Rings HONDA INTEGRA 1994 4.G Manual PDF

Tapered Roller Bearing Preload Adjustment
NOTE: lf any of the items listed below were replaced,
the tapered roller bearing preload must be adjusted,
a Transmission housing
a Clutch housing
a Diffe.ential carrier
a Tapered roller bearing and bea,ing outer race
a Thrust shim
1 . Remove the bearing outer race, the thrust shim, and
the 79.5 mm shim from the transmission housing
(see page 1 5- 14).
CAUTION: Do not reuss lhe thrust shim it the bear-
ing outer raco was driven out.
2. First t.y the same size 79.5 mm shim that was
removeo.
CAUTION; Do not uso moro than two shims.
79.5 rnm SHIM
HOUSING
4.
o.
Instsllthe thrust shim and 79.5 mm shim, then drive
the bearing outer race in the transmission housing
{see page l5-14).
NOTE:
a Install the bearing outer race squarely.
a Check that there is no clearance between the
bearing outer race. thrust shim and transmission
housing.
With the mainshaft and countershaft.emoved, in-
stsllthe differential assembly, and lorque the clutch
housing and transmission housing,
8 x 1.25 mm
27 N.m 12.8 kgf.m, 20 lbf.ft)
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
Rotate the ditterential assembly in both directions
to seat the tapered roller bearings.
Measure the starting torque of the differenlial assem-
bly with the special tool and a torque wrench.
NOTE: Measure the tapered roller bearing preload
in both directions.
STANDARD: 2.1 1 -3.O4 N.m(21.5-31.0 kgf'cm,
18.7-26.9 lbf.inl
{cont'd}
15-15

Differential (B18C1 enginel
Tapered Roller Bearing Preload Adjustment (cont'dl
7. It the tapered roller bearing preload is not within the
standard, select the 79.5 mm shim lrom the follow-
ing table which will give the tapered roller bea.ing
preload closest to the standard mean value of 2.50
N.m (25.5 kgJ.cm, 22 lbf.in).
NOTE: Changing the 79.5 mm shim to the next size
will increase or decrease tapered roller bearing
preload about O.3-O.4 N.m (3-4 kgf.cm,
2.6 - 3.5 lbt.in).
79.5 mm SHIM
Part NumbelThickness
41460-PY4-0000.66 mm (0.0260 in)
AB41461-PY4-0001.17 mm (O.0461In,
AC41462-PY4-0001 .2O mm (0.0472 in)
AD41463-PY4-0001.23 mm (O.O484 in)
AE41464-PY4-0001.26 mm (0.0496 in)
AF41465-PY4-OOO1.29 mm (O.O5O8 in)
AG41466-PY4-OOO1.32 mm (O.O52O in)
AH41 467-PY4-0001.35 mm {O.O531 in)
AI41468-PY4-0001.38 mm (O.O543 in)
AJ41469-PY4-0001 .41 mm (O.0555 in)
AK41470-PY4-OOO1 .44 mm (0.0567 in)
AL41 47 1 -PY 4-OOO1 .47 mm (0.0579 in)
AM41 47 2-PY 4-OOO1.50 mm {O.O591 in)
AN41473-PY4-0001 .53 mm (0.0602 in)
AO41 47 4-PY 4-OOO1.56 mm (0.0614 in)
AP41475-PY4-OOO'l .59 mm (O.0626 in)
AO4'1476-PY4-O001.62 mm (0.0638 in)
AR41 47 7 -PY 4-OOO1 .65 mm (0.0650 in)
AS41478-PY4-0001 .68 mm {0.0661 in)
41479-PY4-OOO1.71 mm (O.0673 in)
AU41480-PY4-OOO1.74 mm (0.0685 in)
41481-PY4-OOO1 .77 mm {0.0697 in}
41442-PY4-OOO1.80 mm (O.O7O9 in)
AX41483-PY4-OOO1.83 mm (0.0720 inl
15-16
9.
Recheck the tapered roller bearing preload.
How to select the correct 79.5 mm shim:- 1) Compare the tapered roller bearing preload you
get with the 79.5 mm shim that was removed
with the specified mean preload of 2.50 N.m(25.5 kgf .cm. 22 lbf.inl.-2) lf your measured tapered roller bearing preload
is less than specified, subtract your's from the
soecified.
lf your's is more than specified, subtract the
specified from your measurement.
For example with a 1 .38 mm (O.O543 in) shim:
@ specified 2.50 N.m (25.5 kgf.cm, 22 lbf.in)- you measure 0.54 N.m (5.5 kgt.cm, 5lbt'in)
2.0 N.m {20 kgf.cm, 18lbt.in} less
@you measure 3.29 N.m {33.5 kgl.cm, 29 lbl.in)- specified 2.50 N.m {25.5 kgf.cm, 22 lbf.in)
0.8 N.m (8 kgf.cm, 7lbt.in) more
3) Each shim size uD or down from standard
makes about O.3-O.4 N.m (3-4 kgf.cm,
2.6-3.5 lbf.in) difJerence in tapered roller
bearing preload.
a In example @, your measured tapered roller
bearing preload was 2.O N.m (20 kgf'cm,
I 8 lbl.in) less than standard so you need a
79.5 mm shim five sizes thicker thsn stan-
dard {trv the 1.53 mm (0.0602 inl shim and
recheck).
a In example @ your's was O.8 N.m (8
kgf.cm, 7 lbJ.in) more than standard, so
you need a thrust shim two sizes thinner (try
the 1.32 mm (0.0520 in) shim and recheck).
After adjusting the tapered .oller bearing preload, as-
semble the transmission, and installthe transmission
housing {see section 13).
8 x 1.25 mm
27 N.m 12.8 kgt.m. 20 lbf.ttl
Rotate the diJJerential assemblv in both directions
to seat the tapered roller bearings.
10.
11.

