Transmission HONDA INTEGRA 1998 4.G Owner's Manual

Transmission Assembly
Removal (cont'dl
14. Remove the driveshafts and the intermediate shaft
(see section 16).
NOTE: Coat all precision finished surfaces with
clean engine oil or grease. Tie plastic bags over the
driveshaft ends.
SET RINGBeplace.
DRIVESHAFTDRIVESHAFT Replace. trweinnro,ora ""ot
15. Remove the heat shield (Bl8c1 engine).
16. Remove the bolt, then disconnect the extension rod.
17. Remove the clip and the spring pin, then disconnect
the shift rod.
8x22mmSPRING PIN
CLIP Replace
fl noo
flil
\
I mm PINPUNCH
(818c1 .ngin.l
13-6
'18. Remove the front (Bl8C1 engine) and the rear
engine stiffeners,
REAR ENGINESTIFFENER
Remove the clutch cover {818C1 and 81881
enganes),
{B188l .ngin.}

Transmission Housing
Removal
NOTE:
. lf tho transmission housing or clutch housing are
replaced, the bearing preload must be adjusted
(818C1 8nd 818C5 engines).
. Place the clutch housing on two pieces of wood thick
enough to keep the mainshaft from the hifting 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.
BACK-UP LIGHTswrTcHTRANSMISSIONHANGER B
STEEL BALLD. 5/16 in
SET SCREW
WASHERReplace.
Remove the reverse idler gear shaft bolt.
13-10
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 the countershaft ball bear-
ing and remove it from the groove using a pair of
snap ring pliers.
6.
7.
ATTACHING BOLT
SNAP RING
32 mm SEALING BoLT

8.
9.
f;:Y:fffrf#:J'uer' Sl[
Measure the clearance between the reverse change
holder and the sth/reverse shift piece pin.
Standard:
Reverse Side: 0.05 - 0.45 mm (0.002 - 0.018 inl
5th Side: 0.4 - 0.9 mm (0.02 - 0.04 in)
Separate the transmission housing from the clutch
housing, and wipe it clean of the sealant.
Remove the 72 mm thrust shim and the oil guide
plate from the transmission housing
72 fifiTHRUST SHIM
10. Remove the l6 mm sealing bolt and the oil gutter
plate.
OIL GUTT6R PLATE
lf the clearance are not within the standard, mea-
sure the width of the grooves in the reverse change
holder.
Standard:
Revsrse Side: 7.05 - 7.25 mm {0.278 - 0.285 in)
5th Side: 7.4-7.7 mm (0.29 - 0.30 in)
REVERSE SIDE
lf the width of the grooves are not within the
standard, replace the rsverse change hbtder with
a new one.
lf the width of the grooves ar€ within the Stan
dard, replace the 9th/revense sHtFI piece wlth
new one.
(cont'

Mainshaft Thrust Glearance
1. Remove the 72 mm thrust shim and oil guide plate
from the transmission housing
72 mm THRUST SHIM
Adiustment
TRANSMISSIONHOUSING
\,
Bo
OIL GUIDE PLATE
Install the 3rd/4th synchro hub, spacer collar,5th
synchro hub, spacer, and ball bearing on the maln-
shaft, then install the above assembly in the trans-
mission housing.
lnstallthe washer on the mainshaft.
Measure distance @ between the end of the trans-
mission housing and washer'
NOTE:
. Use a straight edge and vernier caliper'
a N4easure at three locations and average the read
Ing.END ofTRANSMISSIONHOUSING
3RD,/4TH SYNCHRO HUB
SPACER COLLAR
sTH SYNCHRO HUB
MAINSHAFT
WASHER
BALL BEARING
. Try the 1.68 mm (0.0661 inI shim.
5. Measure distance @ between the end of the clutch
housing and bearing inner race
NOTE:
. Use a straight edge and depth gauge
a Measure at three locations and average the read-
ings.
Select the prcpe( 72 mm thrust shim from the chart
by using the formula below.
NOTE: Use only one 72 mm thrust shim
Shim Selection Formula:
From the measurements you made in steps 4 and 5:
- 1. Add distance @ (step 5) to distance @ (step 4).
-2. Frcm this number. subtract 0.93 (which is the
midpoint ot the flex range of the clutch housing
bearing spring washer).
-3. Take this number and compare it to the avail-
able shim sizes in the chart.
(For examplel
6.
B:2.39
+ C: 0.22- 0.93
1.68
END of CLUTCH HOUSING
INNER RACE o{ BALL BEARING

