clutch HONDA INTEGRA 1998 4.G Workshop Manual

Differential (81 8BJ engine)
Side Clearance Adjustment
1. lnstall the dilferential assembly, making sure at bot-
toms in the clutch housing, using the special tool as
shown.
DRIVER, 40 mm I D.o7746-0030100
HOUSING
2. Install the 80 mm shim.
NOTE: Insrall the 80 mm shim that was removed.
mm SHIM
15-6
3.Install the transmission housing (see section 13).
NOTE: Do not apply liquid gasket to the mating sur-
face of the clutch housing.
Tighten the transmission housing attaching bolts
{see section l3}.
8 x 1.25 mm
27 N.m {2.8 kgf.m. 20 lbf'ft}
Use the special tool to bottom the differential assem-
bly in the clutch housing.
Measure clearance between the 80 mm shim and
bearing outer race in the transmission housing.
5.
6.

Differential (81881 engine)
Oil Seal Installation
1. lnstall the oil seal into the transmission housing us-
ing the special tools as shown
DRIVER07749-0010000
OIL SEALReplace.
HOUSING
15-8
Install the oil seal into the clutch housing using the
special tools as shown.
ORIVER07749-OO10000
OIL SEALReplace.

Differential (B18C1 engine)
lllustrated Index
J
J
NOTE: lI parts marked with an asterisk {*)were replaced, the tapered roller bearing preload must be adjusted (see page
15 15).
*CLUTCH HOUSING
OIL SEAL Replace.Removal, page 15 13Installation, page 15 17
*THRUST SHIMT. 2.5 mm {0.098 in)
*TAPERED ROLLER BEARINGlnsDect for wear and ooeration.Replacement, page 1 5-13
*BEARING OUTER RACEInspect for wear and damage.Replacemenl, page 15 14
10 x 1.0 mm
*DIFFERNTIAL CARRIERInspection, page 15-12
101 N.m {'10.3 kgf.m, 74.5 lbf.It)Le{t hand threads
*TAPERED ROLLER BEARINGInspect tor wear and operation.Replacement, page 15 13FINAL DRIVEN GEARInspect tor wear and damage. -----------r'
Repfacement. page 15-1 2
}BEARING OUTER RACE
*79.5 mm SHIMSelection, page 15 16
*TRANSMISSION HOUSING
OIL SEAL Replace.Removal, page 15-13Installation, page 1 5-17
.la
15-1 1

Tapered Roller Bearing ReplacementoilSealRemoval
1.
2.
Remove the difterential assembly.
Remove the oil seal lrom the transmission housing.
TRANSMISSION HOUSING
3. Remove the oil seal irom the clutch housino.
NOTE:
a The tapered roller bearing and bearing outer race
should be replaced as a set.
a Inspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
a Check the tapered roller bearings for wear and rough
rotation. lI tapered roller bearings are OK, removal is
not necessary.
1. Remove the tapered roller bearings using a bearing
puller and bearing separator as shown.
BEARINGPULLER(Commercially
available)
BEARINGSEPARATOR(Commercially
available)
Install new tapered roller bearings using the special
tool as shown.
NOTE: Drive the tapered roller bearings on until they
bottom against the dillerential carrier.
DRIVER, 40 mm LD.07746 -OO30100
j
1 5-13

CAUTION: Do not reuse the thruEt shim and th€ 79.5
mm shim if the outer race was driven out.
NOTE:
a The bearing outer race and tapered roller bearing
should be reDlaced as a set.
a Inspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
1 . Remove the oil seals from the transmission housing
and clutch housing (see page 15-13).
2. Remove the bearing outer race, the thrust shim, and
the 79.5 mm shim from the transmission housino.
DRIVER07749-0010000
SEAL ORIVERATTACHMENT07JAD -PH80101
DRIVER, 40 mm LD.07746 -O030100
3.
TRANSMISSION HOUSING
Remove the bearing outer race and thrust shim from
the clutch housing.
CLUTCHHOUSING
ORIVERATTACHMENT07NAD-PX40100
ATTACHMENTo7f{AD-PX40lOO
DRIVERo7749 -0010000
TRANSMISSIONHOUSING
BEARINGOUTERRACE
79.5 mmSHIM
BEARINGOUTERRACE
THRUST SHIMT. 2.5 mm 10.098 inl
lnstall the new thrust shim and 79.5 mm shim. then
drive the bearing outer races in the both housings
using the special tools as shown.
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.
ORIVEB
5. Install the oil seal (see page 15-17).
Differential (818C1 engine)
Bearing Outer Race Replacement
15-14
\l
\
\

