Mainshaft HONDA INTEGRA 1994 4.G Workshop Manual

ll
Standards andService Limits
Manual TransmissionSection 13
MEASUREMENTSTANDARD {NEWISERVICE UMIT
Transmission oilCapacity f {US qt, lmp q02.2 {2.3, 1.9}lor oilchange2.3 (2.4, 2.0) lor assembly
MainshaftEnd playDiameter ot ball bearing contact area(clutch housing side)Diameter of 3rd gear contact areaDiameter of ball besring contact area(transmission housing side)Runo!t
0.11 - 0.18 {0,004 - 0.007)27 .977 - 27 s90 l.1.101 - 1 .1021
37.984 - 38.000 {1.495 - 1.495}27.987 - 28.000 {r.1018 - 1.1024}
0.02 (0.0008) max.
Adjust27.93 (1.10)
37.93 {1.493)21 .94 /.1.10!'
0.05 (0.002)
Mainshafi
3rd and4lh gears
t.D.
End playThickness3rd4th
43.009 - 43.025 11.6933 , 1.6939)0.06 - 0.21 (0.0024 0.0083)34.92 - 31.97 (1.3748 - 1.3768)31.12 - 31.17 11.2370 - 1.23SOl
43.08 t 1 .696)0.3 (0.012)
34.8 (1.370)
31.3 (1.2321
Mainshaft5th geart.D.End playThickness
43.009 - 43.025 (1.6933 - 1.6939)0.06 - 0.21 (0.0024 - 0.0083)31.42 - 31.47 t1.237 -1.2391
43.08 {1.696)0.3 (0.012)
31.3 (1.232)
CountershaftDiameter of needle bearing conlact areaDiameter of ball boaring contact areaDiameter of 1st gear contact areaBunout
33.000 - 33.015 (1.299 - 1.300)24.980 - 24.993 {0.9835 - 0.9840)36.984 - 37.000 (1.4561 - 1.4567)0.02 10.0008) max.
32.95 \1.297)24.94 (0.982)
36.93 {1.454)0.05 t0.002)
Countershaftlst geart.D.End play42.009 - 42.025 11.6539 - 1.6545)0.04 - 0.12 (0.0016 - 0.0047)42.08 (1.657)
Adjust
Countershaft2nd gearLD.End playThickness 81881 engino818C1 6ngine
47.009 - {7.025 11.8507 - 1.85r4)0.05 - 0.12 (0.0020 - 0.0047)34.62 - 34.67 (1.3630 - 1.3650)28.92 - 28.97 (1.1386 - 1.1405)
47.0811.854)Adjust3{.5 (1.358)
28.8 (1.134)
Spacer collar(Countershaft
2nd gear)
t.D.o.D.LengthB
36.48 - 36.49 (1.4352 - 1.4366)41.989 - 42.00011.6531 - 1.6535)29.02 - 29.04 (1.r42s - 1.1433)29.07 - 29.09 (1.1444 - 1.1453)
36.5 (1.437)
41.94 (1.651)
Spacer collar{ l'rainshaft4th andsth gears)
t.D.o.D.LengthB
31.002 - 31.012 (1.2205 - '1.2209)
37.989 - 38.000 (1.4956 - 1.4951)56.45 - 56.55 12.2224 - 2.2264126.03 - 26.08 (1.0248 - 1.0268)
31.06 ('1.223)
37.94 (1.494)
3-8

