clutch HONDA INTEGRA 1998 4.G Owner's Manual

Release Bearing
Removal/lnspection
1. Remove the release fork
housrng.
boot from the clutch
5.
6.
Torque the mounting bolts in a crisscross pattern as
shown. Tighten the bolts in several steps to prevent
warping the diaphragm spring.
8 x 1.25 mm25 N.m {2.6 kgf.m,19 tb{.fr}
Remove the special tools.
Recheck the diaphragm spring fingers for height {seepage 12-7).
CLUTCH HOUSING
BELEASE AEAFING
RELEASE FORK
Remove the release fork from the clutch housing by
squeezing the release fork set spring with pliers. Re
move the release bearing.
Check the release bearing for play by spinning it by
hand. lf there is excessive play, replace the release
bearing with a new one.
CAUTION: The release bearing is packed wirhgrease. Do not wash it in solvent.
a;;;:
S",€ r
K4IN/
RELEASE BEARING

Release Bearing
lnstallation
With the release fork slid between the release bear-
ing pawls, install the release bearing on tha main-
shaft while inserting the release fork through the hole
in the clutch housing.
RELEASE FORK BOLT29 N.m (3.0 kgl.m,22 tbt.ttl
Align the detent of the release fork with the release
fork bolt, then press the release fork over the release
fork bolt.
NOTE: Use only Super High Temp Urea Grease {P/N
o8798 - 9002).
Move the release fork right and l6ft to make sute that
the fork fits properly against the release bearing, 8nd
that the release bearing slides smoothly.
4. lnstall the release fork boot.
-6(P/N 08794-
-6
tPlN 08798-
RELEASE
12-12

Manual Transmission
Special Tools ............. 13-2
Maintenance
Transmission Oil .............................. 13-3
Back-up Light Switch
Replacement ......... 13-3
Transmission Assembly
Removal ................. 13-4
lllustrated Index ................................... 13-8
Transmission Housing
Removal ................. 13-10
Peverse Change Holder, Reverse ldler Gear
jGlearance Inspection ....................... 13-1 1
Removal ................. 13-12
Change Holder Assembly
Clearance Inspection .....,.,....,,.....,,.. 13-13
Removal ................. 13-15
Disassembly/Reassembly ............... 13-16
Mainshaft, Countershaft, Shift Fork
Removal ................. 13-17
Shift Rod
Removal ................. 13-18
Shift Fork Assembly
Index ................ ...... 13-19
Clearance lnspection ...................,.,. 13-20
Mainshaft Assembly
fndex ................ ......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
Inspestion .............. 13-31
Reassembly ........... 13-32
Synchro Sleeve, Synchro Hub
Inspection .............. 13-34
Installation ............. 13-34
Synchro Ring, Gear
Inspection .............. 13-35
Clutch Housing Bearing
Replacement ......... 13-36
Mainshaft Thrust Clearance
Adiustment ............ 13-38
Transmission
Reassembly ........... 13-41
Transmission Assembly
Installation ............. 13-46
Gearshift Mechanism
Overhaul ................ 13-51

Transmission Assembly
Removal
r@i Make surs iacks and safety stands sro placod propor-
ly (3ee s€ction 1).
. Apply parking brake and block resr whaeb 30 vohicle
will not roll off stands and hll on You whil6 working
under it.
CAUTION: Use fender covers to svoid damaging
paintod surtacos.
1. Disconnect the negative (-) cable from the battery,
then the positive {+) cable.
2. Remove the intake 8ir duct and the air cleaner hous-
ing assembly,
AIR CLEANERHOUSINGASSEMBL
Disconnect the back-up light switch connector and
the transmission ground wire.
BACK.UP LIGHTSWITCH CONNECTOR
TRANSMISSIONTRANSMISSIO
GROUND WIRE HANGEB B
4. Remove tne lowei radiator hose"clamp from the
transmission hsnger B.
INTAKE AIR DUCT
13-4
\-
5. Remove the wire hsrness clamps.
VSS CONNECTOR
Disconnect the starter motor cables and the vehicle
speed sensor (VSS) connector.
Remove the clutch pipe bracket and the slave cylin-
der.
NOT€: Do not operate the clutch pedsl once the
slave cvlinder has been removed.
7.

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, Countershaft, Shift Fork
Removal
mainshaft and the countershaft assem-
? shift forks from the clutch housing.
the mainshaft spline before removing
ft and the countershaft assemblies.
spring washer and the washer.
differential assembly from the clutch
OIFFERENTIALASSEMBLY
4. Remove the chamber plate.
SPRINGWASHER
1.Remove the m€
biies with the sl
NOTE: Tape th
the mainshaft a
Remove the spr
MAINSHAFT
COUNTERSHAFT
Remove the
housr ng.
CLUTCH HOUSING
CLUTCH HOUSING
CHAMBER PLATE
etsY')
2r}5
(\cyl,//_\::iv/.
13-17

Clutch Housing Bearing
Replacement
Mainshaft:
'L Remove the ball bearing using the special tools as
shown.
3/8" .16 SLIDE HAMMER
{Commorcially avsil.blo)
ADJUSTABLE BEARINGPULLER. 25 - 40 mm07736 - A010o0A
2. Remove the oil seal from the clutch housing.
CLUTCH HOUSING
13-36
BALL BEARING
3. Drive the new oil seal into the clutch housing using
the specialtools as shown.
ATTACHMENT, {2 x o7 mm077ir6 - (x)1 0300
OIL SEALReplace.
Drive the ball bearing into the clutch housing using
the specialtools as shown.
DRIVER07749 - @1U)0
PILOT, 28 mm07746 - 0041100
ATTACHMENT, 52 x 55 mm07?46 - 0010400
-: -,

Countershaft:
1. Bend the tab on the lock washer down, then remove
the bolt and bearing retainer plate.
CLUTCH
;:- Il{oustNG
2.Remove the needle bearing using the special
as shown, then remove the oil guide plate.
3/8- - 16 SLIDE HAMMER
lcommercially .vailablel
tools
ADJUSIABLE BEARINGPULLER,25-40 mm07736
3. Position the oil guide plate and new needle bearing
in the bore of the clutch housing, then drive in theneedle bearing using the special tools as shown.
NOTE: Position the needle bearing with the oil holefacing up.
NEEDLE
OIL HOLE
OIL GUIDE PLATE
CLUTCHHOUSING
lnstall the bearing retainer plate and new lock wash-
er, then bend the tab against the bolt head.
8x1.0mm15 N.m 11.5 kgf.m, 11 lbtftl
LOCKWASHERReplace.
ATTACHMENT, 52 x 5s mm
13€r