HONDA INTEGRA 1994 4.G Workshop Manual

12 N.m (1.2 kgim,9 lbnft)
15 N.m (1.5 kgnm, 11 lbf.ft)
15 N.m (1.5 kgf.m, 11 lbf.ft)
24 N.m (2.4 kgf.m, 17 lbf'ft)
27 N.m (2.8 kgnm,20 lbnft)
30 N.m (3.1 kgf.m, 22 lbf'ft)
Bolt Size
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6x1.0mm
6x1.0mm
I x 1.0 mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.0 mm
i) BALL BEARINGe sroPPER R|NG9 TAPER RINGA NEEDLE EEARINGO SPACER.d SYNCHRO RINGt sYNcHRo SPR|NG!) 5TH/REVEFSE sYNcHRo SLEEVEO 5TH/REVERSE SYNCHRO HUB[0 sYrucxao nlrucii i) 5TH GEARO 38 x 43 x 26 mm NEEDLE BEARINGt3 SPACEE COLLARO 4TH GEAR.iB SYNCHRO FING.Ii9 SYNCHRO SPRING{, 3RD/,ITH SYNCHRO HUB
@ 3RD/4TH SYNCHBO SLEEVEt9 3RD GEARO MAINSHAFTO wasHER@) SPRING WASHER40 BALL BEARINGO 28 x 41 x ? mm OIL SEAL Replace.ad 35 x 56 x 8 mm OIL SEAL Replace.a0 14 x 20 mm OOWEL PIN@ OIL CHAMBER PLATE'A BEVERSE IDLEN GEAR SHAFT@ wasHER t-2).A REVERSE IDLER GEAFO REVERSE CHANGE HOLDER3A sTH/REVERSE SHIFT PIECEO 1ST/2ND SHIFT FORK04 3RD/.TH sHlFr FoRK@ 5TH/REVERSE SHIFT FORKO9' OIL GUTTER PLATE6' SNAP RING@ 72 mm THRUST SHIM) OIL GUIOE PLATEi!0 10 mm WASHER Replace..4i] REVERSE IDLER GEAR SHAFT BOLT54 N.m {5.5 kgt m, 40lblftl) TRANSMISSION HANGER B(3 BREATHER CAP@ TRANSMISSION HANGER A63 BACK.UP LIGHT SWITCH25 N.m (2.5 ksf.m, 18lbfftl@r 14 mrn waSHER Replace.67 16 mm SEALING BOLT29 N.m (3.0 kgl.m, 22 lbf ft)@ 32 mm SEALING BOLT25 N.m (2.5 kgf.m. 18lbt'ft|@ 40 x 62 x 9 mm OIL SEAL Replace.D STEEL BALL D. 5/16 inGl SPRING L. 30 mm {1.2 in}
@ 12 mm WASHER Replace.63) SET SCREW22 N.m 12.2 kgl.m, 16 lbt'ft,@ OIL ORAIN PLUG39 N.m {4.0 kgt.m, 29 lbf'ftl€9 WASHER Replace.@ oIL FILLER PLUG4,1N.m 14.5 kgJ m, 33 lblftl
*1:81881 engine*2:B18Cl engine
WASHER Beplace.TRANSMISSION HOUSING80 mm SHIM (*1)79.5 mm SHIM {*21THRUST SHIM {*2IT. 2.0 mm (0.079 in)BEARING OUTER RACE {*2}SHIFT PIECE SHAFTINTERLOCKSHIFT PIECESHIFT ARM HOLDERSELECT ARMSELECT RETURN SPRING10 mm SHIM10 mm WASHERLOCK COLLAR3 x 16 mm SPRING PIN Replace.8 mm SPRING WASHERCHANGE PIECESET SCREW22 N.m {2.2 kgf.m, 16 lbf.ft}SPRING L.25.6 mm {1.01 inlSTEEL BALL D. 5/16 inMAGNETCLUTCH HOUSING14 x 25 x 16 mm OIL SEAL Replace.SHIFT RODDIFFERENTIAL ASSEMBLYSee section 15BEARING OUTER RACE I*2ITHRUST SHIM I*2)T. 2.5 mm (0.098 in,SHIFT ROD BOOTOIL GUID€ PLATE33 x 60 x 20 mm NEEDLE BEARINGBEARING RETAINER PLATELOCK WASHER Replace.COUNTERSHAFTTHRUST SHIM37 x 42 x 25 mm NEEDLE BEARINGlST GEARFRICTION DAMPERSYNCHRO RINGSYNCHRO SPRINGlST/2ND SYNCHRO HUBREVERSE GEARDOUBLE CONE SYNCHRO I*2ISYNCHRO BING I*1)FRICTION DAMPERSPACER42 x 6? x 24 mm NEEDLE BEARING2ND GEAR3RD GEAR4TH GEAS5TH GEARNEEDLE BEARINGBALL BEARINGSPRING WASHERLOCKNUT Replace.108 - 0- 108 N.m(11.0 - 0* 11.0 kgt m,80- 0- 80lbf.ft)5 x 22 mm SPRING PIN Replace.00
13-9

