HONDA INTEGRA 1994 4.G Workshop Manual

Glearance Inspection
'L Measure the clearance between the thrust shim and
1st gear,
StEndard: 0.0,1- 0.12 mm (0.fi12 - 0.005 inl
Servics Limit: 0.18 mm (0.007 in)
2. lf the cleatance is more than the service
and install the appropriate thrust shim
rect clearance from the chan below.
Thrust Shim
limit, select
to. the cor-
'HRUST SHIM
Part NumbarThicknces
23921 - PKs - 9001.95 mm (0.0768 in)
B23922-PKs-9001.96 mm (0.0772 in)
23923-PK5-9001.97 mm (0.0776 in)
D23924-PKs-9001.98 mm (0.0780 in)
E23925-PKs-9001.99 mm {0.0783 in)
F23926-PKs-9002.00 mm (0.0787 inl
23927-PKs-9002.01 mm (0.0791 in)
H23928-PKs-9002.02 mm (0.0795 in)
23929-PKs-9002.03 mm (0.0799 in)
23930-PKs-9002.04 mm {0.0803 in)
K23931 - PKs - 9002.05 mm (0.0807 inl
L23932-PK5-9002.06 mm (0.0811 in)
M23933-PKs-9002.07 mm (0.0815 in)
N23934-PKs-9002.08 mm (0.0819 in)
o23935-PKs-9002.09 mm (0.0823 inl
P23936-PKs-9002.10 mm (0.0827 in)
13-29
3. Measure the clearance between 2nd and 3rd g68rs.
Stlndlrd: 0.05 - 0.12 mm (0.002 - o.(x}5 inl
Scrvice Limlt 0.18 mm (0.007 inl
4. lf the closrance is more than the service limit, selsct
and install the appropriate spacer for the corr€ct
clearance from the chart below.
Spaccl
Part Numb"rThickncla
A23917-P21 - 01029.02 - 29.0,{ mm
(1.1425 - 1.1433 in)
B23918-P2r-01029.07 - 29.09 mm
(1.1445 - 1.1453 in)

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

Inspection
1. Inspect the gear surfaces and the bearing surfaces
for w€ar and damage, then measure the counter-
shaft at points A, B, and C.
St.ndard:
A: 2/t.980 - 27.9!13 mm (0.91|:15 - 1.1021 inl
B: 36.984 - 37.q)O mm {1.4551 - 1.'156? in}
C: 33.qD - 33.015 mm (1.2992 - 1.2998 inl
Sorvica Limit:
A: 2,a.930 mm (0.9815 in)
B: 35.930 mm (1.a539 inl
C: 32.950 mm 11.2972 inl
Inspect tor wear6nd damage.
Inspect oil passage lor clogging.
lf any parts of the countershaft are less than the
service limit, replace count€rshaft with a new
one.
Inspgct tor runout.
Stlndrrd: 0.02 mm {0.(xn8 inl Max.
Srrvic. Limit 0.05 mm {0.(x)2 in)
NOTE: Suppon the countershaft at both ends as
snown.
Rotate tl/vo compl6t€rcvolutions.
. lf the runout is more than the servic6 limit,
rgDlace the countershaft with a new one.
13-31

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

SYNCHROHUB
Synchro Sleeve, Synchro Hub
Inspection
'1. Inspect gear teeth on all synchro hubs and synchro
sleeves for rounded off corners, which indicates
wear.
2. Install each synchro hub in its mating synchro
sleeve and check for Jrgedom of movement.
NOTE: lf replacement is required, always replace
the synchro sleeve and synchro hub as a set.
Installation
When assembling the synchro sleeve and synchro hub,
be sure to match the thr€e sets of longer testh (120
degrees apart) on the synchro sleeve with the three sots
of deeper grooves in th€ synchro hub.
CAUTION: Do not install thc synchro 3l.6yc with itt
longor tosth in tha 13t/2nd synchro hub 3lob, b.c!u3a
it will d.mago tho spring ring.
sYt{cHRoHUB SLOT
13-34
LONGER TEETH
SLEEVE

Synchro Ring, Gear
r Inspection
1. Inspect the synchro ring and gear.
A: lnspect the inside of the synchro ring for wear.
B: Inspect the synchro sleeve teeth and matching
teeth on the synchro ring for wear (rounded off).
CCGOOD WORN
C: Inspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded offl.
oo
GOOD WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
F: Inspect the teeth on all gears for uneven wear.
scoring, galling, and cracks.
Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear, Rotate the
ring, making sure that it does not slip.
Measure the clearance between the synchro ring
and gear allthe way around.
NOTE: Hold the synchro ring against the gear even-
ly while measuring the clearance.
Synchro Ring-to-Ggar Clgarance
Standard: 0.85 - 1.10 mm(0.033 - 0.0/B in)
Service Limit:0.i1 mm 10.02 inl
Double Cone Synchro-to-Gear Cloaiance
Standald:
@: {Outer Synchro Ring to Synchro Cone)
0.5 - 1.0 mm 10.02 - 0.0i1in)
@: lSynchro Cone to Goar)
0.5 - 1.0 mm (0.02 - 0.04 in)
O: loutsr Synchro Ring to Gsarl
0.95 - 1.68 mm (0.037 - 0.066 inl
Service Limit:
6): 0.3 mm 10.01 inl
@: 0.3 mm t0.01 inl
G): 0.6 mm (0.02 in)
lf the clearance is less than the service limit, replace
the synchro ring and synchro cone.
SYNCHRO SPBING
SYNCHRO RING
SYNCHRO CONE
SYNCHRO RING
o
13-35

Clutch Housing Bearing
Replacement
Mainrhaft:
1. Remove the ball bearing using the special tools as
shown.
3/8' - 16 SI.IDE HAMMCR(commercially av6ilable)
CTUTCH
ADJUSTABIT AEARINGPULER, 25 - a0 mrn07736 - A01moA
2. Remove the oil seal from the clutch housing.
CLUTCH HOUSING
3. Drive the new oil seal into the clutch housing using
the specialtools as shown.
ATTACHMEIVT, a2 x 4t rnm0r7a5 - 0010300
()|L SEAIRoplacs.
Drive the ball bearing into the clutch housing usin!
the sDecial tools as shown.
13-36
BATI. BEAMIO

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 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