length ACURA TL 1995 Service Repair Manual

CHECK BALL

CHECK BALLS

CHECK BALL

FILTERS
CHOKE

MAIN VALVE BODY

(Sectional View)

SPRING SPECIFICATIONS

Unit: mm (in)

No.
Spring

4-3 kick-down valve spring

3-4 shift valve spring

2-3 shift valve spring

1-2 shift valve spring

CPC valve spring
Standard (New)

Wire Dia.

1.1 (0.043)

0.8(0.031)

0.8(0.031)

0.9 (0.035)

1.0(0.039)
O.D.

7.1 (0.280)

6.6 (0.260)

6.6 (0.260)

7.6 (0.299)

6.8 (0.268)
Free Length

51.3(2.020)

42.1 (1.657)

42.1 (1.657)

55.5(2.185)

34.3(1.350)
No. of Coils

22.5

22.0

22.0

24.0

14.2
CHECK BALLSProCarManuals.com

Countershaft
Inspection (cont'd )
4. I f th e clearanc e i s ou t o f tolerance , remov e th e 1st -
hold clutc h distanc e colla r an d measur e it s length .
5. Selec t an d instal l a ne w 1st-hol d clutc h distanc e col -
lar , the n recheck .
1ST-HOL D CLUTC H DISTANC E COLLA R
No.
1
2
3
4
5
6
7
8
9
10
1 1
Par t Numbe r
9045 1 -PY4 - 01 0
9045 2 -PY4 - 01 0
9045 3 -PY4 - 01 0
9045 4 -PY4 - 01 0
9045 5 -PY4 - 01 0
9045 6 -PY4 - 01 0
9045 7 -PY4 - 01 0
9045 8 -PY4 - 01 0
9045 9 -PY4 - 01 0
9046 0 -PY4 - 01 0
9046 1 -PY4 - 01 0 Thicknes
s
72.0 0 m m (2.83 5 in )
72.0 5 m m (2.83 7 in )
72.1 0 m m (2.83 9 in )
72.1 5 m m (2.84 1 in )
72.2 0 m m (2.84 3 in )
72.2 5 m m (2.84 4 in )
72.3 0 m m (2.84 6 in )
72.3 5 m m (2.84 8 in )
72.4 0 m m (2.85 0 in )
72.4 5 m m (2.85 2 in )
72.5 0 m m (2.85 4 in )
6. Afte r replacin g th e 1st-hol d clutc h distanc e collar ,
make sur e tha t th e clearanc e i s withi n tolerance .
7 . Attac h a dia l indicato r t o th e sid e o f th e 2n d gear .
DIAL INDICATO R
3RD CLUTC HASSEMBL Y1ST GEA R2ND GEA R
8. Measur e 2n d gea r axia l clearanc e whil e pushin g th e
1s t gea r toward s th e revers e clutc h assembly .
NOTE : Tak e measurement s i n a t leas t thre e places ,
an d us e th e averag e a s th e actua l clearance .
STANDARD : 0.0 5 - 0.1 3 m m (0.00 2 - 0.00 5 in )
1ST-HOL D
CLUTC H
ASSEMBL Y
THRUST WASHER ,45.5 x 60 m m
9. I f th e clearanc e i s ou t of tolerance , remov e th e
45. 5 x 6 0 m m thrus t washer , an d measur e it s thickness .
10 . Selec t an d instal l a ne w 45. 5 x 6 0 m m thrus t washer ,
the n recheck .
THRUS T WASHER , 45. 5 x 60 m m
No .
1
2
3
4
5
6
7
8
9
10
11
1 2
13
Par t Numbe r
9041 1 - P5 D - 000
90412-P5D-00 0
90413-P5D-000
90414-P5D-00 0
90415-P5D-00 0
90416-P5D-000
90417-P5D-000
90418-P5D-00 0
90419-P5D-000
90420 - P5 D - 00 0
904 2 1-P5D - 00 0
9042 2 - P5 D - 00 0
9042 3 - PS D - 00 0 Thicknes
s
1.3 0 m m (0.05 1 in )
1.3 5 m m (0.05 3 in )
1.4 0 m m (0.05 5 in )
1.4 5 m m (0.05 7 in )
1.5 0 m m (0.05 9 in )
1.5 5 m m (0.06 1 in )
1.6 0 m m (0.06 3 in )
1.6 5 m m (0.06 5 in )
1.7 0 m m (0.06 7 in )
1.7 5 m m (0.06 9 in )
1.80 m m (0.07 1 in )
1.8 5 m m (0.07 3 in )
1.9 0 m m (0.07 5 in )
11. Afte r replacin g th e 45. 5 x 6 0 m m thrus t washer ,
make sur e tha t th e clearanc e i s withi n tolerance .
PARKINGGEAR
2ND GEAR
1ST GEAR
I
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39. Appl y steerin g greas e t o th e circumferenc e o f th e
rac k en d housing .
STEERIN G GREAS E
RAC K EN D HOUSIN G
RAC K EN D GROOV E
40. Appl y a ligh t coa t o f silicon e greas e t o th e boo t
groove s o n th e rac k ends .
41. Instal l th e boot s i n th e rac k en d wit h th e tub e
clamps .
NOTE : Instal l th e boot s wit h th e rac k i n th e straigh t
ahea d positio n (righ t an d lef t tie-rod s ar e equa l i n
length) .
NOTE: Wip e greas e of fthe threa d section .
SILICON E GREAS E
BOO T
TUBE CLAM P
42. Instal l th e ne w boo t band s o n th e boot s a s shown .
NOTE: Th e Lockin g tab s
(stak e points ) shoul d
b e i n thi s range .
LOCKIN G TAB S
43. Ben d bot h set s o f lockin g tabs .
44 . Lightl y ta p o n th e doubled-ove r portion s t o reduc e
their height .
CAUTION : Stak e th e ban d lockin g tab s firmly .
LOCKIN G TAB S
BOO T BAN D
Replace .
45. Slid e th e rac k righ t an d lef t t o b e certai n tha t th e
boot s ar e no t deforme d o r twisted .
46 . Loosel y instal l th e tie-ro d locknut s an d tie-ro d end s
o n th e rac k ends .
SILICON E GREAS E
Band windin g direction .
Front.
RACK EN D
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NOTE: T o sea t ne w brushe s afte r installin g the m in thei r
holders , sli p a stri p o f #50 0 o r #60 0 sandpaper , wit h th e
gri t sid e up , ove r th e commutator , an d smoothl y rotat e
th e armature . Th e contac t surfac e o f th e brushe s wil l b e
sande d t o th e sam e contou r a s th e commutator .
2
. Inser t th e brus h int o th e brus h holder , an d brin g th e
brus h int o contac t wit h th e commutator , the n attac h
a sprin g scal e to th e spring . Measur e th e sprin g ten -
sio n a t th e momen t th e sprin g lift s of f th e brush .
Startin g Syste m
Starter Brus h Holde r Tes t
1. Chec k tha t ther e is n o continuit y betwee n th e an d
brush holders . I f ther e i s continuity , replac e th e
brus h holde r assembly .
Starter Brus h Inspectio n
Measure th e brus h length . I f i t i s no t withi n th e servic e
limit, replac e th e brus h holde r assembly .
Brush Lengt h
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5. If the clearance is out of tolerance, remove the dis-

