HONDA INTEGRA 1994 4.G Workshop Manual

Mainshaft
Inspection
a Clearance Measurement
NOTE: Lubricate all parts with ATF during assembly.
1 . Remove the mainshaft bearing lrom the transmission
housing (see page 14-152).
2. Assemble the parts below on the mainshaft.
NOTE: Do not assemble the O-rings while in-
specting.
LOCKNUT
/ 1ST CLUTCH ASSEMBLY
THRUST WASHER
lST GEAR COLLAR
TBANSMISSIONHOUSING BEARING
THRUST WASHER
4TH GEAR COLLAR
2ND/4TH CLUTCHASSEMBLY
THRUST WASHERSelective part.
TI{RUST NEEDLEBEARING
2ND GEAR
NEEDLE BEARING
THRUST NEEOLEBEARING
MAINSI.IAFT
14-130
3RD GEAR2ND GEAR
Torque the mainshaft locknut to 29 N.m (3.0
kgf .m, 22 lbf.ft).
NOTE: Mainshaft locknut has lett-hand threads.
29 N.m (3.0 kgl.m, 22 lbt.ft)
4. Hold 2nd gear against the 2nd clutch. then meas-
ure the clearance between 2nd gear and 3rd gear
with a feeler gauge.
NOTE: Take measurements in at least three Dlaces
and take the average as the actual clea.ance.
STANDARD: 0.05-0.13 mm {0.002-0.005 inl
THRUST WASHER-36.5 x 55 ftm
3RD GEAR 2ND GEAR

5.lf the clearance is out of tolerance, remove the thrustwasher and measure the thickness
6. Select and install a new washer then recheck.
THRUST WASHER 36.5 x 55 mm
7, AIter replacing the thrust washer, make sure the
clearance is within tolerance.
No,Part NumberThickness
190441 -PG4-O104.OO mm (O.1 57 in)
90442 PG4-0104.05 mm {O. 1 59 in)
90443-PG4 -O104.1O mm (O.161 in)
490444-PG4-O104.1 5 mm (O.163 in)
90445-PG4-O104.20 mm (O.165 in)
690446-PG4-Ol O4.25 mm (O.167 in)
790447,PG4 0r04.3O mm (O.169 in)
890448-PG4-O104.35 mm {O.1 71 in)
q90449-PG4-Or 04.4O mm (O.1 73 in)
14-131

Countershaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricate all parts with ATF belore reassembly.a Install the thrust needle bearings with unrolled edge of bearing retainer facing washer.a Inspect the thrust needle bearings and the needle bearings tor galling and rough movement.a Before installing the O rings, wrap the shaft splines with tape to prevent damaging the O-rings.a Locknut has left-hand threads.
CONICAL SPRINGWASHERReplace.
LOCKNUT {FLANGE NUTI23 x 1.25 mm1O3-0-lO3N.m{10.5-O-'l0.5ksf.m,75.9*O-75.9tbf.fr)Replace.Left-hand threads
REVERSE GEAR COLLAR
NEEDLE EEARINGPARKING GEAR
ONE.WAYCLUTCHREVERSEGEAR
BEVERSESELECTOR
REVERSE SELECTORHUB
4TH GEAR
NEEDLE BEARING
DISTANCE COLLAR,28 mmSelective part.
.I ST GEAR
NEEDLE EEARING
lST GEAR COLLAR
TRANSMISSIONHOUSING BEARING
COUNTERSHAFTCheck splines for excessivewear or damage.Check bearing surface for scoring,scratches or excessive wear_
2ND GEAE
THRUST NEEDLEBEARING
3RD GEAR
NEEDLE BEARING
THRUST NEEDLE BEARING
3RD GEAR COLLAR
3RD CLUTCH ASSEMBLY
O-RINGSReplace.

Disassembly/Reassembly
1, Using a hydraulic press, press out the countershatt
while supponing 4th gear.
NOTE: Place an attachment between the press and
the countershatt to prevent damage to the shaft.
CAUTION: Do not allow the countershaft to lall and
hit the ground.
2.Assemble the parts on the countershaft as shown
oetow.
NOTE:
a Lubricate all parts with ATF during assembling.
a Before installing the O-rings, wrap the shalt
splines with tape to prevent damaging the
O-rings.
4TH GEAR
NEEDLE BEARING
DISTANCE COLLAR. 29 mm
Selective part.
2ND GEAR
THRUST NEEDLE BEARING
3RD GEAR
NEEDLE BEARING
THRUST NEEDLE BEARING
3RD GEAR COLLAR
3RD CLUTCH ASSEMBLY
O-RINGSReplace.
COUNTERSHAFT
{cont'd)

