lock HONDA INTEGRA 1998 4.G Repair Manual

Reassembly
CAUTION:
. Press the 3rd/4th and the 5th synchro hubs on the
mainshaft without lubrication.
. When installing rhe 3rd/4th and the 5th synchro
hubs, support the mainshaft on the steel blocks. and
install synchro hubs using a press.
. Install the 3rd/4th and the 5th synchro hubs with a
maximum pressure of 19.6 kN {2,000 kgf, 14,/166 lbfl.
NOTE: Refer to page 13-21 for reassembly sequence.
'1. Support 2nd gear on steel blocks, then install the
3rd/4th synchro hub using the special tools and a
press, as shown.
NOTE: After installing, check the operation of the
3rd/4th synchro sleeve and hub
81881 engine:
DR|VER,40 mm l.D.07746 - 0030100AITACHMENT.35 mm LD.07746 - 00304003RD/4THSYNCHRO HUB
f
2ND GEAR
818C1 and B18C5 engines: Assemble the 3rd/4th syn-
chro hub and sleeve together before installing them on
the mainshaft.
3RD/4TH PRESS
SYNCHRO HUBORIVER, 40 mm LO.07746 - 0030100Closed endfaces up.
3RD/4THSYNCHROSLEEVE
2ND GEAR
2.
3.
Install the sth synchro hub using the special tools
ano a press as snown.
Install the angular ball bearing using the special
tools and a press as shown.
ATTACHMENT.35 mm LD.
DRIVER, 10 mm LD.
07?,16 - 0030100
J
a
\
13-27
{

'f
I
Gountershaft Assembly
Index
\NOTEI
3
The 4th and sth gears are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4thand sth gears, however, should be installed with a press before lubricating them.
REVERSE GEAR
THRUST
lST/2NOSYNCHROHUB
SYNCHROSPRING
DAMPER
lST GEAR
LOCKNUT Replace.r08- 0- 108N.m
il1.0 - 0 - 11.0 kgJ.m, \180-0-80rbt.fi /
SPRING WASHEB
BALL BEARING
ano operalron.
NEEDLE BEARINGInspect for wearano operaron,
sTH GEAR
4TH GEAR
3RD GEAB
2NO GEAR
NEEDLE SEARINGInspect for wea.ano opera[|on.
SPACER
FRICTION DAMPER
NEEDLE BEARING
ano operalton,
COUNTERSHAFTInspection, page 13'31
DOUBLE CONESYNCHRO {Bl8Cl snd 818C5 ongines)Inspection. page 13-35SYNCHRO RING (B18Bl 6ngin6lInspection. page 13-35
SYNCHRO SPRING
13-24

f-
Countershaft Assembly
BEARING PULLER
{Commerciallyavailable)
Disassembly
Securely clamp the countershaft assembly in a
bench vise with wood blocks.
Raise the locknut tab from the groove in the coun
tershaft, then remove the locknLlt and the spring
washer. +
WOOD BLOCKS
Remove the ball bearing using a bearing puller as
shown.
BALL BEARING
13-30
4.Remove the bearing outer race, then remove the
needle bearing using a bearing puller as shown.
,/NEEDLE BEARING
CAUTION: Remove the gears using a press and the
steel blocks as shown. Use oI a iaw-type puller can
cause damage to the geal teeth.
Support 4th gear on steel blocks. and press the
countershaft out of sth and 4th gears, as shown.
4TH GEAR

Gountershaft Assembly
Reassembly
CAUTION:
. Press 4th and sth gears on the countershaft without
lubrication.
. When installing 4th and 5th gears, supPort the shaft
on steel blocks, and install the gears using a press.
. Install 4th and sth geal with a maximum pressure of
25.5 kN {2,600 kgf, 18,806 lbfl.
NOTEr Refer to page '13-28 for reassembly sequence
Install the thrust shim and the needle bearings on
the countershaft.
NEEOLE BEARING
THRUST SHIM
COUNTERSHAFT
Install the friction damper, the synchro ring, and the
synchro spring on lst gear.
Install the lst/2nd synchro hub by aligning the fin-
gers on the friction damper and the grooves in the
lst/2nd synchro hub, as shown.
lST/2ND
13-32
1ST GEAR
5.
lnstall the reverse gear.
Install the synchro spring. and the double cone
synchro (818C1 and 818C5 engines). or synchro
ring (81881 engine), as shown.
OOUELE CONESYNCHRO
SYNCHROSPRING
REVERSEGEAR
6. Assemble the friction damper, the needle bearing.
and 2nd gear. then install them by aligning the fin-
gers on the friction damper and the grooves in the
1sv2nd synchro hub with the fingers of the double
cone synchro and the grooves on 2nd gear, as
shown.
7. Install the spacer.2ND GEAR
SPACER
FRICTION DAMPER
8.Install the parts assembled in steps 2 - 6 on the
countershaft.

9. Support the countershaft on a steel block, and
install 4th gear using the special tools and a press,
as snown.
DRIVER, 40 mm l.O.07?46 - 0030100
4TH GEAR
ATTACHMENT, 35 mm I D.
07746 - 0030400
Support the countershaft on a steel block, and
install 5th gear using the special tools and a press,
as shown.
DRIVER,40 mm LD.
07746 - 0030100
ATTACHMENT, 30 mm I D.
077{6 - 0030300
10.
I
PRESS
11. Install the needle bearing, then install the balt bear-
ing using the specialtools and a press as shown.
DBIVER, 40 mm LD.07746 - 0030100
ATTACHMENT. 30 mm LD.07746 - 0030300
-..t
12.Securely clamp the countershaft assembly in abench vise with wood blocks.
Install the spring washer, tighten the locknut, then
stake the locknut tab into the groove.
LOCKNUT
108- 0" 108N.m (11.0- 0- 11.0kgf.m,
80'0+80rbr.ft)
WOOD BLOCKS
13-33

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

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

I
Transmission Assembly
1.
2.
Install the dowel pins on the clutch housing.
Apply grease to the parts as shown, then install the
release fork and release bearing.
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
3. Install the release fork boot.
lnstallation
22 tbl.lll
RELEASE FORK BOLT29 N.m {3.0 kgl.m,{P/N 08798 - 9002t
RELEASEBEAFING
RELEASEFORK
lPlN 08798 - 90021
Place the transmission on the transmission jack,
and raise it to the engine level.
Install the transmission mounting bolts and the rear
mount bracket bolts.SELF.LOCKING BOLT
12 x 1.25 mm64 N.m {6.5 kgf.m, {7 lbtftl
Replace.14 x 1.5 mm
RELEASEFORKBOOT
\i'l-r )i-
.+.i
13-46
6. Raise the transmission, then install the transmission
mounr,
NOTE: Torque the mounting bolt and nuts in the
sequence shown.
CAUTION: Check that the bushings are not twisted
or offset.
!) tz x t.zs mm64 N.m {6.5 kgt.m,47 tbl.ftl
7. Install the three upper transmission mounting
and the lower staner motor mountinq bolt.
bolts
10 x 1.25 mm44 N.m (4.5 kgt m.33 tblftl
(a 12 x 1.25 mm74 N.m {7.5 kgf m,54 tbf.ft)
'12x1.25mn
64 N.m {6.5 kst.m,47 lbf,ft)