tance collar and measure its length.

Length

6. Select and install a new distance collar, then recheck.

DISTANCE COLLAR, 35mm

No.

1

2

3

4

5

6

7

8

9

10
Part Number

90501 - PW7 - 000

90502 - PW7 - 000

90503 - PW7 - 000

90504 - PW7 - 000

90505 - PW7 - 000

90506 - PW7 - 000

90507 - PW7 - 000

90508 - PW7 - 000

90509 - PW7 - 000

90510-PW7- 000
Thickness

65.65 mm (2.585 in)

65.70 mm (2.587 in)

65.75 mm (2.589 in)

65.80 mm (2.591 in)

65.85 mm (2.593 in)

65.90 mm (2.594 in)

65.95 mm (2.596 in)

66.00 mm (2.598 in)

66.05 mm (2.600 in)

66.10 mm (2.602 in)

7. After replacing the distance collar, make sure that

the clearance is within tolerance.ProCarManuals.com

Parking Brake Roller Rod

Adjustment

1. Move the detent lever to the position.

2. Measure the clearance between the parking brake

roller rod and the transmission housing as shown.

STANDARD: 3.8 - 4.3 mm (0.15 - 0.17 in)

Measuring Clearance

ROLLER

TRANSMISSION

HOUSING

DETENT LEVER
ROLLER ROD
3. If the clearance is out of tolerance, select and install

a new parking brake roller rod.

PARKING BRAKE ROLLER ROD

Mark

L Length

PARKING BRAKE ROLLER ROD

Mark

1 or None

2

0

3
Part Number

24550 -PW4- 010

24560 -PW4- 010

24580 -PW4- 010

24590 - PW4 - 000
Length "L"

36.0 mm (1.417 in)

35.6 mm (1.402 in)

36.4 mm (1.433 in)

36.2 mm (1.425 in)

4. After replacing the parking brake roller rod, make

sure that the clearance is within tolerance.ProCarManuals.com

Transmission

Installation (cont'd)

8. Install the mid mount spacer and transmission mid

mounts while raising the transmission with a jack.

TRANSMISSION

MID MOUNT

SPACER

Install in this

direction.

MID MOUNT
10 x
1.25
mm

38 N-m (3.9 kgf-m,

28 Ibf-ft)

9. Tighten the bolts using an offset wrench and a torque

wrench as shown.

MID MOUNTS

OFFSET WRENCH

(Commercially available)

TORQUE WRENCH
NOTE: When tightening the bolts using an offset wrench

and a torque wrench, the tightening torque value differs

from torque specification according to a torque wrench.

Before tightening the bolts, calculate actual torque value

by following formula.