- AutomaticTransmissionSection 14Unit ol length: mm (in)- atcuarrurr r.t
MEASUREMENTSIANDARD {NEW}SERVICE LIMIT
iransmissionDiameter of needle bearing contact areaOn mainshatt and stator shaftOn mainshaft 2nd gear
On mainshaft 4th gear collarOn mainshaft lst gesr collarOn countershaft (left side)On countershatt 3rd gear
On countershaft 4th gear
On countershaft reverse gear collarOn countershaft lst gear collaron sub'shaft (left side)On sub-shaft 4th gear collarOn reverse idler gear shaftInside diameter of needle bearing conlact areaOn mainshaft lst gear
On mainshaft 2nd gear
On mainshalt 4th gear
On countershaft lst gear
On countershaft 3rd gear
On countershaft 4th gear
On countershaft reverse gear
On sub-shatt 4th gear
On reverse idler gear
On stator shaft (right side)On stator shaft {stator side)Reverse idler gear shaft holder l.D.End play
Mainshaft 1st gearMainshaft 2nd gear
Mainshatt 4th gear
Countershaft 1st gear
Countershaft 3rd gear
Countershaft 4th gear
Sub-shaft 4th gearReverse idler gear
Countershaft reverse gear
Selector hub O.D.Mainshaft 4th gear collar lengthMainshatt'lst gear collar lengthlvlainshaft Ist g€ar collarflange thickness
22.980 - 22.993 (0.9047 - 0.9052)35.975 - 35.991 0.4163 - 1.4169)31.975 - 31.99r (1.2589 - 1.2595)30.975 - 30.991 t1.2195 - 1 .2201136.004 - 36.017 {r.4r7s - 1.4'l80)35.980 - 35.996 (1.4165 - 1.4172)27.980 - 27.993 {1.1016 - 1.1021)31.975-31.991 (1.2589 - 1.2595)31.975 -31.991 (1.2589 - 1.2595)25.991 - 26.000 (1.0233 1.0236)27.980 - 27.993 (1.1016 - 1.1021)13.990 11.000 (0.5508 - 0.5512)
35.000 - 35.016 (1.3780 - 1.3786)41.000 - 41.016 {1.6142 - r.6148}38.000 - 38.016 (1.4961 - 1.4967138.000 - 38.0161'].4961 - 1.4967)41.000 - 41.016 (1.6142 - 1.6148)33.000 - 33.016 (1.2992 - 1.2998)38.000 - 38.016 0.4961 - 1.4967)32.000 - 32.016 fl.2598 1.2605)18.007, 18.020 {0.7089 0.7094)29.000 - 29.013 (1.14r7 - 1.1422)27.000 - 21.021 (1.0630 - 'j.1638)
14.416 - 14.434 10.5676 - 0.5683)
0.08 - 0.24 (0.003 - 0.009)0.05 - 0.13 (0.002 - 0.005)0.045 - 0.140 (0.002 - 0.006)0.1 - 0.5 (0.004 0.020)0.04 - 0.15 (0.002 - 0.006)0.05 - 0.13 (0.002 - 0.005)0.05 - 0.17 (0.002 - 0.007)0.05 - 0. r8 (0.002 - 0.007)0.10 - 0.25 10.004 - 0.010)51.87 - 51.90 (2.042 - 2.043)49.00 - 49.05 (1.929 - 1.931)27.00 - 27.15 (1.063 - '|.069)
2.5 - 2.6 \2.098 - 2.102)
Wear or damage
Wear or damage
Wear or damage
*rd"-"g"
Wear or damage
Countershaft distance collar length38.97 - 39.0039.02 - 39.0539.07 - 39.1039.12 - 39.r539.17 - 39.2039.22 - 39.2539.27 - 39.3038.87 - 38.9038.92 - 38.95
1.534 1.535)'r.536 - 1.537)1.538 - 1.539)1.540 - 1.541)r.542 - 1.543)1.544 1.545)1.546 - 1.547)1.530 - 1.53r)'1.532 - 1.533)
Countershaft reverse gear collar lengthCountershaft reverse gear collar flangethicknessCountershaft 1st gear collar lengthCountershaft '1st gear collar flange thicknessSub-shaft 4th gear collar lengthSub-shaft 4th gear collar flange thickness
14.5 - 14.610.57r 0.575)
2.4 - 2.6 (0.094 - 0.102)'14.5 - 14.6 (0.57'l - 0.575)2.4 - 2.6 (0.094 0.102)24.0, 24.1 {0.945 - 0.949}3.00 - 3.15 {0.118 0.r24)
Wear or damage
Wear or damageWear or damageWear or damage
(cont'd)
3-11

Standards and Service Limits
Automatic Transmission (cont'dl - Section 14
SERVICE t_tMtTMEASUREMENTSTANDARD {NEW}
Transmission(cont dlMainshaft 2nd gear thrust washer thickngss3.97 - 4.00 {0.156 - 0.'t57}4.02 - 4.05 (0.158 - 0.159)4.07 - 4.10 (0.r60 - 0.16114.12 - 4.'15 (0.162 - 0.163)4.17 - 4.20 (0.164 - 0.'t65)4.22 - 4.25 (0.166 - 0.167)4.27 - 4.30 {0.168 - 0.169)4.32 - 1.35 {0.170 - 0.17r)4.37 - 4.40 (0.172 - 0.173)
Wear or damage
I
I
IWear or damage
Thrust washer thicknessMainshaft ball bearing left sideMainshaft 1st gear left sideMainshatt 1st gear right side
3.45 - 3.55 (0.136 - 0.140)1.45 - 1.50 (0.057 - 0.059)3.43 - 3.50 (0.135 - 0.138)
Wearlor damase
Woar or damage
Sub-shaft 4th gear thrust washer thicknessOne-way clutch contact area l.D.Countershaft lst gearParking gearMainshaft feed pip€ A, O.D. {at 15 mm trom end}Mainshaft leed piDe B, O.O. {at 30 mm from end)Countershaft leed pipe O.D. (at l5 mm from end)Sub-shaft feed pip€ O.D. (at 15 mm trom end)Mainshaft sealing ring thickness{29 mm and 35 mm)Mainshaft bushing LO.Mainshaft bushing LD.Countershaft bushing LD.Sub-shaft bushing l.D.Mainshatt sealing ring goove widlh
2.93 - 3.00 (0.115 - 0.1181
83.339 - 83.365 (3.2810 - 3.2821)66.685 - 66.698 12.6254 - 2.6259)8.97 - 8.98 {0.353 - 0.354)5.97 - 5.98 (0.23s0 - 0.2354f7.97 - 7.98 (0.3138 - 0.3142)7.97 - 7.98 {0.3138 - 0.3142)1.980 - 1.995 (0.0780 - 0.07851
6,018 - 6.030 (0.2359 - 0.2374)9.000 - 9.015 (0.3s43 - 0.3549)8.000 - 8.01s (0.31s0 - 0.3156)8.000 - 8.015 (0.3150 - 0.3156)2.025 - 2.060 (0.0797 - 0.0811)
t-
tWear or damage8.95 {0.352t5.95 (0.2341
7.95 (0.313)
7.9s (0.313)
1.80 {0.071)
6.045 (0.2380)
9.03 (0.356)
8.03 (0.3r6)
8.03 (0.3161
2.08 (0.0821
RegulatorSealing ring contact area LD.35.000 - 35.025 {1.3780 - 1.3782)35.050 (1.3799)
Shifting device andparking brake con-trol
Reverse shift fork tinger thicknessParking brako ratchet pawlParking goarThroftlo cam slopper heighl
5.90 - 6.00 {0.232 - 0.236)
27.0 - 27.r (1.063- 1.067)
5.4O {0.213)
lWear or other
t_'--'
Servo bodyShift fork shaft bore Lo.Shift fork shaft v6lve bore LO.14.000 - 14.010 (0.5512 - 0.5516)37.000 - 37.039 (1.{567 - 1.4582)37.045 {1:4585}
Oil pumpOil pump gear side clearanc€Oil pump gear-to-body cl€6rance DriveDriv€nOil pump driven g6ar I.D.Oil pump shaft O.D.
0.03 - 0.05 (0.001 - 0.002)0.210 - 0.265 {0.0083 - 0.0104)0.070 - 0.125 (0.0028 - 0.0049)14.016 - 1{.034 (0.5518 - 0.5525)13.980 - r3.990 {0.5504 - 0.5508)
0.07 (0.003)
W6ar or damageWear or damage
L
3-12

