Mainshaft HONDA INTEGRA 1994 4.G User Guide

Mainshaft Assembly
Clearance Inspection
NOTE: lf replacement is required. always replace the
synchro sleeve and the synchro hub as a set.
1. Measure the clearance between 2nd and 3rd gears.
Standard: 0.06 - 0.21 mm {0.002 - 0.008 inl
Ssrvica Limit: 0.3 mm (0.01 in)
13-22
Engine Type818C181881
Standard34.92 - 34.97 mm
(1.375 - 1.377 in)
34.42 - 34.47 mm
(1.355 - 1.357 in)
Service Limit34.8 mm
(1.370 in)
34.3 mm(1.350 in)
2. lf the clearance is more than the service limit, mea-
sure the thickness of 3rd gear.
lf the thickness of 3rd gear is less than the ser-
vice limit, replace 3rd gear with a new one.
lf the thickness of 3rd gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one.
3RD GEAR

Mainshaft Assembly
Glearance Inspection (cont'd)
Measure the clearance between 5th gear and the
spacer co ar.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 in)
Service limit: 0.3 mm 10.012 inl
lf the clearance is more than the service limit, mea
sure distance B on the spacer collar.
Standard: 26.03 - 26.08 mm (1.025 - 1.027 in)
SPACER COLLAR
sTH GEAR
13-24
8.lf distance @ is not within the standard, reDlace the
sDacer collar with a new one.
lf distance @ is within the standard, measure the
thickness of sth gear.
Standard: 31.12-31.47 mm (1.237 - 1.239 in)
Service Limit:31.3 mm (1.232 inl
lf the thickness of sth gear is less than the ser-
vice limit, replace sth gear with a new one.
lf the thickness of 5th gear is within the service
limit, replace the 5th synchro hub with a new
one,
sTH GEAR

- 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

Mainshaft Assembly
Inspection
1.Inspect the gear surfaces and the bearing surfacss
for wear and damage, then measure the mainshaft
at points A, B. and C.
Standord:
A: 27.987 - 28.000 mm 11.1018 - 1.102'l inl
B: 37.98/r - 38.q)0 mm {1.il95il - l.il960 in}
Ct 27.977 - 27.99O mm {1.1015 - 1.1020 in}
S€rvico Limit;
A: 27.9{, mm (1.1(XXl in}
B:37.930 mm 11.4933 inl
C: 27.930 mm {1.0996 in}
2. Inspect for runout.
Stlnd.rd: 0.02 mm (0.(xxl8 inl M!I.
S.rvic. Limit 0.05 mm (o.qP inl
NOTE: SuDport the mainsh€ft at both ends as
shown.
Inspect oil passages tor clogging.
lf the runout is mor6 than ths service limit,
rsplace the mainshaft with a n6w one.
lf any parts of the mainshaft are less thsn the
service limit. .eolace mainshaft with a new one.
13-26

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

Mainshaft Thrust Glearance
1. Remove the 72 mm thrust shim and oil guide plate
from the transmission housing.
72 mm THRUST SHIM
TRANSMISSIONHOUSINGOIL GUIDE PLATE
Adjustment
\.u
o
Bo
lnstall the 3rd/4th synchro hub, spacer collar, sth
synchro hub, spacer, and ball bearing on the main-
shaft. then install the above assembly in the trans-
mission housing.
Installthe washer on the mainshaft.
Measure distance @ between the end of the trans-
mission housing and washer.
NOTE:
. Use a straight edge and vernief caliper.
. Measure at three locations and averaoe the read-
Ing.END olTRANSMISSIONHOUSINGMAINSHAFT
WASHER
fr
13-38
AALL AEARING
. Try the 1.68 mm (0.0661 in) shim.
5. Measure distance @ betlveen the end of the clutch
housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
a Measure at three locations and average the read-
Ings.
Select the prcpet 72 mm thrust shim from the chart
by using the formula below.
NOTE: Use only one 72 mm thrust shim.
Shim Sslsction Formula:
From the measurements you made in steps 4 and 5:-1. Add distance @ (step 5lto distance @ (step 4).
-2. From this number. subtract 0.93 (which is the
midpoint of the flex range of the clutch housing
bearing spring washerl.
-3. Take this number and compare it to the avaif
able shim sizes in the chart.
(For example)
B:2.39
+ C: O.22
2.61- 0.93
1.68
END of CLUTCH HOUSING
INNEB RACE ot BALL BEARltac