Transmission Housing
Removal
NOTE:
. lf the transmission housing or clutch housing a.ereplaced, the bearing proload must be adjusted(818C1 engine).
. Place the clutch housing on two pieces of wood thickenough to keep the mainshaft from the hitting the
workbench.
1. Remove the back-up light switch.
2. Remove the transmission hanger B,
3. Remove the set screws, the springs, and the steel
balls.
Tna sMtsstoN
SPBINGL. 30 mm11.2 inl
SET SCBEW
WASHERReplace.
4. Remov€ the reverse idler gear shaft bolt,
WASHERReplace.
REVERSE
L
13-10
ATTACHING BOLT
5. Loosen the transmission housing attaching bolts in
a crisscross pattern in several steps. then remove
them.TRANSMISSION
Remove the 32 mm sealing bolt.
Expand the snap ring on ths countershaft ball bear-
ing and remove it from the groove using a pair of
snap ring pliers.
32 mm SEALING BOLT
7.
SNAP RING

Reverse Change Holder,
Reverse ldler Gear
Clearance Inspection
Measure the clearance between the re
holder and the sth/revsrse shift piece p
Standard:
Bevorse Sido: 0.05 - O.ils mm (0.002 - (
5th Sido: o.ia - 0.9 mm 10.02 - 0.0,1
SHIFT PIECE PIN
REVERSE CHANGE
€,
lf the clearance are not within the sti
sure the width of the grooves in the re
holder.
Standsrd:
Rovsrea Side: 7.05 - 7.25 mm {0.278 - (
sth Sido: 7.1-7.7 mm (0.29 - 0.30
REVERSC SIOE
REVERSE
I ' '-- sTH SIDE
lf the width of the grooves are n
standard, replace the reverse chan€
a new one.
lf the width of the grooves are wi
dard, replace the sth/reverse shift
new one,
Separste the transmission housing from the clutch
housing, and wipe it clean of the sealant.
Remove the 72 mm thrust shim and the oil guide
plate from the transmission housing.
t2 mmTHRUST SHIM
TRANSMISSION HOUSING
Remove the 16 mm sealing bolt and the oil gutter
plate.
OIL GUTTER PLATE
10.
reverse cnange
ptn.
.0.018 inl
),1in)
standard, mea-
reverse change
0.285 in)
I inl
not within the
Inge holder with
within the stan-
rift piece with a
(cont'd)
13-1 1

Measure the clearance between the reverss idler
gear and the reverse change holder.
Standard: 0.5 - 1.1 mm (0.02 - 0.04 inl
Sorvico Limit: 1.8 mm (0.07 inl
4.lf the clearance is more than the service limit, mea-
sure the width ofthe reverse change hold6r.
St.ndrrd: 13.0 - 13.3 mm (0.512 - 0.52/t inl
lf the width is not within the standard, replace
the reverse change holder with a new one.
lf the width is within the standard, reolaco the
reversa idler gear with a new one.
REVERSE CHA'{GE HOLDER
REVERSE CHANGE HOTI'ER
Reverse Change Holder, Reverse ldler Gear
Clearance Inspection lcont'd)Removal
1. Removo the reverse change holder.
2. Remove the revorss idler g€ar, th€ rev6rs6 idlsrgear shaft, and the washor {B18Cl engine}.
REVERSE IDI.TRGEAF SHAFT
13-12
REVERSE CHAMiE HOII'ER