Countershaft
Disassembly/Reassembly (cont'd)Inspection
a Clearance Measurement
NOTE: Lubricate all parts with ATF during assembly.
1. Remove the countershaft bearing from the transmis-
sion housing (see page l4-152).
2. Install the pans below on the counte.shaft using the
special tool and a press as described on this page.
NOTE: Do not assemble the O-rings while in-specting.
aInstall the reverse selector hub on the countershaft
sub-assemblV, and then press the reverse selector
hub using the special tool and a press as shown.
REVERSE SELECTORHUB
4TI{ GEAR
NEEDLE BEAFING
DISTANCE COLLAR, 28 m|nSelective part.
COUNTERSHAFT
14-134

Install the parts below on the countershaft sub-
assembly, then torque the locknut to 29 N'm (3.O
kgf.m, 22 lbf.ft).
LOCKNUTLeft-hand threads
CONICAL SPRI GWASHER
PARKING GEAR/ONE-WAYCLUTCH/1ST GEARASSEMBLY
NEEEDLE BEARING
lST GEAR COLLAR
TRANSMISSION HOUSINGBEARING
REVERSE GEARCOLLAR
Measure the clearance between the 2nd gear and
the distance collar, 28 mm wilh a feeler gauge.
NOTE: Take measurements in at least three places.
and take the average as the actual clearance.
STANDARD: O.O5-0.13 mm (0.OO2-O.O05 in)
DISTANCE COLLAR,28 mm2ND GEAR
2ND GEAR
(cont'd)
14-135

Countershaft
Inspection (cont'dl
5. lf the clearance is out of tolerance, remove the dis-
tance collaf, 28 mm and measure the width,
6. Select and install a new distance collar, then
recheck.
DISTANCE COLLAR, 28 mm
7, Altet selecting a new distance collar, recheck the
clearance and make sure it is within tolerance.
No.Part NumberWidth
190503-PC9-OOO39.O0 mm (1 .535 in)
,90504-PC9-OOO39.10 mm (1.539 in)
90sos,Pc9-ooo39.20 mm (1.543 inl
90507-PC9-00039.30 mm (1.547 in)
590508-PC9-00039.05 mm (1 .537 inl
690509-PC9-00039.1 5 mm {1.541 in)
790510 PCg*00039.25 mm (1.545 in)
I9051 I -PCg-OOO38.90 mm {1.531 in)
90512 PCg 00038.95 mm {1.533 in)
14-136

One-way Clutch/Parking Gear
Disassembly/lnspection
1.Separate countershaft 1st gear from the parking gear
by turning the parking gear in the direction shown.
Inspoct tha psrta a3 tollows:
PARKII{G GEARInspect thg parking
tor w€s. or acoring.
O E.WAY
2. Remove the one-way clutch by prying it up with the
end of a screwdrive..
Inspect tho ono-wayclutch fo. damagea orfaultv movement.
courrERsHAFrlsr.EAR 9IlYlL9iY^t.?INOTE: lnstall in this direction.
l ST GEARInspect counior6haft 1tor wegr or scoaing.
3. After the Darts are sssembled, hold counte.shaft lst
gear and turn tho parking gear in the direction shown
to be sur6 it turns freelv,
O'TE.WAY CLUTCH
COUNTERSHAFT lST GEAR
COUNTERSHAFT 1ST GEAR
COU TERSHAFT 1ST GEAR
SCREWDRIVER
14-137

Sub-shaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricate all parts with ATF during reassembly.
a Install the thrust needle bearings with unrolled edge ot bearing retainer tacing washer.
a lnspect the thrust needle bearings and the needle bearings for galling and rough movement.
a Before installing the O-rings, wrap the shaft splines with tape to prevent dsmaging the O-.ings.
TRANSMISSIOI{ HOUSING
TRANSMISSIONHOUSING BEARING
6 x 1.0 mm12 N.m
lST-HOLD CLUTCHASSEMELY
O.RINGSReplace.
THRUST WASHER
THRUST NEEDLEBEARING
NEEDLE BEARING
4TH GEAR
THRUST I{EEDLEAEARIIIG
4TH GEAB COLLAR
NEEDLE EEARING
(1.2 kgf.m, 8.7 lbf.ft)
SUB.SHAFTCheck splines tor excessivewear or damage.Check bearing surlace torsconng. scratches or excessive
OIL GUIDE CAPReplace.NEEDLE BEARIT{GSTOPPER

Disassembly/Reassembly
Remove the oil guide cap by pushing the sub-shaft
inside the transmission housing.
Remove the 1st-hold clutch assembly by pulling the
sub-shaft, then remove the sub-shatt.
Install new O-rings on the sub-shaft.
NOTE: Wrap the shaft splines with tape to prevent
damaging the O-rings.
Place the sub-shaft in the transmission housing and
install the 1st-hold clutch assembly.
Install new oil guide cap using the special tools as
snown.
DRIVER07749-0010000
ATTACHMENT-32x35mm07746-0010100
,I ST.HOLD CLUTCHASSEMBLY
14-1 39