1994 HONDA INTEGRA Rings

Transmission
Reassembly (cont'dl
SUB-SHAFT
27. Slip the special tool onto the mainshaft as shown.
MAII{SHAFT HOLDERoTGAa - PF5010I
Install the parking b.ake lever on the control shaft.
Installthe mainshaft 1st g6ar collar and thrust wash-
er on the mainshaft.
Install the countershaft 1st gear collar and n6€dls
bearing, then install the count€rshatt 1st gear/one-
way clutch/parking gea, assembly on the coun-
tershalt.
Install the parking b.ake pawl in th€ transmission
housing, then engage it with the parking gear.
PARKI''IG GEAR
PARTI GARAKELEVER
24.
29.
30.
31.
lST CLUTCH
14-1 60
MAIt{SHAFTCOU TERSHAFT
32. Use th6 old locknut and old conicsl spring washot
to tighten th€ parking gear to th€ sp€cifi€d torque,
then loosen the locknut.
TOROUE: 103 .m (1O.5 kgf.m, 75.9 lbf'ftl
NOTE: Locknut has left-hand threads.
PARKII{G GEAR
Install the sub-shaft lst gear on thg sub-shaft.
Install new O-rings on the mainshaft.
NOTE: Wrap the shaft splines with tspa to prevont
damago to the O-rings.
Assemblo th€ thrust wash6r, thrust naedle bearing,
needle bearing and msinshsft lst gear on tho lst
clutch assombly, then install them on the mainshaft.
33.
34.

36. Align the hole of the sub-shaft 1st gear with the hole
of the transmission housing, then insert a pin to lock
the sub-shaft while tightening the sub-shaft locknut.
37. Installnew conicalspring washers and new locknuts
on each shaft.
CAUTION: Install the conical spdng washers in the
dilection shown.
38. Tighten the locknuts to the specified torque.
TOROUE:
MAINSHAFT 93 N.m (9.5 kgf'm, 69 lbf.ft)
COUNTERSHAFT 103 N.m(1O.5 kgf.m, 75.9 lbf.ft)
SUB-SHAFT 93 N.m (9.5 kgf.m. 69 lbf.fi)
NOTE: Mainshalt and countershaft locknuts have
left-hand threads.
CONICAL DISC SPRINGSlnstall in rhis direcrion.
39.Stake each locknut using
. MAINSHAFT
a 3.5 mm punch.
. COUNTERSHAFT
O,7- 1.2 mm
0.7- 1.2 mm1O.03-O.05 in)
SUB-SHAFT LOCKNUT
14-161

Transmission
Installation {cont'd)
14.
15.
Install new set rings on the end of the intermediate
shaft and the driveshaft.
Install the intermediate shaft.
SET RINGBeplace.
16.
10 x 139 N.m14.O kgf.m, 29 lbf.ftl
Install exhaust pipe A. and connect the heated oxv-gen sensor {HO2S) connector.
SELF-LOCKING NUT10 x 1.25 mm54 N.m (5.5 kgl.m,40 rbt.trlReplace.
GASKETReplace.
SELF.LOCKING NUTSI x 1.25 mm22 N.m 12.2 kgl'n,16 lbt.trlRepl6ce.
SHAFT
14-166
DAMPER PINCH BOLT10 x 1.25 mm43 N.m 14.4 kgf.m,32 tbr.ftl
1 7. Install the right and left drivershafts (see section l6l.
NOTE: Turn the right and left steering knuckle fullyoutward, and slide the right driveshaft into the
differential until you feel its spring clip engages theside geaf. Slide the left driveshaft into the intermedi-
ate shaft until you teel the spring clip of the inter-mediate shaft engage the driveshaft.
18. Install right damper fork, then install the right andlett balljoints to each lower arm with the castle nuts
and new cotter Dins.
\
COTTERReplace.CASTLE NUT12 x 1.25 mm49-59 N.m{5.O-6.0 ksf.m, 36-43
SELF.LOCKING NUT12 x 1 .25 mm64 N.m (6.5 kgl.h, 47 lbt.ftlReplace.
rbt'ft1
19. Install the splash shield.
6 x 10 mm BOLT
cltPs, 5

