lock HONDA INTEGRA 1994 4.G Manual PDF

- Disassembly
Remove the ball bearing using a bearing puller as
BEARING PULLER
BALL B€ARING
CAUTION: Remove the synchro hubs using a press
and the steel blocks .s shown. Use of a jaw-type
puller can cau3e damags to the gear teeth.
Support 5th gear on steel blocks, and press the
mainshaft out of the 5th synchro hub, as shown.
3.Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th synchro hub, as shown.
13-25

1_
ReassemblV
ATTACHMENT,35 mm LD.07746 - 0o30/rc0
CAUTION:
o Pless the 3rd/ilth and the 5th synchro hubs on the
msinshafi without lubrication.
. When installing the 3rd/4th and the sth synchro
hubs, support the mainshaft on the steel blocks, and
install synchro hubs using a press,
. Install the 3rd/,lth and the sth synchro hubs with a
maximum pressure of 19.6 kN (2.000 kgf, 1+466lbt).
^JOTEi Refer to page 13-21 for reassembly sequence.
Support 2nd gear on steel blocks, then install the
3rd/4th synchro hub using the special tools and a
press, as shown.
NOTE: After installing, check the operation of the
3rd/4th synchro sleeve and hub.
B18Bl sngine:
DRIVER. 40 mm l.D.07746 - 0030100
3RD/4THSYNCHRO HUB
2NO GEAR
8l8Cl engine: Assemble the 3rd/4th synchro hub and
sreeve together before installing them on the mainshaft.
3RO/4TH PRESS
SYNCHRO HU8DRIVER- 4o mm l.D.07746 - tD30100: osed end
3RD/TTHSYNCHROSLEEVE
2, Install the sth synchro
ano a press as snown.
OBIVER, ,O mm LD.0t7it6 - 003010O
ATTACHMENT,35 mm l.D.
hub using the special tools
PRESS
sTH SYNCHRO HUB
077t6 - 00304{x)
Install the ball bearing using the special tools and a
prsss as shown.
NOTE: Install the ball bearing with the tapered end
facing down.
2ND GEAR
13-27

Countershaft Assembly
lndex
NOTE:
3
The 4th and 5th gears are installed with a press.
Prior to reassembling. clean all the pans in solvent, dry them and apply lubricant to any contact surfaces. The 4th
and sth gears. however, should be installed with a press before lubricating them.
LOCKNUT ReDlace.l(E*0*10EN.m
/r1.0 - 0 - 11.0 kgtm,Il8o- o-80rbf.ft I
WASHER
BALL BEARINGInspect for wearand operat|on,
NEEDLE BEARINGInspect Ior wearand operation.
sTH GEAR
4TH GEAR
3RD GEAR
2ND GEAR
NEEDLE BEARINGInspect for wearand operation.
SPACERSelection. page 13-29
FRICTION DAMPER
DOUB1I @NESYNCHRO l818Cl .ngin.lInspection, page 13-35SYNCHRO RING lBl8Bl .ngin )Inspection, page 13-35
SYNCHRO SPBING
SYNCHRO RING
THRUSTBEARING
13-24

Countershaft Assembly
Disassembly
13-30
't.Securely clamp the countershaft assembly in a
bench vise with wood blocks.
Raise the locknut tab from the groove in the coun-
tershaft, then remove the locknut and the spring
washer.
4,Remove the bearing outer .ace, then remove the
needle bearing using a bearing puller as shown.
2.
BEARING PULLER
BEARING
Remove the ball bearing using a bearing puller as
shown.
CAUTION: Romove the gclrs using a pross and tho
steol blocks rs shown. U3a of a l.w.typo pullor can
cau36 damagg to tho gsar iocth.
Support 4th gear on steel blocks. and press the
countershaft out of sth and 4th gears, as shown.
PULlTR
\-Y

Countershaft Assembly
Reassembly
GAUTION:
. Pr93r 4th and 5th goar3 on the qountorshrft without
lubricrtion.
. Whon in3talling 4th and sth goa6, srpport the shaft
on st..l block3, 8nd in3tall thc 9.116 uring a prors.
. Inst.ll 4th lnd 5th gcar with a maximum pro33ur€ of
25.5 kN (2,6@ ksr. 18,806 lbo.
NOTE: Refer to page 13-28 for reassembly sequence.
Install the thrust shim and the needle bearinos on
the countershaft.
NEEDLE BEARING
THRUST SHIM
COUNTERSHAFT
Installthe friction damper. the synchro ring, and the
synchro spring on lst gear,
Install the lsv2nd synchro hub by aligning the fin-gers on the friction damper and the grooves in the'lsV2nd synchro hub, as shown.
1ST/2ND
13-32
lST GEAR
4. Install the reverse gear.
Install the synchro spring, and the double cone
synchro (818C'l engine), or synchro ring (81881
engine), as shown.
SYNCHROSPRING
REVERSEGEAfi
Assemble the friction damper, the needle bearing,
and 2nd gear, then install them by aligning the fin-gers on the friction damper and the grooves in the
1sv2nd synchro hub with the fingers of the double
cone synchro and the grooves on 2nd gear, as
shown.
2ND GEAR
NEEDLE BEARING
SPACER
FRICTION DAMPER
8.Install the parts assembled in steps 2 - 6 on the
countershaft.
Install the spacer.

