ACURA NSX 1991 Service Repair Manual

Transmission Assembly

Removal (cont'd)

19. Remove the intermediate shaft heat cover and the intermediate shaft mounting bolts.
20. 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.

INTERMEDIATE SHAFT

SUPPORT BASE

SET RING
Replace.

INTERMEDIATE SHAFT

21. Remove the parking brake cable holder and the Anti-lock Brake sensor wire clamp.
22. Scribe a reference mark on the flange of the adjusting bolt, adjusting cam and lower control arm.
23. Loosen the ball joint nut, then separate the toe control arm from the knuckle using the special tool (see section 18).
24. Remove the damper fork bolt.
25. Remove the bolts and lower control arm from the side beam.
26. Remove the left driveshaft from the differential.
27. 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.

INTERMEDIATE SHAFT

MOUNTING BOLT

INTERMEDIATE SHAFT

HEAT COVER

DAMPER FORK BOLT
TOE CONTROL ARM

LOWER CONTROL ARM
ADJUSTING

BOLT
ADJUSTING

CAM


SET RING

Replace.
ProCarManuals.com

28. Remove the one of the upper control arm mounting bolts.
29. Remove the lower cover, change wire bracket and upper cover.
30. Remove the shift cable and select cable.
31. Remove the slave cylinder from the transmission. NOTE: Do not operate the clutch pedal once the slave
cylinder has been removed.
32. 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

ASSEMBLY

UPPER COVER

COTTER PIN
Replace.

SHIFT CABLE

UPPER ARM MOUNTING

BOLT
CHANGE WIRE

BRACKET

33. Remove the clutch housing cover.
34. Attach a chain hoist to the transmission hangers.
35. Place a jack under the transmission and raise the transmission just enough to take weight off mounts.
36. 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.
37. Remove the rear transmission mounting bolts and engine stiffener.
38. Remove the transmission housing mounting bolts.
39. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmission jack.
SELECT CABLE

LOWER COVER

RELEASE FORK

Corrosion resistant bolt/nut
REAR TRANSMISSION

MOUNT

REAR TRANSMISSION

MOUNTING BOLT
TRANSMISSION JACK
TRANSMISSION HOUSING
MOUNTING BOLT
ENGINE STIFFENER
CLUTCH HOUSING

COVER
FRONT ENGINE MOUNTING

BOLT (Transmission side
)

FRONT ENGINE MOUNTING

BOLT (Engine side
)

TRANSMISSION HOUSING

MOUNTING BOLTSProCarManuals.com

CLUTCH RELEASE HANGER
RELEASE HANGER SPRING
RELEASE BEARING GUIDE
40 x 68 x 12.5 mm OIL SEAL
Replace.
10 x 20 mm DOWL PIN

CLUTCH HOUSING

SPEED SENSOR
SENSOR DUMMY COVER O-RING

Replace.

HOLDER PLATE
REVERSE SHIFT FORK ASSEMBLY Disassembly/Reassembly, page
13-16

REVERSE IDLE GEAR SHAFT

ASSEMBLY Disassembly/Reassembly, page
13-15
OIL GUIDE RING

90 mm WASHER
BEARING OUTER RACE
DIFFERENTIAL ASSEMBLY See section 15
OIL GUIDE PLATE
44 x 72 x 23 mm NEEDLE BEARING
BEARING RETAINING PLATE
COUNTERSHAFT ASSEMBLY Index, page
13-29

MAINSHAFT ASSEMBLY

Index, page

13-23
75 mm SPRING WASHER
32 x 46 x 7 mm OIL SEAL

Replace.
TRANSMISSION MAGNET

SHIFT FORK ASSEMBLY Disassembly/Reassembly, page
13-22

OIL PUMP ASSEMBLY
Disassembly/Reassembly, page
13-37

CHANGE HOLDER ASSEMBLY
Disassembly/Reassembly, page
13-19

UPPER COVER
SELECT LEVER ASSEMBLY
Removel, page
13-17 Installation, page 13-43
REVERSE SHIFT ARM
14x20 mm DOWEL PHIS

14 x 20 mm DOWEL PIN

Clean all parts thoroughly in solvent and dry with compressed air.

Illustrated Index

Lubricate all parts with oil before reassembly.