Differential (AutomaticTransmission)
Backlash InspectionBearing Replacement
1.Place the differential assembly on V-blocks and in-
stall both axles.
Check backlash of both pinion gears.
Standard (New): 0.05-O.15 mm (0.002-0.006 inl
3. lf backlash is out of tolerance, replace the differen-
tial carrier.
SIDE GEARS
NOTE: Check the bearings for wear and rough rotation.
lf the bearings are OK, removal is not necessary.
1. Remove the ball bearings using a bearing puller.
BEARING PULLER
Install the new ball bearings using the special tool
with a Dress as shown.
BALL BEAING
DRIVER, 40 mm l.D.07746 0030100
15-22

Differential Carrier Replacement
1.Remove the final driven gear from the differential
carrier.
NOTE: Tho final driven gear bolts have left-hand
threads.
Pry the snsp ring ofl differential carrier. then remove
the speedometer drive gear 8nd 5 x 1O mm roller.
lnstall th6 5 x 1O mm roller in the differentisl csrrier'
Install the speedom€ter drive gear with its chamfered
side facing the carrier, Align the cutout on the bore
of the speedometer drive gesr with the 5 x 10 mm
roll€r.
5.
4.
SPEEDOMETEBDRIVE GEARInstsll in thisdiroction.
DRIVE GEAR
5. Align the hooked end of the snap ring with the pin-
ion shaft as shown, then installthe snap ring in the
diff€rential carrior groove.
Hooksd €nd
SI{AP RII{GInstall in this direction.
o.Install the final driven gear, then tighten the bolts
to th6 spscified torque.
TOROUE: 101 N.m (10.3 kgf.m, 74.5 lbf.ft)
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS10 r 1.0 mmlOi N.m (1O.3 kgf.m,74.5 tbt'ft)Left-hand thrgads
7. Install the ball bearings {see page 15-22).
15-23

Intermediate shaft
Removal
Drsin the transmission oil or fluid (see section 13 or14).
Remove the left driveshaft (see page 16-3).
Remove the three dow€l bolts.
Remove the intermediate shaft f.om the differential.
CAUTION; Hold the intormediato shaft horizontrl
until it b clear of the dittorential to prevent damago
to thr dittarontial oil so!|.
Disassembly
NOTE: Be careful not to damage the metal rings on theintermediate shaft during disassembly.
1. Remove the set ring,
2. Remove the intermediate shaft outer seal from thebearing support.
3. Remove the eldernalcirclip.
OUTEB SEALReplsce.
2.
t
SET RINGReplace.
16-12

1.Press th6 intermBdiate shaft out of the shaft bearing
using the special tools and a press as shown.
Remove the internal circliD.
Press the intermediate shaft bearing out of th€ boar-
ing support using ths spscial tools and a prsss as
snown.Praa!5.
Pmar
I
SUPPORT BASEATTACHMENT07JAF - SH2oalXtFLOANNG RUBB€RDA'iIPERCheck for det€riorationand dama9e.
ATTACHMENT,1i2x a7 fim07ta6 - 00ro:!00INTEBNAL CIRCLIP
BEARING SUPFORT RINGChsck tor damagg or distonion.
SUPPORT BASEATTACHMENT- SHZ!(|O
BASE07965 - Sll9or00
INIERiIEDIAIE SHAFT
Check for damage.
SUPPORT BASE07965 - SDg,|q'
BEARING SUPPORTCheck for damage.
NOTE:
. Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber
parts with solvent.
. Be car€ful not to damage the metal rings on the intermedists shaft during reass€mbly
DOvvEL BOLTS10 r 1.25 ftm:tlt N.m {a.O tgt m, 29 lbfftl
Pack the intoriorof the outer saal.2.0- 3.5 g {0.07 - 0.12 oz}
EXTENTAL CIRCUP
ob.
BEARING
INTERMEOIATE SHAFT BEABINGReolaco.
SET RINGReplace.
v
ourER SEAL {conr'd)Rspbce.