NOTE: Check the ball bearings for wear and rough ro-
tation. It bearings are OK, removal is not necessary.
1. Remove the ball bearings using a standatd bearing
puller and bearing separator as shown.
BEARING PULLEB
BALL BEARING
Install new ball bearings using the special tool as
snown.
NOTE: Drive the bearings squarely until they bot-
tom against the carrier.
DRIVER, 40 mm l.D.07746-0030100
BALL BEARING
Bearing ReplacementOil Seal Removal
1.Remove the ditterential assembly.
Remove the 8O mm shim from the transmission
housing.
80 mm SHIM
TRA[{SMtSStONHOUSING
3. Remove the oilseal from the t.ansmission housing.
4. Remove the oil seal from the clutch housing,
OIL SEALR€plac6.
15-5

Tapered Roller Bearing Replacement
NOTE:
a The tapered roller bearing and bearing outer race
should be replaced as a set.
a Inspect and adjust the tapered roller bearing preload
whenevef the tapered rollef bearing is replaced.
a Check the tapered roller bearings tor wear and rough
rotation. lf tapered roller bearings are OK, removal is
not necessary.
1. Remove the tapered rolle. bearings using a bearing
puller and bearing separator as shown,
BEARING
BEARII{GSEPANATOR(Commercially
available)
Install new tapered roller bearings using the special
tool as shown.
NOTE: Drive the tapered roller bearings on until they
bottom against the differential carrier.
oilSealRemoval
1.Remove the differential assembly.
Remove the oil seal from the transmission housing.
3. Remove the oil seal from the clutch housino.
15-13

Differential (B18c1 eng:nel
Bearing Outer Race Replacement
CAUTION: Do not rous€ the thrust lhim and tho 79.8mm shim il tho outer rac6 was ddvon out.
NOTE;
a The bearing outer race and taper€d toller bearingshould be reDlaced as a set.a Inspect and adjust the tapered roller bearing proload
whenever th€ tapered roll€f bearing is roplac€d.
1 . Remove the oil seals from the transmission housing
and clutch housing (see page 15-13).
2. Remove the bearing outer raca, the thrust shim, andthe 79.5 mm shim from th€ transmission housing.
Remove the bearing outer racs and thrust shim tromthe clutch housing.
TRANSMtSStOl{ HOUStl{c
15-14
5. lnstall the oil sesl (see page 15-171.
4.Install the new thrust shim and 79.5 mm shim, then
drive the bearing outer races in the both housings
using the special tools as shown.
NOTE:
a Install the bearing outsr race squarely.a Check that there is no clearance between tha
bearing outer race, thrust shim, and transmission
housing.
BEARIl{GOUTER
07749-OOTOOOO
ONNERATTACHMENTOTttAD-PX/IOlOO

Tapered Roller Bearing Preload Adjustment
NOTE: lf any of the items listed below were replaced,
the tapered roller bearing preload must be adjusted,
a Transmission housing
a Clutch housing
a Diffe.ential carrier
a Tapered roller bearing and bea,ing outer race
a Thrust shim
1 . Remove the bearing outer race, the thrust shim, and
the 79.5 mm shim from the transmission housing
(see page 1 5- 14).
CAUTION: Do not reuss lhe thrust shim it the bear-
ing outer raco was driven out.
2. First t.y the same size 79.5 mm shim that was
removeo.
CAUTION; Do not uso moro than two shims.
79.5 rnm SHIM
HOUSING
4.
o.
Instsllthe thrust shim and 79.5 mm shim, then drive
the bearing outer race in the transmission housing
{see page l5-14).
NOTE:
a Install the bearing outer race squarely.
a Check that there is no clearance between the
bearing outer race. thrust shim and transmission
housing.
With the mainshaft and countershaft.emoved, in-
stsllthe differential assembly, and lorque the clutch
housing and transmission housing,
8 x 1.25 mm
27 N.m 12.8 kgf.m, 20 lbf.ft)
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
Rotate the ditterential assembly in both directions
to seat the tapered roller bearings.
Measure the starting torque of the differenlial assem-
bly with the special tool and a torque wrench.
NOTE: Measure the tapered roller bearing preload
in both directions.
STANDARD: 2.1 1 -3.O4 N.m(21.5-31.0 kgf'cm,
18.7-26.9 lbf.inl
{cont'd}
15-15