NOTE:
This transmission uses no gaskets between the major housings; use P/N 08718 — 0001 sealant.
Assemble the housings within 20 minutes after applying the sealant and allow it to cure at least 30 minutes after

assembly before filling the transmission with oil.
Always clean the magnet whenever the transmission housing is disassembled.
ProCarManuals.com

BEARING OUTER RACE

75 mm THRUST SHIM

Selection.

CLAMP
BACK-UP LIGHT SWITCH
25 N·m (2.5 kg-m, 18 Ib-ft)
CLAMP
TRANSMISSION HANGER A
TRANSMISSION HANGER B

STAY

WASHER

Replace.

OIL FILLER PLUG
45 N·m (4.5 kg-m, 33 Ib-ft)
42 x 63 x 12.5 mm OIL SEAL
Replace.

WASHER

Replace.

DRAIN PLUG
40 N·m (4.0 kg-m, 29 Ib-ft) 36 mm SEALING BOLT
35 N·m (3.5 kg-m. 25 Ib-ft)
STRAINER COVER O-RING

Replace.

STRAINER SET SPRING
OIL PUMP STRAINER
14 mm SEALING BOLT
33 N·m (3.3 kg-m. 24 Ib-ft)
SPRING (L. 25 mm)
STEEL BALL (LARGE) 16 mm SEALING BOLT
42 N·m (4.2 kg-m, 30 Ib-ft) SPRING (L. 24.2 mm)
16 mm SEALING BOLTS
42 N·m (4.2 kg-m, 30 Ib-ft)
SPRING (L. 30 mm)
STEEL BALL (SMALL)
SHIFT LEVER ASSEMBLY
0 Removal, page
13-17

• Installation, page 13-43

NEUTRAL SWITCH

25 N·m (2.5 kg-m, 18 Ib-ft)

TRANSMISSION HOUSING
OIL GUIDE PLATE

82 mm THRUST SHIM
• Selection, page
13-41
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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 switch
and speed sensor.

SPEED SENSOR
NEUTRAL

SWITCH

BACK-UP LIGHT SWITCH
2. Remove the sealing bolts, springs and steel balls.
3. Remove the upper cover, then remove the transmission housing attaching bolts.
4. Remove the 36 mm sealing bolt.

ATTACHING

BOLTS
36 mm SEALING BOLT

SEARING
BOLT

SPRING

STEEL BALL

UPPER COVER
OIL GUIDE

PLATE

THRUST SHIM

6. Separate the clutch housing from the transmission

housing.

7. Remove the thrust shim and oil guide plate from the
transmission housing.
SNAP RING
SNAP RING PLIER

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

ing and remove it from the groove using a pair of

snap ring pliers.ProCarManuals.com

Transmission

Reassembly

SHIFT LEVER
3. Install the oil seal, select arm and select lever in the
clutch housing.

OIL SEAL
Replace.

SELECT LEVER

4. Install the differential assembly in the clutch housing.

DIFFERENTIAL ASSEMBLY

(cont'd)
1. Install the oil seal, shift arm and shift lever in the
transmission housing.

8 x 1.0 mm SPECIAL BOLT
32 N·m (3.2 kg-m, 23 Ib-ft) SPRING WASHERReplace.

SHIFT ARM

OIL SEAL
Replace.

2. Install the shift detent spring and spring set plate.

8 x 1.25 mm SPECIAL BOLT

26 N·m (2.6 kg-m, 19 Ib-ft)
SPRING SET PLATE

SHIFT DETENT SPRING
8 x 1.0 mm SPECIAL BOLT
32 N·m (3.2 kg-m, 23 Ib-ft)
SPRING WASHERReplace.
SELECT ARMProCarManuals.com

Transmission

Reassenbly (cont'd)
5. Install the spring washer, then insert the mainshaft and countershaft into the shift forks and install
them as an assembly.
NOTE: Tape the mainshaft spline, before instal-

lation.

COUNTERSHAFT

ASSEMBLY

MAINSHAFT

ASSEMBLY

SPRING WASHER
SHIFT FORK

ASSEMBLY

6. Install the change holder assembly in the clutch
housing.

NOTE: Plate the interlocker finger in the groove of

the select arm.

6 x 1.0 mm SPECIAL BOLTS
15 N·m (1.5 kg-m, 11 Ib-ft)

CHANGE HOLDER

ASSEMBLY

INTERLOCKER FINGER

SELECT

ARM
REVERSE SHIFT FORK

ASSEMBLY

8. Shift the reverse shift fork to the driven gear side.
Lift the mainshaft assembly and reverse idle gear
shaft assembly, then install the reverse shift fork
assembly.

