Transmission assembly HONDA INTEGRA 1998 4.G Service Manual

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

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

Differential
Ted Roll
(B18C1
er Bearinr
engine)
Preload Adjustment (cont'd)aperelng
7. lf the tapered roller bearing preload is not within the
standard, select the 79.5 mm shim from the follow-
ing table which will give the tapered roller bearing
preload closest to the standard mean value o{ 2.50
N.m (25.5 kgt.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.3-0.4 N.m (3-4 kgl.cm,
2.6 - 3.5 lbf.in).
79.5 mm SHIM
Part NumberThickness
41460-PsD-0000.66 mm (0.0260 in)
AB41461 - P5D - 0001.17 mm (0.0461 in)
AC41462-PsD-0001.20 mm (0.0472 in)
AD41463-P5D-0001.23 mm (0.0484 in)
AE41464-PsD-000'1.26 mm (0.0496 in)
AF41465-PsD-0001.29 mm (0.0508 in)
AG41466-PsD-0001.32 mm (0.0520 in)
AH41467-PsD-0001.35 mm 10.0531 in)
AI41468-PsD-0001.38 mm (0.0543 in)
41469-P5D-0001.41 mm (0.0555 inl
AK41470-PsD-0001.44 mm (0.0567 in)
AL41471 - PsD - 000'1.47 mm {0.0579 in}
41472-P5D-0001.50 mm (0.0591 in)
AN41473-PsD-0001.53 mm {0.0602 in}
AO41474-P50-0001.56 mm (0.0614 in)
AP41475-PsD-0001.59 mm (0.0626 in)
AO41476-P5D-000'1.62 mm {0.0638 in}
AR41477-P5D-0001.65 mm (0.0650 in)
41478-P5D-0001.68 mm (0.0661 in)
41479-P50-0001.71 mm (0.0673 in)
AU41480-PsD-0001.74 mm (0.0685 in)
41481 - PsD - 000'1.77 mm (0.0697 in)
41482-PsD-000'1.80 mm (0.0709 in)
AX41483-P5D-0001.83 mm (0.0720 in)
8. Recheck the tapered roller bearing preload.
9. 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 soecified mean Dreload of 2.50 N'm
(25.5 kgf .cm, 22 lbf.in).- 2l ll vour measured tapered roller bearing preload
is less than specified, subtract your's from the
specitied.
lf vour's is more than specitied, subtract the
soecified from vour measurement.
For example with a 1.38 mm {0.0543 in) shim:
@ specified 2.50 N.m (25.5 kgf.cm, 22 lbl.in)- you measure 0.54 N.m (5.5 kg{.cm, 5lbl.in}
2.0 N.m (20 kgf.cm, 18lbf.in) less
@you measure 3.29 N.m (33.5 kgI.cm, 29 lbt.in)- specified 2.50 N.m (25.5 kgf.cm, 22 lbf.in)
0.8 N.m (8 kgf.cm,7lbf.in) more
-3) Each shim size up or down from standard
makes about O.3-0.4 N.nt (3-4 kgf.cm,
2.6-3.5 lbl.in) difterence in tapered roller
bearing preload.
a In example @, your measured tapered roller
bearing preload was 2.O N.m (2O kgt.cm,
18 lbf in) less than standard so you need a
79.5 mm shim live sizes thicker than stan-
dard {try the 1.53 mm (O.0602 in) shim and
recheck).
a ln example @ your's was 0.8 N.m {8
kgf.cm,7lbf.in) more than standard. so
you need a thrust shim two sizes thinner (try
the 1 .32 mm (O.O52O in) shim and recheck).
1O. After adjusting the tapered roller bearing preload, as-
semble the transmission, and installthe lransmission
housing (see section 13).
8 x 1.25 mm
27 N,m (2.8 kgt'm, 20 lbf.ft)
11. Rotate the difterential assembly in both directions
to seat the tapered roller bearings.
1 5-16
\