I
\
72 mm Thrust Shim
Part NumberThickness
23931 - P21 -0000.60 mm (0.0236 in)
B23932-P21-0000.63 mm (0.0248 in)
c23933 - P21 -0000.66 mm (0.0260 in)
D23934 P21 0000.69 mm (0.0272 in)
E23935 P21 - 0000.72 mm (0.0283In)
23936 P21 0000.75 mm (0.0295n)
G23937 - P21 0000.78 mm 10.0307n)
23938 - P21 -0000.81 mm 10.0319n)
23939 P21 - 0000.84 mm {0.0331n)
J23940 P21 0000.87 mm (0.0343 in)
K23941 - P21 -0000.90 mm (0.0354 in)
L23942 - P21 - 0000.93 mm (0.0366 in)
M23943 - P21 -0000.96 mm (0.0378 in)N23944-P21 -0000.99 mm {0.0390 in)
o23945 - P21 -0001.02 mm (0.0402 in)
23946 P2r - 0001.05 mm (0.0413 in)
o23947 P2r - 0001.08 mm (0.0425 in)
23948 P21 - 0001.11 mm (0.0437;ni
23949 P21 - 0001.14 mm (0.0449 ini
T23950-P21 -0001.17 mm (0.0461 in)
23951 - P21 -0001.20 mm (0.0472 in)
23952 P21 - O001.23 mm (0.0484 in)
23953 P21 - 0001.26 mm (0.0496 'n)
23954 - P21 000'1.29 mm (0.0508 in)
23955, P21 0001.32 mm (0.0520 in)
z23956 P21 - 0001.35 mm (0.0531 in)
23957 P2r - 0001.38 mm (0.0543 in)
AB23958 P21 - 0001.41 mm (0.0555 in)
AC23959-P21 -0001.44 mm (0.0567 in)
AD23960 P2r 0001.47 mm (0.0579 in)
AE23961 - P21 000L50 mm 10.0591 rn,
23962 - P21 0001.53 mm {0.0602 in)
AG23963, P21 0001.56 mm (0.0614 in)
AH23964 P21 0001.59 mm (0.0626 jn)
23965 P21 0001.62 mm (0.0638 in)
23966 - P21 0001.65 mm (0.0650 in)
AK23967-P2t-0001.68 mm (0.0661 In)
23968-P21 -0001.71 mm (0.0673 in)
23969 P21 - 0001.74 mm (0.0685 in)
AN23970 P21 - 0001.77 mm {0.0697 in)
AO23971 P21 - 000'l -80 mm {0.0709 in)
1.
72 mm THRUST
TRANSMISSIONHoustNG --'-.rft=>t
o
Check the thrust clearance in the manner described
oerow.
NOTE: Check the measurement at normal room
temperature.
a. Install the thrust shim selected and oil guide
plate in the transmission housing.
OIL GUIOE PLATE
b.
f.
NOTE:
. Clean the spring washer, washer and thrust shim
throughly before installation,
. Install the spring washer, washer and thrust
shim properly.
- -- /wAsHER(€>P-
X -spnrruc wlssen
a a.7l=\-\-
Install the mainshaft in the clutch housing.
Place the transmission housing over the main-
shaft and onto the clutch housing.
Tighten the clutch and transmission housings
with several I mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
8 x 1.25 mm
27 N.m (2.8 kgf.m, 20 lbt.ft)
Tap the mainshaft with a plastic hammer.
c.
o.
t:oInstall the spring
ball bearing.
wash erand washer on the
(cont'd)
il
13-39