REVERSE IDLE GEAR

SHAFT ASSEMBLY

7. Lift the mainshaft assembly, then install the
reverse idle gear shaft assembly with the spring pin
matching the groove of the clutch housing.ProCarManuals.com

9. Install the reverse shift arm.

6 x 1.0 mm SPECIAL BOLTS

15 N·m (1.5 kg-m. 11 Ib-ft)

REVERSE SHIFT ARM

10. Apply liquid gasket to the transmission mating sur-

face of the clutch housing.

NOTE: This transmission uses no gasket between

the major housings; use Honda Genuine liquid

gasket (P/N 08718 —0001)'. Assemble the housing

within 20 minutes after applying the liquid gasket

and allow it to cure at least 30 minutes after

assembly before filling it with oil.

(cont'd)
SHIFT PIECE
SHIFT ARM
Neutral

position.
SHIFT LEVER
a. Place the shift lever as a shown.
CLUTCH HOUSING

DOWEL PINS
TRANSMISSION

HOUSING
Groove
3RD/4TH SHIFT FORK SHAFT COLLAR
11. Install the dowel pins on the clutch housing.

12. Place the transmission housing over the clutch

housing, being careful to line up the shafts.

NOTE: Make sure the 3rd/4th shift fork shaft col-

lar mates with the 3rd/4th shift fork shaft.ProCarManuals.com

Transmission

Reassembly (cont'd)

b. Lower the transmission housing, then place the
shift arm in the groove of the shift piece by turn-
ing the shift lever.

TRANSMISSION HOUSING
SHIFT LEVER
SHIFT

ARM

SHIFT PIECE

c. Check the operation of the shift lever.

14. Check that the snap ring is securely seated in thegroove of the countershaft bearing.
Dimension A as installed: 1.60–8.15 mm

(0.0630–0.3209 in)
COUNTERSHAFT

BEARING

SNAP RING

13. Lower the transmission housing with the snap ring

expanded and set the snap ring in the groove of thecountershaft bearing.ProCarManuals.com

1 5. Tighten the transmission housing attaching bolts in

the numbered sequence shown below.

Torque: 45 N·m (4.5 kg-m, 33 Ib-ft)

16. Install the 36 mm sealing bolt.

NOTE: Apply Honda Genuine liquid gasket (P/N

08718-0001) to the flange.

17. Install the steel balls, spring and sealing bolts.

NOTE: Apply Honda Genuine liquid gasket (P/N

08718 — 0001) to the threads, but don't plug the

hole with liquid gasket.

18. Install the upper cover.

STEEL BALL

(3/8 in)

10 x
1.25

mm BOLTS

45 N·m

(4.5 kg-m,

33 Ib-ft)
14 x 1.0 mm SEALING BOLT

33 N·m (3.3 kg-m, 24 Ib-ft)

SPRING (L. 25 mm)

36 mm SEALING BOLT

35 N·m (3.5 kg-m, 25 Ib-ft)

STEEL BALL (5/16 in)

SPRING

(L. 30 mm)

SPRING

(L.
24.2
mm)

UPPER COVER
19. Install the back-up light switch and neutral switch.

NOTE: Apply Honda Genuine liquid gasket (P/N

08718 — 0001) to the threads.

20. Install the speed sensor.

6 x 1.0 mm BOLT

12 N·m (1.2 kg-m, 8.7 Ib-ft)

SPEED SENSOR

8 x 1.25 mm BOLT

26 N·m
(2.6
kg-m,

19 Ib-ft)
NEUTRAL SWITCH

25 N·m
(2.5
kg-m,

18 Ib-ft)

SPRING

(L. 30

mm)
16 x 1.0 mm

SEALING

BOLTS

42 N·m

(4.2 kg-m,

30 Ib-ft)

6 x 1.0 mm BOLTS

12 N·m (1.2 kg-m. 9 Ib-ft)
8 x 1.25 mm BOLTS

24 N·m (2.4 kg-m, 17 Ib-ft)

8 x 1.25 mm BOLTS

24 N·m (2.4 kg-m, 17 Ib-ft)
BACK-UP LIGHT SWITCH

25 N·m (2.5 kg-m, 18 Ib-ft)ProCarManuals.com