 Ib-ft )
NEUTRA L POSITIO N SWITC H
2 5 N- m (2. 5 kg-m , 1 8 Ib-ft )
OI
L FILLE R PLU G
4 5 N- m (4. 5 kg-m , 3 3 Ib-ft )
WASHE R Replace .
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Gearshift Mechanism
Overhaul
NOTE:
• Inspec t rubber parts fo r wea r an d damag e whe n disassembling .
• Chec k tha t th e ne w cotte r pi n i s seate d firmly .
SELEC T LIN KCOLLA RSHIFT LEVE R 6
x 1. 0 m m BOLT S
10 N- m (1. 0 kg-m ,7 Ib-ft ) 6 x 1. 0 m m
1 0 N- m (1. 0 kg-m , 7 Ib-ft )COTTE
R PI N
Replace .
6 x 1. 0 m m BOL T
1 0 N- m (1. 0 kg-m , 7 Ib-ft )
SHIF T LEVE R
LINKAG E
(Silicone Grease )
1 0 N- m (1. 0 kg-m , 7 Ib-ft )
SHIF T LEVE R
BRACKE T
8 x 1.2 5 mm22 N- m (2. 2 kg-m ,16 Ib-ft )
8 x 1.2 5 mm22 N- m (2. 2 kg-m , 1 6 Ib-ft )
A : SELF-LOCKIN G NU T
Replac e6 x 1. 0 m m10 N- m (1. 0 kg-m , 7 Ib-ft )
2
2 N- m (2. 2 kg-m , 1 6 Ib-ft )
SHIF
T CABL E
PIVO T
BUSHIN G
SHIF T LEVE R
PIVO T GUID E
SHIF
T LEVE R
BAL L SEA T STEE
L WASHE R
PLASTI C WASHE R
SELEC T CABL E
SHIFTLEVE RPIVOTSHIFTLEVE RBUSHIN G
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Cable Adjustmen t
1. Remov e th e cente r consol e pane l (se e sectio n 20 ).
2 . Mov e th e shif t leve r int o 1s t gear .
3. Instal l th e 6 m m bol t t o th e shif t lever .
NOTE : Whil e movin g th e shif t leve r bac k an d
forth , an d righ t an d left , tighte n th e bol t unti l th e
rang e of fre e pla y of the shif t leve r i s 1 — 2 mm .
6 x 1. 0 m m BOL T
Lengt h o f thread s
30 m m (1.1 8 in)
SHIF T LEVE R
SHIF T LEVE R
BRACKE T
4. Remov e th e transmissio n lowe r cover .
5 . Disconnec t th e selec t an d shif t cable s fro m th e
transmission , the n remov e th e cabl e bracke t wit h
th e selec t an d shif t cables .
6 . Remov e th e selec t an d shif t cable s fro m th e cabl e
bracket .
7. Measur e th e distance s
NOTE:
• Hol d th e cabl e end s u p t o th e selec t an d shif t
lever s a s i f the y wer e connecte d t o them .
• Adjus t b y loosenin g th e locknu t a t th e cabl e en d
an d turnin g th e cabl e end .
SHIF T LEVE R
SHIF T CABL E
SELECT LEVE R
SELEC T CABL E
SELEC T CABL E
155.4 mm (6.1 2 in)
LOCKNU T
(Silicon e Grease )
SHIFT CABL E178.5 mm (7.0 3 in)
LOCKNU T
(Silicon e Grease )
8. Instal l i n th e revers e orde r of removal .
9 . Afte r installing , chec k operatio n of the shif t lever .
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Transmission Assembl y
Removal
Make sur e lift s ar e place d properly , an d
hois t bracket s ar e attache d t o correc t position s (se e
sectio n 1 ).
CAUTION : Us e fende r cover s t o avoi d damagin g
