1994 HONDA INTEGRA Workshop Manual

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

Countershaft Assembly
lndex
NOTE:
3
The 4th and 5th gears are installed with a press.
Prior to reassembling. clean all the pans in solvent, dry them and apply lubricant to any contact surfaces. The 4th
and sth gears. however, should be installed with a press before lubricating them.
LOCKNUT ReDlace.l(E*0*10EN.m
/r1.0 - 0 - 11.0 kgtm,Il8o- o-80rbf.ft I
WASHER
BALL BEARINGInspect for wearand operat|on,
NEEDLE BEARINGInspect Ior wearand operation.
sTH GEAR
4TH GEAR
3RD GEAR
2ND GEAR
NEEDLE BEARINGInspect for wearand operation.
SPACERSelection. page 13-29
FRICTION DAMPER
DOUB1I @NESYNCHRO l818Cl .ngin.lInspection, page 13-35SYNCHRO RING lBl8Bl .ngin )Inspection, page 13-35
SYNCHRO SPBING
SYNCHRO RING
THRUSTBEARING
13-24

Glearance Inspection
'L Measure the clearance between the thrust shim and
1st gear,
StEndard: 0.0,1- 0.12 mm (0.fi12 - 0.005 inl
Servics Limit: 0.18 mm (0.007 in)
2. lf the cleatance is more than the service
and install the appropriate thrust shim
rect clearance from the chan below.
Thrust Shim
limit, select
to. the cor-
'HRUST SHIM
Part NumbarThicknces
23921 - PKs - 9001.95 mm (0.0768 in)
B23922-PKs-9001.96 mm (0.0772 in)
23923-PK5-9001.97 mm (0.0776 in)
D23924-PKs-9001.98 mm (0.0780 in)
E23925-PKs-9001.99 mm {0.0783 in)
F23926-PKs-9002.00 mm (0.0787 inl
23927-PKs-9002.01 mm (0.0791 in)
H23928-PKs-9002.02 mm (0.0795 in)
23929-PKs-9002.03 mm (0.0799 in)
23930-PKs-9002.04 mm {0.0803 in)
K23931 - PKs - 9002.05 mm (0.0807 inl
L23932-PK5-9002.06 mm (0.0811 in)
M23933-PKs-9002.07 mm (0.0815 in)
N23934-PKs-9002.08 mm (0.0819 in)
o23935-PKs-9002.09 mm (0.0823 inl
P23936-PKs-9002.10 mm (0.0827 in)
13-29
3. Measure the clearance between 2nd and 3rd g68rs.
Stlndlrd: 0.05 - 0.12 mm (0.002 - o.(x}5 inl
Scrvice Limlt 0.18 mm (0.007 inl
4. lf the closrance is more than the service limit, selsct
and install the appropriate spacer for the corr€ct
clearance from the chart below.
Spaccl
Part Numb"rThickncla
A23917-P21 - 01029.02 - 29.0,{ mm
(1.1425 - 1.1433 in)
B23918-P2r-01029.07 - 29.09 mm
(1.1445 - 1.1453 in)

Countershaft Assembly
Disassembly
13-30
't.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 locknut and the spring
washer.
4,Remove the bearing outer .ace, then remove the
needle bearing using a bearing puller as shown.
2.
BEARING PULLER
BEARING
Remove the ball bearing using a bearing puller as
shown.
CAUTION: Romove the gclrs using a pross and tho
steol blocks rs shown. U3a of a l.w.typo pullor can
cau36 damagg to tho gsar iocth.
Support 4th gear on steel blocks. and press the
countershaft out of sth and 4th gears, as shown.
PULlTR
\-Y

