1994 HONDA INTEGRA Workshop Manual

Shift Fork Assembly
I erior,o ,"""sembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts
mm PIN PUNCH
5TH/REVEFSESHIFT FORK
3RD/{TH SHIFT FORK
13-19

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sl€€v€ and the synchro hub should
be replac€d as a set,
1. Measure th€ clearance between each shift fork and
its matching synchro sleeve.
Strndud: 0.35 - 0.65 mm (0.014 - 0.026 in)
S€rvico Limit 1.0 mm (0.0'l in)
SHIFT FORK
lf the clearance is more than the service limit. mea-
sure the thickness of the shift fork finoers.
Standard: 7.4 - 7.6 mm (0.291 - 0.299 inl
lf the thickness of the shift fork fingers is not
within the standard, replace the shift fork with a
now one.
lf the thickness of the shift lork fingers is within
the standard, replace the synchro sleeve with a
new one.
SYNCHRO SLEEVE
13-20
Measure the clearance between the shift Diece and
the shift fork shafts.
Strndard: 0.2 - 0.5 mm {0.qt8 - 0.02 in]
S.rvico Limit: 0.8 mm (0.03 inl
SHIFT PIECE
lf the clearance is more than the service limit, mea-
sure the width of the shift piece.
Stsndard: 11.9 - 12.0 mm (0.469 - 0.472 in)
lf the width of the shift piece is not within the
standard, rsplace the shift piece with a new one.
lf the width of the shift piece is within the stan-
dard, replace the shift fork with a new one.
IFT FORK
/

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

1.
Measure the clsarance betw€en,lth gear and the
soacer collar.
St.ndffd: 0.06 - 0.21 mm (0.002 - 0.(xt8 in)
Scwicr Limh: 0.3 mm (0.01 in)
lf the clearanc8 is more than the service limit, mea-
sure distance @ on the spacer collar
Stlnd.rd: 26.03 - 26.m mm 11.025 - 1.027 in)
SPACER GOLLAR
,,1
5. lf distance O is not within the standard, replace the
spacer collar with a n€w one. lf distance @ is within
th€ standard, measure the thickness of 4th gear.
lf the thickness of 4th gear is less than the ser-
vice limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replaco the 3rdl4th synchro hub with a new
one.
(cont'd)
Engine Type818C181881
Standard31.42 - 31.47 mm
(1.237 - 1.239 in)
30.92 - 30.97 mm
\1.211 - '1.2'19 inl
Service Limit31.3 mm
l'1.232 inl
30.8 mm
(1.213 in)
13-23

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