painte d surfaces .
1 . Chec k an d recor d th e rea r whee l alignmen t (se e
sectio n 18 ).
2 . Disconnec t th e batter y negativ e (- ) an d positiv e (+ )
cable s fro m th e battery .
3 . Drai n transmissio n oil . Reinstal l th e drai n plu g wit h
a ne w washer .
Corrosio n resistan t bolt/nu t
4. Remov e th e stru t bar .
5 . Remov e th e ai r cleane r assembly .
6 . Remov e th e connector s fro m th e contro l box , an d
remov e th e contro l box .
CAUTION : D o no t remov e th e vacuu m tube s fro m
th e contro l box .
7 . Remov e th e wir e harnes s holder , jumpe r connecto r
an d transmissio n ground cable.
8 . Disconnec t th e back-u p ligh t switch , neutra l posi -
tio n switch , differentia l spee d sensor , an d vehicl e
speed senso r (VSS ) connectors .
9. Disconnec t th e starte r moto r cables , the n remov e
th e starte r motor .
10 . Remov e th e transmissio n mount .
11 . Remov e th e tw o transmissio n housin g bolts .
TRANSMISSIO N
HOUSIN G BOLT S
CONTROL BO X
BACK-U PLIGHT SWITC H
CONNECTO R
WIR E HARNES S HOLDE R
STARTER MOTOR
CABLES
NEUTRA L
POSITIO N
SWITCHCONNECTO R
DIFFERENTIA L
SPEE D SENSO R
VEHICL E SPEE D
SENSO R (VSS )
CONNECTO R
JUMPERCONNECTO R
TRANSMISSIO N
MOUNTING BOLT S
TRANSMISSIO NHANGER
STARTE RMOTOR MOUNTIN
G TRANSMISSIO N
BOLT S MOUN T
TRANSMISSIO
N
GROUN D
CABLE
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12. Remov e th e parkin g brak e cabl e holder s fro m th e rea r bea m rod .
13 . Remov e th e rea r bea m rod .
14 . Remov e th e fron t exhaus t pip e A .
Corrosio n resistan t bolt/nu t
SELF-LOCKIN G NU T
Replace .
EXHAUS TPIPE A
GASKE T
Replace .
REAR BEA M RO D
GASKE TReplace .PARKING BRAK E
CABL E HOLDER S
SELF-LOCKIN G NU T
Replace .
1 5 . Remov e th e parkin g brak e cabl e holde r an d th e whee l senso r wir e clamp .
16 . Remov e th e bolt , an d separat e th e to e contro l ar m fro m th e sid e bea m (se e sectio n 18 ).
17 . Remov e th e dampe r for k bol t (se e sectio n 18 ).
18 . Remov e th e bolts , an d separat e th e lowe r contro l ar m fro m th e sid e bea m (se e sectio n 18 ).
19 . Pr y th e driveshaf t ou t o f th e differential . Pul l an d remov e it .
Corrosio n resistan t bolt/nu t
PARKIN G BRAK E
CABL E HOLDE RSELF-LOCKIN
G NU T
Replace .
FLANG E BOL T DAMPE
R FOR K BOL T
WHEE L SENSO R
WIR E CLAM P
SID E BEA M
SELF-LOCKIN G NU T
Replace .ADJUSTIN GCAM
DRIVESHAF T ADJUSTIN G BOL T LOWE
R CONTRO L
ARM
SELF-LOCKIN G NU T
Replace .
TO
E CONTRO L AR M
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Transmission Assembly