Inspection
1. Inspect the gear surfaces and the bearing surfaces
for w€ar and damage, then measure the counter-
shaft at points A, B, and C.
St.ndard:
A: 2/t.980 - 27.9!13 mm (0.91|:15 - 1.1021 inl
B: 36.984 - 37.q)O mm {1.4551 - 1.'156? in}
C: 33.qD - 33.015 mm (1.2992 - 1.2998 inl
Sorvica Limit:
A: 2,a.930 mm (0.9815 in)
B: 35.930 mm (1.a539 inl
C: 32.950 mm 11.2972 inl
Inspect tor wear6nd damage.
Inspect oil passage lor clogging.
lf any parts of the countershaft are less than the
service limit, replace count€rshaft with a new
one.
Inspgct tor runout.
Stlndrrd: 0.02 mm {0.(xn8 inl Max.
Srrvic. Limit 0.05 mm {0.(x)2 in)
NOTE: Suppon the countershaft at both ends as
snown.
Rotate tl/vo compl6t€rcvolutions.
. lf the runout is more than the servic6 limit,
rgDlace the countershaft with a new one.
13-31

Countershaft Assembly
Reassembly
GAUTION:
. Pr93r 4th and 5th goar3 on the qountorshrft without
lubricrtion.
. Whon in3talling 4th and sth goa6, srpport the shaft
on st..l block3, 8nd in3tall thc 9.116 uring a prors.
. Inst.ll 4th lnd 5th gcar with a maximum pro33ur€ of
25.5 kN (2,6@ ksr. 18,806 lbo.
NOTE: Refer to page 13-28 for reassembly sequence.
Install the thrust shim and the needle bearinos on
the countershaft.
NEEDLE BEARING
THRUST SHIM
COUNTERSHAFT
Installthe friction damper. the synchro ring, and the
synchro spring on lst gear,
Install the lsv2nd synchro hub by aligning the fin-gers on the friction damper and the grooves in the'lsV2nd synchro hub, as shown.
1ST/2ND
13-32
lST GEAR
4. Install the reverse gear.
Install the synchro spring, and the double cone
synchro (818C'l engine), or synchro ring (81881
engine), as shown.
SYNCHROSPRING
REVERSEGEAfi
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.
2ND GEAR
NEEDLE BEARING
SPACER
FRICTION DAMPER
8.Install the parts assembled in steps 2 - 6 on the
countershaft.
Install the spacer.

9. Support the countershaft on a steel block, and
install 4th gear using the special tools and a press,
as snown.PRESS
DRIVER, 40 mm l.O.
077{6 - 0030100
10. SuDDort the countershaft on a steel block, and
install 5th gear using the special tools and a press,
as shown.
DRIVER, 40 mm l.O.07746 - 0030100
ATTACHMENT, 30 mm l.O.
0?7a6 - (X)303(x)
11.Install the needle bearing. then install the ball bear-
ing using the specialtools and a press as shown.
PRESSDRIVER.,l0 mm l.D.07746 - 0030100
ATTACHMENT, 30 mm l.D.07746 - d)30300BALL BEARING
NEEDLE BEARING
12.
13.
Securely clamp the countershaft assembly in a
bench vise with wood blocks.
Install the spring washer. tighten the locknut, then
stake the locknut tab into the groove.
LOCKNUT
108* 0* 108 N.m (11.0 - 0 - 11.0 kgf.m,
80+0*80lbf.ftl
LOCKNUT
wooo BLocKs
13-33

SYNCHROHUB
Synchro Sleeve, Synchro Hub
Inspection
'1. Inspect gear teeth on all synchro hubs and synchro
sleeves for rounded off corners, which indicates
wear.
2. Install each synchro hub in its mating synchro
sleeve and check for Jrgedom of movement.
NOTE: lf replacement is required, always replace
the synchro sleeve and synchro hub as a set.
Installation
When assembling the synchro sleeve and synchro hub,
be sure to match the thr€e sets of longer testh (120
degrees apart) on the synchro sleeve with the three sots
of deeper grooves in th€ synchro hub.
CAUTION: Do not install thc synchro 3l.6yc with itt
longor tosth in tha 13t/2nd synchro hub 3lob, b.c!u3a
it will d.mago tho spring ring.
sYt{cHRoHUB SLOT
13-34
LONGER TEETH
SLEEVE