Unovon or rcugh 8te6ring.
3
Adjust rack guide (se€ poge 17-21).
ll the probl6m is not corrected bYadjusting lhe rack guide. replacothe gearbox.
Adiud bolt t€nsion. Roplace b€lt, ifn€c€ssary {s€e page 17-20).
lf the ongin€ stalls when wheel isturned whil€ car is stoDPed ormoving at low spoed, adjust idlesp€€d (soe section 1 1 ).
ldl6 soosd low or orrrtic.
Chock power sieering Iluid levol. Itlgv6l ie excessivoly low, ch€ck forleaks in the system. Add fluid totho spocifiod level.
Air in rssorvoir. or ch€ck pow6a
steoring fluid l6v6l.
lf fluid lev6l is OK, check o-ringsand seals on both €nds of ihopump inlet hose, and th€ oilpump housing mating surfacosfor suction leaks. Reolace oarts65 n€CeSSAry.
Adjust belt tonsion (see page 17-m) or r€Dlaco beh.Pump b6lt slipping on pull6y(pump stops momontarily).
Check if pump prossure is withinthe ranoe 6.400 - 7,100 kPa (65 - 75kgr/cm,, 924 - 1,067 psil and th6gsuge needls travol is 1500 kPa {15kgflctn2, t71 p6i) or less. Check theflow control valve if the needletr.vel €xcoods 1500 kPa {15kg?cm,, i71 psi). lf rhe flow controlvalvo is normal, replace th€ pump
as an assomblv.
Sel the power itooring p.oasuregaug6. Cl066 th€ shut-off v6lv6fully and m€a5uro tho pumppr6ssur6 (6s€ pagg 17-221,
7-1

Troubleshooting
Fluid Leaks
Check the gearbox assembly for oil leaks carefully. Oil can leak out of various points. depending on location of thefaulty oil seals/seal rings. Check the following before removing the gearbox from the frame.
Steering GearboxLeaking from the oil seal on thetop of the valve housing.Roplace the valve oil seal fromthe valve housing.
Leaking from cylinder end intoleft tie'rod boot.Replace the valve oil seal lromthe pinion shaft.
Reolace the cvlinder end seal.
Leaking from cylinder end intoright tie rod boot.
Tighten attaching bolts or replacethe valve body unit or gear hous-Ing.
Leaking from the vslve bodyuniVhousing mounting soction.
Tighten connector. It still leaking.replace the pipe, cylinder orvalve housing unil.
Leaking from cylind6r pipe A or Bconnection (at tlare nut).
Leaking caused by damaged cy-linder pipe A or B.Replace the cylinder pipe A or B.
Leaking from feed pip6 andreturn pipe of the valve body unit(at flare nut).
Tighten connector. lI still leaking,replace the pipe or valve housIn9,
17-16

Pump outlet line(high pressure)
Low pressure hoses
Replace housing O-rings.lI the housing still leaks, replacethe pump.
Reservoir overfilled.Pullotfthe hose and drain to pro'per tevet.
Air leak in suction side of systemlreservoit inlet hose, front pumpseal),
Leaking b€cause ol dsmage, de'terioration, or improp€r assem-Replace or repair as necessary.
Tighten connector. lf still leaking,replace the pipe or v€lve hous'Ing,
Leaking at g6srbox connection.{at flare nut}.
17-17

Steering Column
lnspection
Check the steering column ball bearing and steeringjoint bearings for play and proper movement.
lf there is noise or excessive play, replace the joint orcolumn assembly.
Check the retaining collar for damage.
lf it is damaged, replace the retaining collar.
COI-UMN BALLEEARINGSTEERING JOINTBEARINGS
RETAINING COLLAR
Check the absorbing plates, absorbing plate guides
and sliding capsules for distonion or breakage.
Replace them as an assembly if they are distoned orbroken.
ABSONBING
SLIDING CAPSULEThis part is attachedto the column bracketwith the plastic injections.
17-30
Check the tilt mechanism for proper movement andoamage.
- Attach a spring scale to the knob of the tilt lever.Measure the preload required to move the lever.
Pr6load: 70 - 90 N 17 - 9 kgt, 15 - 20 tbf)
- lf the preload measured is not within the sDecifica-tion. remove the 6 mm bolt and stoDDer.
Adjust the preload by retightening the rilt tock boltuntil the correct force can be obtained.- Reinstall the stopper and 6 mm bolt and recheck
the Dreload.
9.8 N'm {1.0 kgt.m,7.2lbt'ftl
TILT LOCK BOLT