72 mm Thrust Shim
Part NumberThickness
23931 - P21 -0000.60 mm (0.0236 in)
23932-P21 -0000.63 mm (0.0248 in)
c23933 - P21 -0000.66 mm {0.0260 in}
D23934-P21 -0000.69 mm (0.0272 in)
23935 - P21 -0000.72 mm (0.0283 in)
F23936-P21 -0000.75 mm (0.0295 in)
23937-P21 -0000.78 mm (0.0307 in)
23938-P21 -0000.81 mm (0.0319 in)
23939-P21 -0000.84 mm (0.0331 in)
J23940-P2r-0000.87 mm (0.0343 in)
K23941 - P21 -0000.90 mm (0.0354 in)
L23912-P21-OOO0.93 mm (0.0366 in)
M23943-P21 -0000.96 mm (0.0378 in)
N23944-P21 -0000.99 mm (0.0390 in)
o23915 - P21 -0001.02 mm (0.0402 in)
P23946 - P21 ,0001.05 mm (0.04'13 in)
o23947 -P21 -0001.08 mm (0.0425 in)
23948 - P21 0001.11 mm {0.0437 in}
s23919-P21 -0001.14 mm (0.0449 inl
T23950-P21 -0001.17 mm (0.0461 in)
23951 - P21 -0001.20 mm {0.0472 in)
23952 - P21 0001.23 mm {0.0484 in)
23953-P21 -0001.26 mm (0.0496 in)
X23954-P2r-0001.29 mm 10.0508 in)
23955-P21 -0001.32 mm 10.0520 in)
z239s6-P21 ,0001.35 mm (0.0531 in)
23957-P21 -0001.38 mm (0.0543 inl
AB23958 - P21 -0001.41 mm (0.0555 in)
AC23959 - P21 -0001.44 mm (0.0567 in)
AD23960 - P21 -0001.47 mm (0.0579 in)
AE23961 -P21 -0001.50 mm {0.0591 in)
23962 P21 ,0001.53 mm {0.0602 in)
23963-P21 -0001.56 mm {0.0614 in}
AH23964 - P2'1 -0001.59 mm (0.0626 in)
AI23965 - P2'1 -0001.62 mm (0.0638 in)
23966-P21 -0001.65 mm (0.0650 in)
AK23967-P21 -0001.68 mm {0.0661 in)
23968 - P21 -0001.71 mm 10.0673 in)
23969 - P21 0001.74 mm (0.0685 in)
AN23970-P21 -000'1.77 mm (0.0697 in)
AO23971 P21 0001.80 mm (0.0709 in)
7. Check the thrust clearance in the manner described
below.
NOTE: Carry out the measurement at normal room
remperarure.
-1. Install the thrust shim selected and oil guide
plate in th€ transmission housing.
?2 mm THRUSTotLPLATE
TRANSMISSIONHOUSING
Install the spring
ball bearing.
washer and washer on the
NOTE:
. Clean the spring washer, washer and thrust shim
throughly before instaliation.
. Install the spring washer. washer and thrust
shim properly.
a-=s-.r*os".^
.,,-B*^INGWASHER
-4.
Installthe mainshaft in the clutch housing.
Place the transmission housing over the main-
shaft and onto the clutch housing.
Tighten the clutch and transmission housings
with severalS mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
8 x 1.25 mm
27 N.m {2.8 kgf.m, 20 lbf.ft}
Tap the mainshaft with a plastic hammer,
(cont'd)
13-39

