oil HONDA INTEGRA 1998 4.G Repair Manual

rtr
1
Clutch Disc
Removal/lnspection
CLUTCH DISC
1. Remove the clutch disc and special tools.Measure the depth from the lining surface to the
rivets. on both sides.
Standa.d {N.w}: 1.2 - 1.7 mm (0.05 - 0.07 in} min.
Service Limit 0.2 mm (0.01 inl
07LAB- Pv001OO or07924 PD20003
CLUTCH ALIGNMENT SHAFT07NAF-PR30100HANDLE07936- 3710100
Inspect the lining of the clutch disc for signs of slip-ping or oil. lf it is burned black or oil soaked, replace
it.
Measure the clutch disc thickness. lf the thickness is
less than the service limit, replace the clutch disc.
Standard lNew): 8.3 - 9.0 mm 10.33 - 0.35 in)
Sorvica Limit 6.0 mm 10.2i[ inl
CLUTCH DISC
3.
lf the rivet depth is less than the service limit,
reolace the clutch disc.
CLUTCH DISC
LINING SURFACE
12-8

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

aintenance
Transmission Oil
NOTE: Check the transmission oil with the engine OFF
and the vehicle on level ground.
1. Remove the oil filler plug, then check the level and
condition of the oil.
OIL FILLER PLUG44 N.m {4.5 kgf.m,Proper Level33 tbf.ftl
The oil level must be up to the filler hole. lf it is
below the hole, add oil until it runs out, then rein-
stall the oil filler plug.
lf the transmission oil is dirty, remove the drainplug and drain the oil.
Reinstall the drain plug with a new washer, and
refillthe transmission oilto the proper tevet.
NOTE: The drain plug washer should be replaced at
every oil change.
Oil Capacity
2.2 | i.2.3 US.qr,1.9 lmp.qtl at oil ch.nge.
2.3 t l2.1US.qt,2.O lmp.qtl at ovorhaul.
Always use genuine Honda manual transmission
fluid (MTF). Using motor oil can causa€tiffer shift-
ing because it does not contain the proper addi-
Back-up Light Switch
Replacement
NOTE: To check the back-up light switch. see section 23.
1. Disconnect the connector, then remove the back-up
light switch connector from the connector clamp.
l.m {2.5 kgf.m, 18lbf.ft) Replace.
Remove the back-up light switch.
Install the new washer and the back-up light switch.
Check the transmission oil level.
!ves.
OIL FILLER PLUG
DRAIN PLUG39 N.m {4.0 kg{.m,29 rbf.ftlReplace.
5. Reinstall the oil filler plug with a new washer,
Replace.
EACK.UP LIGHT SWITCH25 N.m {2.5 kgf.m, 18 lbf.ft)
13.3

I
T
Remove the three upper transmission mounting
bolts and the lower starter motor mountino bolt.
STARTERMOTOEMOUNTINGBOLT
Drain the transmission oil, then reinstall the drainplug with a new washer (see page 13-3).
Remove the engine splash shield.10.
11.
6tr!
/
SELF.LOC1(ING NUTReplace.
Disconnect the heated oxygen sensor (HO2S) con-
nectors, then remove the exhaust pipe A. and the
three way catalytic converter (B'18C1 and B18C5
engines).
Feplace. THREE WAYCATALYNCCONVERTENlg18C1 lnd 818C5 onginrsl
Remove the cotter pins and loosen the castle nuts,
then separate the ball joints from the lower arm(see sectiotr'l8).
LOWER ARM
DAMPER CASTLE NUTFORK
13. Remove the right damper FORK
(cont'd)
13-5

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.}

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'

Shift Rod
- Removal
13-18
1. Remove the shift rod boots.
2. Remove the change piece attaching bolt and the
spring washer,
3. Remove the set screw. then remove the spring and
the steel ball.
4,
5.
Remove the shift rod, then remove the change
prece.
Remove the oil seal.
CHANGE
\
\
I
PIECE
SPRINGL.25.6 r(1.01 in)
STEEL B(D.5/16
OIL SEALReplace.
*q
SHIFTRODBOOTS
SPRING WASHER
SET screw
ATTACHING BOLT

I
Mainshaft Assembly
Inspection
\1.Inspoct the gear surfaces and the bearing surfaces
for wear and damage, then measure the mainshaft
at points A. B, and C.
Standard:
A: 27.987 - 28.000 mm (1.1018 - 1.1024 inl
B: 37.984 - 38.000 mm 11.4954 - 1.4960 inl
Ci 27 .977 - 27 .99O mm { 1.1015 - 1.1020 inl
Se.vice Limit:
A: 27.940 mm 11.1000 inl
B:37.930 mm 11.4933 inl
C:27.930 mm {1.0996 inl
2. Inspect for runout.
Standard: 0.02 mm 10.0008 inl max.
Service Limit 0.05 mm (0.002 inl
NOTE: Support the mainshaft at both ends
shown.
lnspect oil passages for clogging.
lf the runout is more than the service limit,
reolace the mainshaft with a new one.
lf any parts of the mainshaft are less than the
service limit, reDlace mainshaft with a new one.

I
t
Inspect the gear surfaces and the bearing surfaces
for wear and damage, then measure the counter-
shaft at points A. B, and C.
Standard:
A: 24.980 - 24.993 mm {0.9835 - 0.9840 inl
B: 36.984 - 37.000 mm 11.4561 - 1.4557 inl
C: 33.000 - 33.015 mm (1.2992 - 1.2998 inl
Service Limit:
A: 24.930 mm {0.9815 inl
B:36.930 mm (1.4539 in)
C: 32.950 mm {.1.2972 inl
Inspect oil passage for clogg;ng.
lf any parts of the countershaft are less than the
service limit, replace countershaft with a new
one.
ano oamage,
I
2.Inspect for runout.
Standardr 0.02 mm (0.0008 in) max.
Service Limit:0.05 mm (0.002 in)
NOTE: Support the countershaft at both ends
shown.
Rotate two complete
lf the runout is more than the service limit,
replace the countershaft with a new one.
13-31
-,i

Synchro Ring, Gear
Inspection
1. Inspect the synchro ring and gear.
Ar Inspect the inside of the synchro ring for wear.
B: Inspect the teeth on the synchro ring tor wear(rounded off).
ccGOOD WORN
C: Inspect the synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
00GOOD WORN
D: lnspect the gear hub thrust surface for wear.
E: Inspect the cone surtace for wear and roughness.
F: Inspect the teeth on all gears for uneven wear,
scoring, galling. and cracks.
Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear, Rotate the
ring, making sure that it does not slip.
Measure the clearance between the synchro ring
and gear all the way around.
NOTE: Hold the synchro ring against the gear even-ly while measuring the clearance.
Synchro Ring-to.Goar Clearance
Standard: 0.85 - 1.10 mm
(0.033 - 0.0/B inl
Service Limh:0.4 mm {0.02 in)
Double Cone Svnchro-to-Gea. Clgarance
Standard:
@r (Outer Synchro Ring to Synchro Conel
0.5 - 1.0 mm {0.02 - 0.04 in}
@: (synchro ConG to Gear)
0.5 - 1.0 mm (0.02 - 0.04 inl
@: lOute; Synchro Ring to Gearl
0.95 - 1.68 mm 10.037 - 0.066 inl
Servic€ Limit:
@: 0.3 mm (0.01 in)
@: 0.3 mm 10.01 in)
O: 0.6 mm {0.02 in}
lf the clearance js less than the service limit, reDlace
the synchro ring and synchro cone.
SYNCHRO SPRING
SYNCHRO RING
SYNCHRO CONE
I
SYNCHRO RING
13-35