Manual Transmission
Special Toofs ............. 13-2
Maintenance
Transmission Oi1,...,........,........,.,..... 13-3
Back-up Light Switch
Replacement ......... 13-3
Transmission Assembly
Removal ..,.......,...... 13-4
lllustrated Index ................................... 13-8
Transmission Housing
Removal ...........,..... 13-10
Reverse Change Holder, Reverse ldler Gear
Glearance lnspestion ....................... 13-1 1
Removaf ................. 13-12
Change Holder Assembly
Clearance Inspection ....................... 1 3-1 3
Removal ................. 13-15
Disassembly/Reassembly ............... 13-16
Mainshaft, Gountershaft, Shift Fork
Removal ...,............. 13-17
Shift Rod
Removal ................. 13-18
Shift Fork Assembly
Index ................ ...... 13-19
Clearance Inspection ....................... 13-20
Mainshaft Assembly
Index ................ ...... 13-21
Clearance f nspection ....................... 13-22
Disassembly .......... 13-25
Inspection .............. 13-26
Reassembly ........... 13-21
Countershaft Assembly
Index ................ ...... 13-28
Clearance Inspection ....................... 13-29
Disassembly .......... 13-30
Inspection .............. 13-31
Reassembly ........... 13-32
Synchro Sleeve, Synchro Hub
Inspection .............. 13-34
Installation ............. 13-34
Synchro Ring, Gear
lnspection .............. 13-35
Clutch Housing Bearing
Replacement ......... 13-36
Mainshaft Thrust Clearance
Adiustment ............ 13-38
Transmission
Reassembly ........... 13-tl1
Transmission Assembly
lnstallation ............. 13-46
Gearshift Mechanism
Overhaul ................ 13-50

Special Tools
Rsf. No. I Tool NumbrrD!3criptionOty I Prgc R.{.rcnc.
o
o
o
o
@
@
@
@
@
07GAJ - PG20110
07GAJ - PG20130.07736 - A010004
07746 - 0010300
07746 - 0010400
07746 - 0030r00
07746 - 0030300
07746 - 0030400
07745 - 0041100
07749 - 0010000
Mainshaft Holder
Mainshaft Bas€
Adjustable Bearing Puller, 25 - 40 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Oriver, 40 mm l.D.
Attachment, 30 mm l.D.
Attachment, 35 mm l.D,
Pilot, 28 mm
Driver
1
1
1
1
1
1
1
1
1
1
'13 - 40
13-40
13 - 36, 37
13-36
13 - 36, 37
13 - 27,33
13 - 27,33
13 - 27,33
13-36
13 - 36, 37
* Must be used with commerciallv available 3/8" - 16 Slide Hammer.
o@
@@@
o@@
ll
13-2

19. Remove the clutch cover.
MOUNT/BRACKET
TRANSMISSION MOUNT
21.Place a transmission iack under the transmission
and a jack stand under the engine.
Remove the transmission mount.
23. Remove the rear mount bracket bolts and the trans-
mission mounting bolts.
24. Pull the transmission away from the engine until it
clears the mainshaft, then lower it on the transmis-
sion iack.
BRACKET
13-7

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
,l
{
@@69
@
@@@@@@@@6Dq0
o€xv0@
@0!@@@@al
61@
B
c
D
E
F
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

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

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