Operational Check
Set the parking brake and block the rear wheels.
Raise the front of the vehicle, and support it with
safety stands in the proper locations (see section 1).
With the engine off, shift the transmission into lstgear,
Rotate either front wheel bv hand and check that
the other wheel rotates in the opposite direction.
lf the opposite tront wheel does not rotste, or if voucannot spin the front wheels at all, the limited slip
differential is faulty and should be roplaced.
Rotating Torque Check
Setting parking brake and block the rear wheels.
Raise the front of the vehicle, and support it with
safety stands in proper locations (see section 1).
With the engine off, shift the transmission into
Neutral.
Measure the rotating torque with a beam-type
torquo wrench in the direction shown, Rotate the
torque wrench morg than two complete turns and
take the maximum reading.
Shift the transmission into 1st gear and measure
the rotating torque again.
Calculate the rotating torque:
Service Limit:
Measur€ment from steD 5
Measurementfrom step 4 =--
For example:
7.8 N.m (0.8 kgf.m)
zg N"ll (03 kgf'ntl = z'ot > z''
Repeat step 3 through 6 for the other wheel.
Replace the limited slip differential assembly if the
rotsting lorque is lower than the service limit.
!
15-23

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

Limited Slip Differential (B18C5 engine)
Tapered Roller Bearing Preload Adiustment (cont'd)
7. lf the tapered roller bearing preload is not within the
standard, select the 79.5 mm shim from the follow-
ing table which will give the tapered roller bearing
preload closest to the standard value of 2.50 N'm
(25.5 kgicm, 22 lbf in). Changing the 79.5 mm shim
to the next size will increase or decrease tapered
roller bearing preload about 0.3 - 0.4 N'm (3 - 4
kgl.cm, 2.6 - 3.5 lbf.in).
79.5 mm SHIM
Part NumberThickness
41460-PsD-0000.66 mm (0.0260 in)
A841461 - P5D - 0001.17 mm (0.0461 in)
AC41462-P5D-0001.20 mm (0.0472 in)
AD41463-P5D-0001.23 mm (0.0484 in)
AE41464-P5D-0001.26 mm (0.0496 in)
AF41465-P5D-0001.29 mm (0.0508 in)
41466-PsD-0001.32 mm (0.0520 in)
AH41467-PsD-0001.35 mm (0.0531 in)
AI41468-P5D-0001.38 mm (0.0543 in)
AJ41469-PsD-0001.41 mm (0.0555 in)
AK41470-PsD-0001.44 mm (0.0567 in)
AL41471 - PsD - 0001.47 mm (0.0579 inl
41472-P5D-0001.50 mm (0.0591 in)
AN41473-P5D-0001.53 mm (0.0602 in)
AO41474-PsD-0001.56 mm (0.0614 in)
AP41475-P5D-0001.59 mm (0.0626 in)
AO41476-P5D-0001.62 mm (0.0638 in)
AR41477-P5D-0001.65 mm (0.0650 in)
AS41478-PsD-0001.68 mm (0.0661 in)
AT41479-P5D-0001.71 mm (0.0673 in)
AU41480-PsD-0001.74 mm (0.0685 in)
41481 - PsD - 0001.77 mm (0.0697 in)
41482-P5D-000'1.80 mm (0.0709 in)
AX41483-P5D-0001.83 mm (0.0720 in)
15-26
\
8. 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 sDecified preload of 2.50 N'm (25.5
kgf.cm, 22 lbf.in).-2) lf vour measured tapered roller bearing preload
is less than specified, subtract your's from the
sDecified.
lf your's is more than specified, subtract the
specified from your measurement.
For example with a 1.38 mm (0.0543 in) shim:
@ specified 2.50 N.m (25.5 kgf.cm,22 lbiin)- you measure 0.54 N.m (5.5 kgf'cm, 5 lbf in)
2.0 N.m (20 kgf.cm, 18 lbf.in) less
@ you measure 3.29 N.m (33.5 kgf.cm, 29 lbf in)
- specified 2.50 N'm (25.5 kgf'cm, 22 lbf in)
0.8 N.m {8 kgf.cm. 7 lbf in) more
-3) Each shim size up or down from standard
makes about 0.3 - 0,4 N.m (3 - 4 kgf'cm,
2.6 - 3.5 lbf.in) difference in tapered roller
bearing preload.
o In example @, your measured tapered roller
bearing preload was 2.0 N.m (20 kgf.cm,
18 lbf.in) less than standard so you need a
79.5 mm shim five sizes thicker than stan-
dard (try the 1.53 mm (0.0602 in) shim and
recheck).
. In example @, your's was 0.8 N.m (8
kgf.cm,7 lbf.in) more than standard, so you
need a thrust shim two sizes thinner (try
the 1.32 mm {0.0520 in) shim and recheck).
Recheck the tapered roller bearing preload.
After adjusting the tapered roller bearing preload,
assemble the transmission, and install the transmis-
sion housing.
Rotate the difterential assembly in both directions
to seat the tapered roller bearings.
10.
11.