Differential (B18C1 enginel
Tapered Roller Bearing Preload Adjustment (cont'dl
7. It the tapered roller bearing preload is not within the
standard, select the 79.5 mm shim lrom the follow-
ing table which will give the tapered roller bea.ing
preload closest to the standard mean value of 2.50
N.m (25.5 kgJ.cm, 22 lbf.in).
NOTE: Changing the 79.5 mm shim to the next size
will increase or decrease tapered roller bearing
preload about O.3-O.4 N.m (3-4 kgf.cm,
2.6 - 3.5 lbt.in).
79.5 mm SHIM
Part NumbelThickness
41460-PY4-0000.66 mm (0.0260 in)
AB41461-PY4-0001.17 mm (O.0461In,
AC41462-PY4-0001 .2O mm (0.0472 in)
AD41463-PY4-0001.23 mm (O.O484 in)
AE41464-PY4-0001.26 mm (0.0496 in)
AF41465-PY4-OOO1.29 mm (O.O5O8 in)
AG41466-PY4-OOO1.32 mm (O.O52O in)
AH41 467-PY4-0001.35 mm {O.O531 in)
AI41468-PY4-0001.38 mm (O.O543 in)
AJ41469-PY4-0001 .41 mm (O.0555 in)
AK41470-PY4-OOO1 .44 mm (0.0567 in)
AL41 47 1 -PY 4-OOO1 .47 mm (0.0579 in)
AM41 47 2-PY 4-OOO1.50 mm {O.O591 in)
AN41473-PY4-0001 .53 mm (0.0602 in)
AO41 47 4-PY 4-OOO1.56 mm (0.0614 in)
AP41475-PY4-OOO'l .59 mm (O.0626 in)
AO4'1476-PY4-O001.62 mm (0.0638 in)
AR41 47 7 -PY 4-OOO1 .65 mm (0.0650 in)
AS41478-PY4-0001 .68 mm {0.0661 in)
41479-PY4-OOO1.71 mm (O.0673 in)
AU41480-PY4-OOO1.74 mm (0.0685 in)
41481-PY4-OOO1 .77 mm {0.0697 in}
41442-PY4-OOO1.80 mm (O.O7O9 in)
AX41483-PY4-OOO1.83 mm (0.0720 inl
15-16
9.
Recheck the tapered roller bearing preload.
How to select the correct 79.5 mm shim:- 1) Compare the tapered roller bearing preload you
get with the 79.5 mm shim that was removed
with the specified mean preload of 2.50 N.m(25.5 kgf .cm. 22 lbf.inl.-2) lf your measured tapered roller bearing preload
is less than specified, subtract your's from the
soecified.
lf your's is more than specified, subtract the
specified from your measurement.
For example with a 1 .38 mm (O.O543 in) shim:
@ specified 2.50 N.m (25.5 kgf.cm, 22 lbf.in)- you measure 0.54 N.m (5.5 kgt.cm, 5lbt'in)
2.0 N.m {20 kgf.cm, 18lbt.in} less
@you measure 3.29 N.m {33.5 kgl.cm, 29 lbl.in)- specified 2.50 N.m {25.5 kgf.cm, 22 lbf.in)
0.8 N.m (8 kgf.cm, 7lbt.in) more
3) Each shim size uD or down from standard
makes about O.3-O.4 N.m (3-4 kgf.cm,
2.6-3.5 lbf.in) difJerence in tapered roller
bearing preload.
a In example @, your measured tapered roller
bearing preload was 2.O N.m (20 kgf'cm,
I 8 lbl.in) less than standard so you need a
79.5 mm shim five sizes thicker thsn stan-
dard {trv the 1.53 mm (0.0602 inl shim and
recheck).
a In example @ your's was O.8 N.m (8
kgf.cm, 7 lbJ.in) more than standard, so
you need a thrust shim two sizes thinner (try
the 1.32 mm (0.0520 in) shim and recheck).
After adjusting the tapered .oller bearing preload, as-
semble the transmission, and installthe transmission
housing {see section 13).
8 x 1.25 mm
27 N.m 12.8 kgt.m. 20 lbf.ttl
Rotate the diJJerential assemblv in both directions
to seat the tapered roller bearings.
10.
11.