Bearing HONDA INTEGRA 1994 4.G Owner's Guide

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

Mainshaft Assembly
NOTE: The 3rd/4th and the 5th svnchro hubs are installed with a press.
818Cl cngino:Inirllstion dstailr, pag. 13-27
Prior to reassembling. clean all the parts in solvent, dry them and apply lubricant to any contact surfaces, The
3rdl,lth and the sth synch.o hubs, however, should be installed with a press before lubricating them.
SYNCHRO BINGInspection, page'13_35
3RD/'TH SYNCHRO SLEEVE
3RD/'TH SYiICHRO HUB
STOPPER RING
TAPER RING
NEEDLE BEARINGlnspect for wearand operation.
SPACER
Insp6clron,page 13-35
SPRING
SYNCHRO HUBSPRING
3RD GEARInspectaon.page 13-22
NCEDE AEARINGInspocl tor wearand operalton.
SYNCHRO SI..EEVE
SYNCHROSPRING
Inspectaon.pag6 13-35
5TH GEARrnspec!on,page 13-24
4TH GCARInspection,page 13-23
SPACERCOLLAR
13-21

- 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

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

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