Differential (Automatic Transmissionl
Backlash Inspection
1. Place the dilferential assembly on V-blocks and in-
stall both axles.
2. Check backlash of both pinion gears.
Standard lNsw): 0.05 - 0.15 mm {0.(Xt2 - o.(Xl6 in)
3. lf the backlash is not within the standard, reDlace
the differential carrier.
15-30I
Bearing Replacement
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'
Install the new ball bearings using the special tool
with a press as shown.
SIDE GEARS
EEABING PULLER(CommerciallY
available)
\
DRIVER, 40 mm l.O.07746-0030100

Differential (Automatic Transmissionl
Oil Seal Removal
Remove the differential assembly.
Remove the oil sealfrom the transmission housing.
Remove the oil seal from the torque converter
housing.
Oil Seal Installation/Side Clearance-
1 . Install a 2.50 mm {O.O98 in} thrust shim in the trans-
mission housing.
NOTE: Do not install the oil seal yet.
TRANSMISSIONHOUStf{G
Install the differential assembly into the torque con-
verter housing using the special tool as shown.
DRIVER, 40 mm l.D.07746-0030100
DIFFERENTIALASSEMBLY
/--1TOROUE CONVERTERHOUSING
Assemble the transmission lsee section 141.
Installthe transmission housing and tighten the bolts(see section 14).TOROUE CONVERTERHOUSING
15-32
OIL SEALReplace.

4.Tap on the transmission housing side of the ditferen-tial assembly with the special tool to seat thedifferential assembly in the torque convener housing.
o.
Measure the clearanc; between the thrust shim and
outer race of the ball bearing in the transmission
nousrng.
STANDARD: O-0.15 mm (O-O.O06 in)
It out of limits. select a new thrust shim from the
tollowing table:
THRUST SHIM, 80 mm
NOTE: Il the thrust shim-to-ball bearing outer race
clearance measured in step 5 is within the standard,
it is not necessary to perform steps 7 and 8.
Remove the transmission housing.
Replace the 2.50 mm {0.098 in) thrust shim with
the one of the correct thickness selected in step 6.
Install the transmission housing (see sectjon 14).
7.
L
Part NumberThickness
904r4-689-000
90415-689-000
90416-689*000
90417-689-OOO
90418-689-O00
90419-PH8-000
2.50 mm (0.09843 in
2.60 mm (0.10236 in
2.70 mm (O.10630 in
2.80 mm {O. 1 1O24 in
2.90 mm {O.1 141 6 in
3.OO mm (O. l '181 1 in
9.

Intermediate Shaft
Removal
Drain the transmission oil or fluid {see section 13 or
14t.
Remove the left driveshaft (see page 16-3).
Bemove the three dowel bolts.
Remove the intermediate sh8ft from the differential.
CAUTION: Hold the intermediate shaft horizontal
until it is clear ot th6 difforantirl to prevont damage
to thc ditf€rential oil seal.
7. Install the knuckle on the lower arm.
NOTE: Wipe off the grease before tightening the
nut at the ball joint.
CAUTION:
. Be careful not to damago the ballioint boot.
. Torque the castle nut to tho low€r torque speci-
tication, then tighten it only lar onough to align
th6 slot whh tho pin hols. Do not align the nut
by loosening.
,.<__coTTEF PtNCASTLE NUT12 x 1.25 mm49 - 59 N.m {5.0 - 5.0 kgf.m, 36 - t3 lbl.ft)
Beplace.On reassembly,bend the cotter pin
8. Install a new spindle nut, then tighten the nut.
9. Installthe front wheel with the wheel nuts.
NOTE: Before installing the wheel, clean the mating
surfaces of the brake disc and the wheel.
FRONT WHEELWH€EL NUT 12 x 1.5 mm108 N.m (11.0 kgt m,80lbf ft)
10.
NUT 22 x '1.5 mm181 N m 118.5 kgl.m, 134lbtftlNOTE: After tightening, use a drift tostake the spindle nut shoulderagainst the driveshatt.
Tighten the flange bolts and the new self-locking
nut with the vehicle's weight on the damper.
Refill the transmission with recommended oil or
fluid (see section 13 or 14).
11.
12. Check the front wheel alignment and adjust if nec-
essary (see page 18-4).
INTERMCOIATE SHAFT
16-15