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 Ditferential carrier
a Tapered roller bearing and bearing 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 15-14).
CAUTION: Do not reuse the thrust shim if the bea.-
ing outer race was driven out-
2. First try the same size 79,5 mm shim that was
removeo.
CAUTION: Do not use more than two shims,
79.5 mm SHIM
HOUSING
3.Install the thrust shim and 79.5 mm shim, then drive
the bearing outer race in the transmission housing
{see page 15-'14).
NOTEI
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 mainshatt and countershaft removed, in-
stall the dillerential assembly, and torque the clutch
housing and transmission housing.
8 x 1.25 mm
27 N.m (2.8 kgf.m. 2O lbf.ft)
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
Rotate the ditferential assembly in both directions
to seat the tapered roller bearings.
Measure the tapered roller bearing preload ot the
dilferential assembly 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.O kgf'cm,
18.7 -26.9 lbt.inl
PRELOAD INSPECTION TOOL07HAJ-PK40201
(cont'd)
6.
5-1

l.lnstallthe oil seal into the transmission housing us-
ing the special tools as shown.
Installthe new oil seal into the clutch housing using
the soecial tools as shown.
DR|vENo7749-0010000DRIVER07749-OOIOOOO
OIL SEALReplace.OIL SEALReplace.
HOUSING
SealInstallation
15-17

J
Tapered Roller Bearing Preload Adjustment
lf any of the items listed below were replaced, the
tapered roller bearing preload must be adjusted,
. Transmission housing
. Clutch housing
. Limited slip diffsrential assembly
. Tapored roller bearing and bearing outer race. Thrust shim
. 79,5 mm shim
Remove the bearing outer race, the thrust shim, and
the 79,5 mm shim from the transmission housing.
Replace the thrust shim and the 79.5 mm shim if
they were dsmaged when the bearing outer race
was driven out.
First try the same size 79.5 mm shim that was
removeo.
HOUSING
Install the thrust shim and only one 79.5 mm shim
in the transmission housing, then drive in the bear-
Ing our€r race.
Noto these items during rassembly:
. Install the bearing outer race squarely.. Check that there is no clearance between the
bearing outer race, shims and transmission
housing,
With the mainshatt and countershaft removed,
installthe differential assemblv. Assemble the clutch
housing and transmission housing without a sealing
a9ent, and torque the case bolts.
8 x 1.25 mm
27 N.m (2.8 kgf.m, 20 lM.ft)
Rotate the differential assemblv in both directions
to seat the tapered roller bearings.
Measur€ the tapered roller bearing preload of the dif-
ferential assembly in both directions with the special
tool and a toroue wrench.
STANDARD: 2.11 - 3.04 N.m(2!.5 - 31.0 kgt'cm,
18.7 - 26.9 lbf.in)
PNELOAD INSPECTION TOOL07TAJ - ST701dt
(cont'd)
15-25

Moonroof
Troubleshooting
SymptomP.obable Cause
Clogged drain tube.
Gap between glass weatherstrip and roof panel
De{ectrve or improperly Installed glass weatherstrip
Gap between drain seal and rool panel.
Excessive clearance between glass weatherstrip and roof panel-
Loose motor.
Worn gear or bearing.
Cable assemblv deformed.
1
2
3
4
1
2
3
1.
Water leaks
Wind noise
Motor noise
Glass does not move, but motor
turns
Clutch out ol adiustment.
Foreign matter stuck between guide rail and slider'
lnner cable loose.
Cable assembly not attached properly
,l
2
3
4
Glass does not move and motor
does not turn (glass can be moved
with moonroof wrench)
1. Blown fuse.
2. Faulty switch.
3. Battery run down.
4. Delective motor.
5. Faulty relay.
Glass Height Adiustment
The roof panel should be even with the glass weather-
srrip, to within 1.8 t O.5 mm {O.07 t 0.02 in} all the
way around. lf not, slide the sunshade back, and:
1. Tilt-up the glass.
2. Loosen the bolts and adjust the glass.
3. Repeat on opposite side if necessary.
1.8 i 0.5 mm 10.07 i 0.02 inl
V : Boll locations, 6
]-
ROOF PANELGLASS BRACKET
Side-to-side iit of glass weatherstrip can be adJust-
ed by loosening the frame mounting bolts and mov-
ing the frame right or left and {orward or backward
by hand (see page 2O-8Oi.
GLASS BRACKETGLASS WEATHERSTRIP
{
$
I
!
20-78

OpeningDragGheck
(Motor Removedl
Before installing the motor, measure the effort required
to open the glass using a spring scale as shown.
CAUTION: Wh€n using a spring scale, piotect the lead-
ing odge of the glass with a shop towel.
lf load is over 40 N 14 kgf, 9lbf), check side clearance
and glass height adjustment (see page 20-78).
Closing Force Check
(Motor Installedl'1. After installing all removed parts, have a helper hold
the switch to close the glass whjle you measure
{orce required to stop it. Attach a spring scale as
shown. Read the force as soon as the glass stops
moving, then immediately release the switch and
spflng scate.
CAUTION: When using a sp.ing scale, protect the
leading edge of the glass with a shop towel.
Closing Fo.ce: 200-29O N
{2O- 30 kst. 44-66 lbf)
SPRINGscAt_E
lf the force is not within specification, install a new
lock washer, adjust the tension by turning the mo
tor clutch adjusting nut, and bend the lock washer
against the motor clutch adjusting nut.
2.
LOCKWASHERReplace.
COUNTERcLocKwtsETo decrease
GLASS
t;-<
20-83