Removal

20. Remove the intermediate shaft heat cover and the intermediate shaft mounting bolts.
21. Pry the intermediate shaft out of the differential. Pull and remove it. NOTE:
• Coat all precision finished surfaces with clean engine oil or grease.
• Tie plastic bags over the driveshaft ends.

Corrosion resistant bolt/nut
INTERMEDIATE SHAFT
SUPPORT BASE
INTERMEDIATE SHAFT INTERMEDIATE SHAFT
HEAT COVER
INTERMEDIATE SHAFT
MOUNTING BOLT
22. Remove the parking brake cable holder and the wheel sensor wire clamp.
23. Remove the bolt, and separate the toe control arm from the side beam (see section 18).
24. Remove the damper fork bolt (see section 18).
25. Remove the bolts, and separate the lower control arm from the side beam. 26. Pry the driveshaft out of the differential. Pull and remove it. NOTE:
• Coat all precision finished surfaces with clean engine oil or grease.
• Tie plastic bags over the driveshaft ends.

Corrosion resistant bolt/nut
DAMPER FORK BOLT SELF-LOCKING NUT

Replace.

TOE CONTROL ARM
WHEEL SENSOR WIRE CLAMP PARKING BRAKE
CABLE HOLDER
FLANGE BOLT
LOWER CONTROL ARM SELF-LOCKING NUTReplace. ADJUSTING

BOLT
ADJUSTING

CAM
SELF-LOCKING NUT

Replace.
SET RING

Replace.ProCarManuals.com

27. Remove the one of the upper control arm mounting bolt.

28. Remove the lower cover, change wire bracket and upper cover.

29. Remove the shift cable and select cable.

30. Remove the slave cylinder from the transmission.

NOTE: Do not operate the clutch pedal once the slave

cylinder has been removed.

31. Remove the release fork from the clutch release hanger,

then hang the release fork on the clutch housing.

Corrosion resistant bolt/nut

UPPER CONTROL ARM DAMPER

SLAVE CYLINDER

UPPER COVER

COTTER PIN

Replace.

SHIFT CABLE

CHANGE WIRE

BRACKET

UPPER CONTROL ARM

MOUNTING BOLT
LOWER COVER

SELECT CABLE

32. Remove the clutch housing cover.

33. Attach a chain hoist to the transmission hangers.

34. Place a jack under the transmission, and raise the transmission just enough to take weight off mounts.

35. Remove the front engine mounting bolts on the transmission side, and retighten the bolt on the engine side.

CAUTION: Loosen the front engine mounting bolt on the engine side, but do not remove it. After removing the two

bolts on the transmission side, be sure to retighten the bolt on the engine side.

36. Remove the rear transmission mounting bolts and engine stiffener.

37. Remove the transmission housing mounting bolts.

38. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmission jack.

Corrosion resistant bolt/nut

REAR TRANSMISSION

MOUNT

REAR TRANSMISSION

MOUNTING BOLT

TRANSMISSION JACK
TRANSMISSION HOUSING

MOUNTING BOLTS

FRONT ENGINE MOUNTING

BOLT (Engine side)

FRONT ENGINE MOUNTING

BOLT (Transmission side)