9. Support the countershaft on a steel block, and
install 4th gear using the special tools and a press,
as snown.PRESS
DRIVER, 40 mm l.O.
077{6 - 0030100
10. SuDDort the countershaft on a steel block, and
install 5th gear using the special tools and a press,
as shown.
DRIVER, 40 mm l.O.07746 - 0030100
ATTACHMENT, 30 mm l.O.
0?7a6 - (X)303(x)
11.Install the needle bearing. then install the ball bear-
ing using the specialtools and a press as shown.
PRESSDRIVER.,l0 mm l.D.07746 - 0030100
ATTACHMENT, 30 mm l.D.07746 - d)30300BALL BEARING
NEEDLE BEARING
12.
13.
Securely clamp the countershaft assembly in a
bench vise with wood blocks.
Install the spring washer. tighten the locknut, then
stake the locknut tab into the groove.
LOCKNUT
108* 0* 108 N.m (11.0 - 0 - 11.0 kgf.m,
80+0*80lbf.ftl
LOCKNUT
wooo BLocKs
13-33

Countcr'h!ft:
'1. Bsnd the tab on the lock washer down, then remove
the bolt 8nd bearing retainer plate.
Remove th€ needle bearing using the specisl
as shown, then remove the oil guide pl8te.
3rE' - 16 SUI'€ HAiiMER
{commorcially availabls)
lools
AD.'USTABII BEARIITGPULIIR, 25 - ao mm07t36 - A0rm0 a
CLUTCH HOUSING
3. Position the oil guide plate and new needle bearing
in the bore of the clutch housing, then drive in the
needle bearing using the specialtools as shown.
NOTE: Position the needle bearing with the oil hole
facing up.
OIL GUIDC PLATE
CI-UTCHHOUSING
Install the bearing retainer plate and new lock wash-
er, then bend the tab againstthe bolt head.
8x 10 mm15 N.m ll.5 kd.m, 11 lbf.ttl
LOCKWASHEARepl6ce.
13-37

Mainshaft Thrust Clearance
Adjustment (cont'd)
MAINSHAFT
-),.
"7t/'-
'..' .'i'
-7. Slide the mainshaft base over the mainshaft.
i.,
MAINSHAFT BASE07GAJ - PG20130
-8. Attach the mainshaft holder to the mainshaft as fol-
NOTE:
. Back-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip is
towards the transmission.
. Align the mainshaft holder's lip around the
groove at the inside ot the mainshaft splines,
then tighten the hex bolts.
MAINSHAFT HOLOERBOLT
f- t{-c
lnrTh l
ex
| \-_.r' ._/_/ lrl Borrs
L ___E_J
\MAINSHAFTHOLDER07GAJ - PG20110
MAINSHAFT BASE07cAJ _ PG20130
-9.Seat the mainshaft fully by tapping its end with a
plastic hammer.
-10.Thread the mainshaft holder bolt in until it just con-
tacts the wide surface of the mainshaft base.
- 1 1. Zero a dial gauge on the end of the mainshaft.
12.Turn the mainshaft holder bolt clockwise; stop turn-
ing when the dial gauge has reached its maximum
movement. The reading on the dial gauge is the
amount of mainshaft end play.
CAUTION: Turning the mainshaft holder bolt mor€
than 60 degrees after the needle ol the dial gauge
stops moving may damage the transmission,
DIAL GAUGE
MAINSHAFT HOLDER07GAJ - PG201r0
- 13.lf the reading is within the standard, the clearance is
correq.
lf the reading is not within the standard, recheck the
shim thickness.
Standard: 0.11 - 0.18 mm {0.004 - 0.007 in)
\
13-40

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

Transmission
Reassembly (cont'd)
11. Install the change holder assembly.
6x1.0mm15 N.m (1.5 kgf.m,11 tbf.ftl
CHANGE HOLDERASSEMBLY
Install the shift piece
the shift piece shaft.
and the interlock, then install12.
13-42
13. Measure the distance @ after mounting the shiftpiece shaft. lf it's incorrect, check the installation.
Distance O: 11.9 - 12.3 mm 10.47 - 0.48 in)
14.lnstall the washer (B18C1 engine), the reversegear. and the reverse idler gear shaft.
idlo.
REVERSE IDLER GEAR