drive shaft HONDA INTEGRA 1994 4.G Owner's Manual

Installation (engine removal not
S€AL DRIVEB07LAD - PRimroAlnstallse6lwith tho
Pan numbertacing out.
Using the special tool, drive in the flywheel-end seal
until the driver bottoms against block.
NOTE: Align the hole in the drivsr attachment withthe Din on the crankshaft.
Oil Seal
required)
The seal surface on the block should b€ dry.Apply a light coat of grease to the crankshaft andto the lio of seal.
Using the special tool, drive in the timing pullsy-
end seal until the driver bottoms against the oilpump.
When the seal is in place, clean any excess grease
off lhe crankshaft and check that the oil seal tiD isnot distoned.
7-26

Oil Pump
5.
4.
Removal/lnspection/lnstallation
6. Remov€ the timing belt.
7. R€move the drive pulley.
8. Remov€ the oil pan and oil screen.
9. Remove the oil pump.
Drain the engine oil.
Turn the crankshatt and align the white groove on
the crankshalt pulley with the pointer on the lower
cover.
Remove the cylinder head cover and middle cover.
Remove the power steering pump belt, air condition-
er belt and the alternator belt.
Remove the crankshaft pulley and remove the low-
er cover.
OIL PUMP
OIL PAN
8-10
1O. Remove the screws trom the pump housing, thsn
separate the housing and coveJ.
1 1. Check the inner-to outer roto. radial clearance on thepumP rotor.
Innor Rotol-to-Outor Rotor Radial Cloaranco
StandErd (Newl: O.O4-O.16 mm(0.O02-0.006 in)
Service Limit: O.2O mm (0.008 inl
Check the housing-to-rotor axial clearance
pump rotor.
Housing-to-Botor Axial Claalanc€
Standard (Nowl: O.O2-O.O7 mm(O.OO1 -O.OO3 inl
Service Limit: O.15 mm (0.006 in)
on the12.
HOUSING

Transaxle
Clutch
Manual Transmission ......................
Automatic Transmission ..................
Differential
Manual Transmission
81881 engine
818C1 engine
Automatic Transmission ...............
Driveshafts
12-1
13-1
14-1
15-1
15-9
15-19
16-1

Special Tools
Ref. No, I Tool NumberDescriptionOty Page Reference
o/^
ri)
@
@
OTJAF_PM7011A
OTLAB PVOO1 OO or
o7 924-PD20003
07NAF-PR30100
07746-0010100
07749-OO10000
07936-3710100
Clutch Alignment Disc
Ring Gear Holder
Clutch Alignment Shaft
Attachment, 32 x 35 mm
Driver
Handle
'I
1
I
1
I
I
12,7
12-1, 8, 9, 10
12-7 , 8, 10
12-10
12-10
12-1 , 8, 10
I
12-2

Clutch Disc,
l.
t
Flywheel, Flywheel BearingPressure Plate
Replacement (cont'd)Installation
Install the ring gear holder.
Apply grease to the spline of the clutch disc, theninstall the clutch disc using the special tools assnown.
NOTE: Use only Super High Temp Urea Grease (P/N
08798-9OO2).
CLUTCH DISC
RING GEAR HOLDEROTLAB-PVOOI O0 ot07924-PD20003
3. Instali the pressure
CLUTCH ALIGNMENT SHAFT07NAF-PR30100HANDLE07936-3710100
plate.
CLUTCH ALIGNMENT SHAFToTNAF-PR30100HANDLE
PRESSURE PLATE
12-10
4. Drive the new flywheel bearing into the flywheel us-
ing rhe special tools as shown.
DRIVER07749-O010000
ATTACHMENT.32x35mm07746-OOlO100
o.
5.
FLYWHEEL
Align the hole in the flywheel with the crankshaft
dowel pin and installthe flywheel. Installthe mount-
ing bolts finger-tight.
Install the special tool as shown, then torque the
flywheel mounting bolts in a crisscross pattern in
several steDs as shown.
MOUNTING BOLTS12 x 1.0 mm103 N.m 110.5 kgf.m,76 tbf.fr)
FLYWHEEL BEARING
FLYWHEEL
07936-3710100
t\_

Special Tools
Rsf. No. I Tool NumbrrD!3criptionOty I Prgc R.{.rcnc.
o
o
o
o
@
@
@
@
@
07GAJ - PG20110
07GAJ - PG20130.07736 - A010004
07746 - 0010300
07746 - 0010400
07746 - 0030r00
07746 - 0030300
07746 - 0030400
07745 - 0041100
07749 - 0010000
Mainshaft Holder
Mainshaft Bas€
Adjustable Bearing Puller, 25 - 40 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Oriver, 40 mm l.D.
Attachment, 30 mm l.D.
Attachment, 35 mm l.D,
Pilot, 28 mm
Driver
1
1
1
1
1
1
1
1
1
1
'13 - 40
13-40
13 - 36, 37
13-36
13 - 36, 37
13 - 27,33
13 - 27,33
13 - 27,33
13-36
13 - 36, 37
* Must be used with commerciallv available 3/8" - 16 Slide Hammer.
o@
@@@
o@@
ll
13-2

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

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

Transmission Assembly
14. Install the intermediate shaft and the driveshafts(see section 16)-
NOTE: Replace the set rings with new ones.
Installation (cont'd)
-Sl
SET RINGReplace.
INTERMEDIATESHAFT
Replace.10 x 1.25 mm38 N.m (3.9 kgt m,28 tbtft)
15. Install the ball joints onto the lower arm (see sec-
tion 18).
16. Install the right damper fork (see section 18).
10 x 1.25 mm43 N.m {4.o ksf.m.32 lbf.ft)
RIGHTDAMPERFOBK
SELF.LOCKING NUTReplace.12 x 1.25 mm64 N.m {6.5 kgf.m,47 tbtft)
tLOWER ARM
:\
COTTER PIN
CASTLE NUT12 x 1.25 mm49 - 59 N.m 15.0 - 6.0 kgf m. Reptace.36 - 43 tbf.frl
13-44
DNIVESHAFTS
::.t
L
17. lnstall the exhaust pipe A, and the three way cat-
alytic converter (Bl8C'1 engine), and connect theheated oxygen sensor (HO2S) connector.
SELF-LOCKING NUTHO2SCONNECTORReplace.10 x 1.25 mm33 N.m (3.4 kgt.m,2s tbtftt
GASKETReplace.SELF.LOCKING NUTReplace.8 x 1.25 mm
SELF.LOCKING NUTReplace.THREE WAYCATALYTICCONVERTER1818C'l enginel
16 N'm 11.6 kgt m, 10 x 1 25 mm
l2tbt.ftl 54 N.m 15.5 kgt m,iro lbf.ftl
18. Install the engine splash shield.
GASKET

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