1994 HONDA INTEGRA Mainshaft

Mainshaft, Gountershaft, Shift Fork
- Removal
1. Remove the mainshaft and the countershaft assem-
blies with the shift forks from the clutch housing.
NOTE: Tape the mainshaft spline belore removing
the mainshaft and the countershaft assemblies.
2 Remove the spring washer and the washer.
Remove the differential assembly from the clutch
housing.
OIFFERENTIAL
CLUTCH HOUSING
13-17
4. Remove the chamber plate.
CLUTCH HOUSING
CHAMBCR PLATE

Mainshaft Assembly
NOTE: The 3rd/4th and the 5th svnchro hubs are installed with a press.
818Cl cngino:Inirllstion dstailr, pag. 13-27
Prior to reassembling. clean all the parts in solvent, dry them and apply lubricant to any contact surfaces, The
3rdl,lth and the sth synch.o hubs, however, should be installed with a press before lubricating them.
SYNCHRO BINGInspection, page'13_35
3RD/'TH SYNCHRO SLEEVE
3RD/'TH SYiICHRO HUB
STOPPER RING
TAPER RING
NEEDLE BEARINGlnspect for wearand operation.
SPACER
Insp6clron,page 13-35
SPRING
SYNCHRO HUBSPRING
3RD GEARInspectaon.page 13-22
NCEDE AEARINGInspocl tor wearand operalton.
SYNCHRO SI..EEVE
SYNCHROSPRING
Inspectaon.pag6 13-35
5TH GEARrnspec!on,page 13-24
4TH GCARInspection,page 13-23
SPACERCOLLAR
13-21

Mainshaft Assembly
Clearance Inspection
NOTE: lf replacement is required. always replace the
synchro sleeve and the synchro hub as a set.
1. Measure the clearance between 2nd and 3rd gears.
Standard: 0.06 - 0.21 mm {0.002 - 0.008 inl
Ssrvica Limit: 0.3 mm (0.01 in)
13-22
Engine Type818C181881
Standard34.92 - 34.97 mm
(1.375 - 1.377 in)
34.42 - 34.47 mm
(1.355 - 1.357 in)
Service Limit34.8 mm
(1.370 in)
34.3 mm(1.350 in)
2. lf the clearance is more than the service limit, mea-
sure the thickness of 3rd gear.
lf the thickness of 3rd gear is less than the ser-
vice limit, replace 3rd gear with a new one.
lf the thickness of 3rd gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one.
3RD GEAR

Mainshaft Assembly
Glearance Inspection (cont'd)
Measure the clearance between 5th gear and the
spacer co ar.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 in)
Service limit: 0.3 mm 10.012 inl
lf the clearance is more than the service limit, mea
sure distance B on the spacer collar.
Standard: 26.03 - 26.08 mm (1.025 - 1.027 in)
SPACER COLLAR
sTH GEAR
13-24
8.lf distance @ is not within the standard, reDlace the
sDacer collar with a new one.
lf distance @ is within the standard, measure the
thickness of sth gear.
Standard: 31.12-31.47 mm (1.237 - 1.239 in)
Service Limit:31.3 mm (1.232 inl
lf the thickness of sth gear is less than the ser-
vice limit, replace sth gear with a new one.
lf the thickness of 5th gear is within the service
limit, replace the 5th synchro hub with a new
one,
sTH GEAR

- Disassembly
Remove the ball bearing using a bearing puller as
BEARING PULLER
BALL B€ARING
CAUTION: Remove the synchro hubs using a press
and the steel blocks .s shown. Use of a jaw-type
puller can cau3e damags to the gear teeth.
Support 5th gear on steel blocks, and press the
mainshaft out of the 5th synchro hub, as shown.
3.Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th synchro hub, as shown.
13-25

Mainshaft Assembly
Inspection
1.Inspect the gear surfaces and the bearing surfacss
for wear and damage, then measure the mainshaft
at points A, B. and C.
Standord:
A: 27.987 - 28.000 mm 11.1018 - 1.102'l inl
B: 37.98/r - 38.q)0 mm {1.il95il - l.il960 in}
Ct 27.977 - 27.99O mm {1.1015 - 1.1020 in}
S€rvico Limit;
A: 27.9{, mm (1.1(XXl in}
B:37.930 mm 11.4933 inl
C: 27.930 mm {1.0996 in}
2. Inspect for runout.
Stlnd.rd: 0.02 mm (0.(xxl8 inl M!I.
S.rvic. Limit 0.05 mm (o.qP inl
NOTE: SuDport the mainsh€ft at both ends as
shown.
Inspect oil passages tor clogging.
lf the runout is mor6 than ths service limit,
rsplace the mainshaft with a n6w one.
lf any parts of the mainshaft are less thsn the
service limit. .eolace mainshaft with a new one.
13-26

1_
ReassemblV
ATTACHMENT,35 mm LD.07746 - 0o30/rc0
CAUTION:
o Pless the 3rd/ilth and the 5th synchro hubs on the
msinshafi without lubrication.
. When installing the 3rd/4th and the sth synchro
hubs, support the mainshaft on the steel blocks, and
install synchro hubs using a press,
. Install the 3rd/,lth and the sth synchro hubs with a
maximum pressure of 19.6 kN (2.000 kgf, 1+466lbt).
^JOTEi Refer to page 13-21 for reassembly sequence.
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.
B18Bl sngine:
DRIVER. 40 mm l.D.07746 - 0030100
3RD/4THSYNCHRO HUB
2NO GEAR
8l8Cl engine: Assemble the 3rd/4th synchro hub and
sreeve together before installing them on the mainshaft.
3RO/4TH PRESS
SYNCHRO HU8DRIVER- 4o mm l.D.07746 - tD30100: osed end
3RD/TTHSYNCHROSLEEVE
2, Install the sth synchro
ano a press as snown.
OBIVER, ,O mm LD.0t7it6 - 003010O
ATTACHMENT,35 mm l.D.
hub using the special tools
PRESS
sTH SYNCHRO HUB
077t6 - 00304{x)
Install the ball bearing using the special tools and a
prsss as shown.
NOTE: Install the ball bearing with the tapered end
facing down.
2ND GEAR
13-27

Mainshaft Thrust Glearance
1. Remove the 72 mm thrust shim and oil guide plate
from the transmission housing.
72 mm THRUST SHIM
TRANSMISSIONHOUSINGOIL GUIDE PLATE
Adjustment
\.u
o
Bo
lnstall the 3rd/4th synchro hub, spacer collar, sth
synchro hub, spacer, and ball bearing on the main-
shaft. then install the above assembly in the trans-
mission housing.
Installthe washer on the mainshaft.
Measure distance @ between the end of the trans-
mission housing and washer.
NOTE:
. Use a straight edge and vernief caliper.
. Measure at three locations and averaoe the read-
Ing.END olTRANSMISSIONHOUSINGMAINSHAFT
WASHER
fr
13-38
AALL AEARING
. Try the 1.68 mm (0.0661 in) shim.
5. Measure distance @ betlveen 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 prcpet 72 mm thrust shim from the chart
by using the formula below.
NOTE: Use only one 72 mm thrust shim.
Shim Sslsction Formula:
From the measurements you made in steps 4 and 5:-1. Add distance @ (step 5lto distance @ (step 4).
-2. From this number. subtract 0.93 (which is the
midpoint of the flex range of the clutch housing
bearing spring washerl.
-3. Take this number and compare it to the avaif
able shim sizes in the chart.
(For example)
B:2.39
+ C: O.22
2.61- 0.93
1.68
END of CLUTCH HOUSING
INNEB RACE ot BALL BEARltac