TRANSMISSION HOUSING

MOUNTING BOLT
CLUTCH HOUSING

COVER

ENGINE STIFFENER
RELEASE FORKProCarManuals.com

Illustrated Inde x
Clean al l part s thoroughl y i n solven t an d dr y wit h compresse d air .
Lubricat e al l part s wit h oi l befor e reassembly .
NOTE:
• Thi s transmissio n use s n o gasket s betwee n th e majo r housings ; us e liqui d gaske t (P/ N 08718—0001) .
I f 2 0 minute s hav e passe d afte r applyin g liqui d gasket , reappl y i t an d assembl e th e housing s an d allo w it t o cur e
a t leas t 3 0 minute s afte r assembl y befor e fillin g th e transmissio n wit h oil .
• Alway s clea n th e magne t wheneve r th e transmissio n housin g i s disassembled .
CLUTCH RELEAS E HANGE R
RELEAS E HANGE R SPRIN G
RELEAS E BEARIN G GUID E
4 0 x 6 8 x 12. 5 m m OI L SEA L
Replace .14 x 2 0 m m DOWE L PI NCLUTC H HOUSIN GVEHICLE SPEE D SENSO R (VSS )
DIFFERENTIA L SPEE D SENSO R
O-RIN G
Replace .
RELEAS E BEARIN G GUID E COVE R
REVERS E SHIF T FOR K ASSEMBL Y
• Disassembly/Reassembly , pag e
13-16REVERS E IDL E GEA R SHAF T
ASSEMBL Y
• Disassembly/Reassembly , pag e
13-15
OIL GUID E RIN G
9 0 m m WASHE R
BEARIN G OUTE R RAC E
DIFFERENTIA L ASSEMBL Y
• Se e sectio n 1 5OI L GUID E PLAT E
4 4 x 7 2 x 23 m m NEEDL E BEARIN G
•Inspect fo r wea r an d operation .BEARING RETAININ G PLAT E
COUNTERSHAF T ASSEMBL Y
• Index , pag e 13-2 9MAINSHAF T ASSEMBL Y
• Index , pag e 13-2 3
7 5 m m SPRIN G WASHE R
3 2 x 4 6 x 7 mm OI L SEA L
Replace . TRANSMISSIO
N MAGNE T
SHIF T FOR K ASSEMBL Y
• Disassembly/Reassembly , pag e
13-22OIL PUM P ASSEMBL Y
• Disassembly/Reassembly , pag e
13-37CHANG E HOLDE R ASSEMBL Y
• Disassembly/Reassembly , pag e
13-19UPPE R COVE R
SELEC T LEVE R ASSEMBL Y
• Removal , pag e 13-1 7
• Installation , pag e 13-4 3REVERS E SHIF T AR M
1 4 x 2 0 m m DOWE L PI N
1 0 x 2 0 m m DOWE L PI N
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BEARING OUTE R RAC E75 m m THRUS T SHI MSelection .CLAMPBACK-U P LIGH T SWITC H
2 5 N- m (2. 5 kg-m , 1 8 Ib-ft )
CLAM P
TRANSMISSIO N HANGE R B
TRANSMISSIO N HANGE R A
STA Y
WASHER
Replace .OIL FILLE R PLU G
4 5 N- m (4. 5 kg-m . 3 3 Ib-ft )
4 2 x 63 x 12. 5 m m OI L SEA L
Replace .
WASHE R
Replace .DRAIN PLU G
4 0 N- m (4. 0 kg-m , 2 9 Ib-ft ) 3
6 m m SEALIN G BOL T
3 5 N- m (3. 5 kg-m , 2 5 Ib-ft )
STRAINE R COVE R
O-RIN G
Replace .STRAINE R SE T SPRIN G
OI L PUM P STRAINE R
1 4 m m SEALIN G BOL T
3 3 N- m (3. 3 kg-m , 2 4 Ib-ft )
SPRIN G (L . 2 5 mm )
STEE L BAL L (3/ 8 in )
1 2 m m SEALIN G BOL T
2 2 N- m (2. 2 kg-m , 1 6 Ib-ft ) SPRIN
G (L . 24. 2 mm )
1 6 m m SEALIN G BOL T COM P
4 2 N- m (4. 2 kg-m , 3 0 Ib-ft )
STEE L BAL L (5/1 6 in )
SHIF T LEVE R ASSEMBL Y
• Removal , pag e 13-1 7
• Installation , pag e 13-4 3
NEUTRA L POSITIO N SWITC H
2 5 N- m (2. 5 kg-m , 1 8 Ib-ft )
TRANSMISSIO N HOUSIN GOIL GUID E PLAT E82 m m THRUS T SHI M• Selection , pag e 13-4 1
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Transmission Housing

Removal

NOTE: Place the clutch housing on two pieces of wood

thick enough to keep the mainshaft from hitting the

workbench.

1. Remove the back-up light switch, neutral position

switch, differential speed sensor and vehicle speed

sensor (VSS).

VSS

(O-RING Replace.)
NEUTRAL

POSITION

SWITCH

DIFFERENTIAL

SPEED SENSOR

BACK-UP LIGHT SWITCH

2. Remove the sealing bolts, springs and steel balls.

3. Remove the transmission housing attaching bolts

in a crisscross pattern in several steps.

4. Remove the 36 mm sealing bolt.

SPRING

(L. 25 mm)

ATTACHING

BOLT
.14 mm SEALING BOLT

36 mm SEALING BOLT

STEEL BALL (3/8 in)

12 mm SEALING

BOLT

16 mm SEALING

BOLT COMP
5. Expand the snap ring on the countershaft ball bear-

ing, and remove it from the groove using a pair of

snap ring plier.

SNAP RING PLIER

SNAP RING

6. Separate the clutch housing from the transmission

housing.

7. Remove the thrust shim and oil guide plate from the

transmission housing.

THRUST SHIM

OIL GUIDE

PLATE

TRANSMISSION HOUSING
SPRING

(L.
24.2
mm)

STEEL

BALLS (5/16 in)ProCarManuals.com