Mainshaft Thrust Clearance
g. Slide the mainshaft base over the mainshaft.
Adjustment (cont'dl
/\
/-
MAINSHAFT BASE07GAJ - PG20130
Aftach the mainshaft holder to the mainshaft as fol-
lows:
NOTE:
o Eack-out the mainshaft holder bolt and loosen
the two hex bolts.
. Fit the holder over the mainshaft so its lip is
towards the transmission.
. Align the mainshaft holder's lip around the
groove at the inside of the mainshaft splines,
then tighten the hex bolts.
MAINSHAFT HOLDERbolt
MAINSHAFT BASE07GAJ - PG20130
Seat the mainshaft fully by tapping its end with a
plastic hammer.
Thread the mainshaft holder bolt in until it just con-
tacts the wide surface of the mainshaft base.
MAINSHAFT
f----M---E
|".ffi f\.xex
I \J \--l./ l/ Borrs
L- LE
\
MAINSHAfiHOLDER07GAJ - PG20110
13-40
Zerc a dial gauge on the end of the mainshaft.
Turn the mainshaft holder bolt clockwise; stop turn-
ing when the dial gauge has reached its maximum
movement. The reading on the dial gauge is the
amount of mainshaft end plav.
CAUTION: Turning the mainshaft holder bolt more
than 60 degrees after the needle of the dial gauge
stops moving may damage the transmission.
MAINSHAFT HOLDER07GAJ - PG20110
lf the reading is within the standard, the clearance is
correct.
It the reading is not within the standard, recheck the
shim thickness.
Standard: 0.11 - 0.18 mm (0.004 - 0.007 in)
DIAL GAUGE

I
t
\
Transmission
Reassembly
1. Install the new oil seal.
2. Set the change piece.
3. lnstall the shift rod.
4. Install the steel ball, the spring, and the set screw.
5. Install the change piece attaching bolt.
6. Install the shift rod boots.
8x1.0mm30 N.m (3.1 kgf.m,22tbfitl
SHIFT ROD
7. Installthe oil chamber plate.
7 .' L. 25.6 mfi BOI
@ ,zt tt.o'ti"t I
Y-",:'b>,",CI
6x1.0mm12 N.m {1.2 kgl.m,9 lbf.ft)
8. Install the differential assembly.
DIFFERENTIALASSEMBLY
Position the spring washer and the washer onto the
mainshaft bearing.
Install the mainshaft, the countershaft. and the shift
fork assemblies.
NOTE: Align the finger of the interlock with rhegroove in the shift fork shaft.
MAINSHAFT
SHIFT FORKS
(cont'd)
10.
13-41

Transmission
Reassembly (cont'dl
1't. lnstallthe change holder assembly.
6x1.0mm15 N.m ('1.5 kgf.m,11 rbf.ft)
lnstall the shift piece and the
the shift piece shaft.
interlock, then install't2.
6x1.0mm12 N.m 11.2 kg{.m,I lbf.ftl
13-42
13. Measure the distance @ after mounting the shift
piece shaft. lf it's incorrect, check the installation.
Distance @: 11.9 - 12.3 mm (0.47 - 0.48 inl
Install the reverse idler gear, and the reverse
gear shaft,
idler14.
REVERSE IDLER GEAR

'15. lnstall the reverse chanqe holder.
6x1.0mm15 N.m 11.5 kgt m, l l lbf.ft)
16.Install the oil guide plate and the 72 mm thrust shim
into the transmission housing.
72 mm THBUST SHIM
fl
t
i
17.Install the oil gutter plate.
Bend the hook of the oil gutter plate, then install the
16 mm sealing bolt.
NOTE: Apply liquid gasket (P/N 08718 - 0001)to the
threads.
16 mm SEALING BOLT29 N.m 13.0 kgt.m, 22 lbf.ftl
Apply ljquid gasket to the surface of the transmis-
sion housing as shown.
NOTE:
. Use liquid gasket (P/N 08718 - 0001).. Remove the dirt and oil from the sealing surface.. Seal the entire circumterence of the bolt holes to
prevent oil leakage.
. lf 20 minutes have passed after applying liquid
gasket, reapply it and assemble the housings,
and allow it to cure at least 30 minutes after
assembly before filling the transmission with oil.
(cont'd)
18.
19.
Liquid gaskot
13-43

Transmission
20.
21.
Reassembly (cont'dl
Installthe dowel pins.
Install the transmission housing by aligning the
groove in the housing with finger on the stop ring.
GROOVE
Lower the transmission housing with the snap ring
pliers, and set the snap ring in the groove of the
countershaft bearing.
TRANSMISSIONHOUSING
13-44
23. Check that the snap ring is securely seated in the
groove of the countershaft bearing.
Dimension @ as installed: 4.6 - 8.3 mm
(0.181 - 0.327 inl
24. Install the transmission hanger A and back-up light
switch clarnp, then tighten the transmission hous-
ing attaching bolts in the numbered sequence
shown below.
ATTACHING BOLTSI x 1.25 mm27 N.m (2.8 kgf.m, 20 lbf.ft)
BACK.UP LIGHTSWITCH CLAMP
\'