Change Holder Assembly
Clearance Inspection
Measure the clearance between the shift piece and
the shift arm holder.
Silndrd: 0.1 - 0.3 mm (0.004 - 0.012 inl
Scwic. Limit: 0.6 mm (0.02 inl
It the cloarance is more than the service limit, mea-
sure th€ width of the groove in the shift piece.
Stlndffd: 8.1 - 8.2 mm (0.319 - 0.323 inl
ll the width of the groove is not within the stan-
dard, replsce the shift piecs with a new one.
lf the width of the groove is within the standard.
roolace the shift arm holder with a new one.
SHIFT PIECE
SHIFT ARM HOI.I'ER
SHIFT PIECE
INTERLOCK
{
3. Measure the clearance between the select 8rm and
the interlock.
Standlrd: 0.05 - 0'25 (0.002 - 0.010 in)
Scrvica Limit 0.5 mm (0.02 in)
4. lf the clearance is more than the service limit, mea-
sure the width ot the interlock.
Stlndrrd: 9.9 - 10.0 mm (0.391t - 0.39a in)
lf the width is not within the standard. replace
the interlock with a new one.
lf the width is within the standard, replace the
select arm with a new one.(cont'd)
13-13

Change Holder Assembly
Clearance Inspection {cont'd}
7, Measure the clearance between the select arm
the 10 mm shim.
Stsndard: 0.01 - 0.2 mm (0.0004 - 0.008 inl
8. lf the clearance is not within the standard. select
and install the appropriate 10 mm shim for the cor-
rect clearance from the chan below.
10 mm Shim
SETICT ABM
10 mm SHIM
Part NumbsrThickn€ss
24435-689-0000.8 mm (0.03'l in)
B24436-689-000'1.0 mm (0.039 in)
24437-689-0001.2 mm (0.047 inl
24438-689-0001.4 mm {0.055 in)
24439-689-0001.6 mm (0.063 in)
13-14
SHIFT ARM HOLDER
9. Measure the clearance between the shift arm holder
and the change piece.
Standard: 0.05 - 0.35 10.002 - 0.01i1 in)
Sorvico Limit: 0.8 mm (0.03 in)
ll the clearance is more than the service limit. mea-
sure the groove of the change piece.
Standafd: 12.05 - 12.15 mm {0.47ilil - 0.iU83 in)
lf the groove is not within the standard, replace
the change piece with a new one.
lf the groove is within the standard, replace the
shift arm holder with a new one.
10.

11.Moasure th€ clsarance between the s6l6ct arm 8nd
tho change piece.
Sundrrd: 0.05 - 0.35 mm (0'002 - 0'014 in)
S.rvic. Limit 0.5 mm 10.02 Inl
lf the clesrance is more than the service limit, mea-
sure the width ofthe change Piece.
Strndrrd: 12.05 - 12.15 mm {0./17,11 - o.'U&l in)
CHANGE PIECE
lf ths width is not within the standard, replace
the change piec€ with a n€w one.
lf the width is within the standard, replaco th€
select arm with a new one.
Removal
Removs the shift piece shaft, then remove the shift
pieca and the interlock.
SHIFT PIECE SHAFT
2. Remove the change holder assembly.
12.
SEI.ECT ARl,l
CHANGE HOLDER ASSEMBLY
13-15

Change Holder Assembly
Disassembly/Reassembly
I erior to reassembling. clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.
10 mm SHIM
3 mm PIN
SELECT RETURN SPRING
13-16

Mainshaft, Gountershaft, Shift Fork
- Removal
1. Remove the mainshaft and the countershaft assem-
blies with the shift forks from the clutch housing.
NOTE: Tape the mainshaft spline belore removing
the mainshaft and the countershaft assemblies.
2 Remove the spring washer and the washer.
Remove the differential assembly from the clutch
housing.
OIFFERENTIAL
CLUTCH HOUSING
13-17
4. Remove the chamber plate.
CLUTCH HOUSING
CHAMBCR PLATE

Shift Rod
CHANGE PIECE
SPRINGL 25.6ll.0r in,
STEEL AALL(D.5/16
SPRING WASHER
Removal
1. Remove the shift rod boots.
2. Romove the change piece sttaching bolt and the
spring washer.
3. Remove the set screw, then remove the spring and
the steol ball.
4. Remov€ tho shitt rod, then remove the chsngepiece.
5. Remove th€ oilseal.
OIL SEALRoploc€.
*q
ACHING BOLT
SET SCBEW
13-18