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

Automatic Transmission
'l4-2
14-3't 4-6
14-8
14-14
14-23
Hvdraulic Flow ...--...... 14-24
Lock-up System ........ 14-38
Eloctrical Systom
Component Location ............,...,................ I 4-45
Circuit Diagram ............. 14-46'Troubleshooting Procedures ........,..........., l4-48
Symptom-to-Component Chart
Electrical System ...... 14-50
Electrical Troubleshooting
Troubleshooting Flowchart .................... 14-52
Lock-uo Control Solenoid Valve A/8
Test .................. --.... \4-82
ReDlacement ,...,...,..,. 14-82
Shift Control Solenoid Vslve A/B
Test .................. ...... 14-83
Reolacement .............. 14-83
Transmission Control Module (TCM)*ReDlacement ........... 14-84
Mainshalt/CountershaJt SDeed Sensors
Reolacement ............. 14-85
Hydraulic Systom
Symptom-to-Component Chart
Hydraulic System
Road Test
Slall Speed
Test ..................
Fluid Level
Checking/Changing
Pressu.e Testing
Transmission
Transmission
Removal ............. ...... 14-99
lllustrated Index
Right Side Cover .................................. 1 4- 1 04
Transmission Housin9 ..................,,....... I 4-1 06
Torque Converter HousingNalve
Body .................. ... 14- 1O8
Right Side Cover
Removal ............. ...... 14-110
Transmission Housing
Removal ............. .-..-. 14-112
Torque Convener HousingNalve Body
Removal ............. ...... 14-114
Valve Caps
Description ................ 14-116
Valve Body
Repair ................ ...-.. 14-117
Valve
Assembly ...........
Oil Pump
Main Valve Body
Disassembly/lnspection/Reassembly
Regulator Valve Body
Disassembly/lnspection/Reassembly
Lock-up Valve Body
Disassembly/lnspection/Reassembly .......
Secondary Valve Body
Disassembly/lnspection/Reassembly .......
Servo Body
Disassembly/lnspection/Reassembly .......
1st-hold Accumulator/Right Side Covet
Oisassembly/lnspection/Reassembly .,..,..
Mainshaft
Disassembly/lnspection/Reassembly -.. -... 1 4- 1 29
lnsDection ................. 14- 130
Countershaft
Disassembly/lnspection/Reassembly ....... 14-132
Disassembly/Reassembly ....................... 1 4-1 33
lnsDection ................. 14-134
One-way Clutch/Parking Gear
Disassembly/lnspection .................... -.. -. 1 4-137
Sub-shaft
Disassembly/lnspection/Reassembly ....... 14-138
Disassemblv/Reassemblv ....................... 1 4-1 39
Sub-shaft Bearings
Replacement ............. l4-140
Clutch
fllustrated lndex ................. -..-...-.......... 14-1 41
Disassembly ,,,.,,........ 14-144
Reassembly .............. 14-146
Torque Converter Housing Bearings
Mainshaft Bearing/Oil Seal
Reolacement ......... 14-1 50
Countershaft Bearing Replacement .......,, 14-1 5l
Transmission Housing Bearings
Mainshsft/Countershaft Bearing
Repfacement ...-..-..14-152
Sub-shaft Bearing Replacement .............. 1 4-1 53
Reve.se ldler Gear
lnstallation ................ 14-154
Parking Brake Stopper
lnspection/Adjustment ..........................'14-'154
Transmission
Reassemblv .............,. .14_156
Toroue Converter/Drive Plate ..,..,............... 1 4- 1 63
Transmission
14-120
14-122
14-123
14-124
14-126
14-124
14-86
14-90
't4-92
14-93
14-94
lnstallation
Cooler Flushing'Shitt Cable
Removal/lnstallation ..............................
Adiustment ...-..-......-. 14-'171*Gearshift Selector
Disassembly/Reassembly .....................,. 1 4-17 2*Shift Indicator Panel
Adjustment -..........-...14-173
Throttle Control Cable
fnspection .......,..,...... 14-17 4
Adjustment .............. 14-176
14-164
14-168
14-'t 7 0
Inspection