TORQUE

WRENCH

OFFSET WRENCH

Example:

Torque Specification: 38 N-m (3.9 kgf-m, 28 Ibf-ft)

Effective Length of Torque Wrench: 0.345 (m)

Effective Length of Offset Wrench: 0.13 (m)

WASHER

MID MOUNT NUTS

10 x
1.25
mm

43 N-m (4.4 kgf-m, 32 Ibf-ft)
10. Install the mid mount nuts.ProCarManuals.com

69. Appl y steerin g greas e t o th e circumferenc e o f th e
rac k en d housing .
STEERIN G GREAS E
RAC K EN D HOUSIN G
RAC K EN D GROOV E
SILICON E GREAS E
70. Appl y a ligh t coa t of silicon e greas e t o th e boo t
groove s o n th e rac k ends .
71 . Instal l th e boot s in th e rac k en d wit h th e tub e clamps .
NOTE : Instal l th e boot s wit h th e rack , i n th e straigh t
ahea d positio n (righ t an d lef t tie-rod s ar e equa l i n
length) .
NOTE: Wip e greas e of fthe threa d section .
SILICON E GREAS E
BOO T
TUBE CLAM P
72. Adjus t th e ai r tub e fittin g positio n o f th e boot s b y
turnin g it a s show n below .
LEFT BOO T RIGH T BOO T
(Viewe d fro m th e (Viewe d fro m th e
lef t side ) righ t side )
Offse t shaf t
center lin e
135°±10 °
BOO T110° ± 10 '
BOO T
AI R TUB E FITTIN G
AIR TUB E FITTIN G
73. Instal l th e tw o pip e clamp s a s show n below .
74 . Connec t th e ai r tub e betwee n th e righ t an d lef t
boot , an d instal l i t i n th e clip s o f th e pip e clamps .
Offset shaf t cente r line .
AIR TUB E
AI R TUB E PIP
E CLAMP S
Front
. Front
.
Front .
RACK EN D
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RUBBERDAM
RUBBE RDAM
Mak e a slightl y thicke rbead a t eac h corner .
WINDSHIEL D
14. Us e suctio n cup s t o hol d th e windshiel d ove r th e
opening , alig n i t wit h th e alignmen t mark s mad e i n
ste p 7 , an d se t i t dow n o n th e adhesive . Lightl y
pus h o n th e windshiel d unti l it s edg e i s full y seated
o n th e adhesiv e al l th e wa y around .
NOTE : D o no t ope n o r clos e th e door s unti l th e adhe -
siv e i s dry .
ALIGNMEN T MAR KWINDSHIEL D
SUCTION CUP S
15. Scrap e o r wip e th e exces s adhesiv e of f wit h a putt y
knife o r towel .
NOTE : T o remov e adhesiv e fro m a painte d surfac e
o r th e windshield , wip e wit h a sof t sho p towe l damp -
ene d wit h alcohol .
16 . Instal l th e clip s o n th e uppe r moldin g an d bot h sid e
moldings .
Uppe r molding :
UPPER MOLDIN G
EPT seale rLength : 3 3 m m (1. 3 in )Width : 1 0 m m (0.3 9 in )Thickness : 5 m m (0. 2 in )
NOTE : Glu e th e EP T seale r t o th e portio n clips .
Side molding :
SIDE MOLDIN G
13. Pac k adhesiv e int o th e cartridg e withou t ai r pocket s
to ensur e continuou s delivery . Pu t th e cartridg e in a
caulkin g gun , an d ru n a bea d o f adhesiv e aroun d
th e edg e o f th e windshiel d a s shown .
NOTE : Appl y th e adhesiv e withi n 3 0 minute s afte r
applyin g th e glas s primer .
ADHESIV E
WINDSHIEL D
22 mm(0.08 in)
13 m m(0.5 1 in)
8 m m (0.3 1 in)
All around .2 m m (0.0 8 in)
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Starting Syste m
Starter Brus h Holde r Tes t
1. Chec k tha t ther e is n o continuit y betwee n th e an d
brush holders . I f ther e i s continuity , replac e th e
brus h holde r assembly .
BRUS H HOLDE R BRUS
H HOLDE R
BRUS H HOLDE R
BRUSH HOLDE R
2 . Inser t th e brus h int o th e brus h holder , an d brin g th e
brus h int o contac t wit h th e commutator , the n attac h
a sprin g scal e t o th e spring . Measur e th e sprin g ten -
sion a t th e momen t th e sprin g lift s of f th e brush .
SPRIN G SCAL E
BRUSH
SPRIN G
Spring Tensio n
15.7-17. 7 N (1.60-1.8 0 kgf , 3.53-3.9 7 Ibf )
Starte r Brus h Inspectio n
Measure th e brus h length . I f no t withi n th e servic e limit ,
replac e th e brus h holde r assembly .
Brus h Lengt h
Standar d (NEW )
15.8- 16. 2 mm
(0.6 2 -0.6 4 in)
Servic e Limi t
11.0 mm
(0.4 3 in)
BRUS H
NOTE : T o sea t ne w brushe s afte r installin g the m in thei r
holders , sli p a stri p of #50 0 o r #60 0 sandpaper , wit h th e
grit sid e up , ove r th e commutator , an d smoothl y rotat e
the armature . Th e contac t surfac e o f th e brushe s wil l b e
sande d t o th e sam e contou r a s th e commutator .
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