1998 HONDA INTEGRA Workshop Manual

/f Prior to reassembling. clean all the parts in solvent, drythem and apply lubricantto any contact parts
5 mm PIN PUNCH
sTH/REVERSESHIFT FORK
3RD/,rTH SHIFT FORK
1ST/2ND SHIFT FORK
SHIFT PIEC€
Shift Fork Assembly
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13-19

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub shouldh6 ronlr.o.l ,.. car
Measure the clearance between each shift fork and
its matching synchro sleeve.
Standard: 0.35 - 0.65 mm {0.014 - 0.026 inl
Service Limit: 1-0 mm 10.04 inl
SHIFT FORK
lf the clearance is more than the service limit, mea-
sure the thickness of the sh ift fork finoers.
Standard: 7.il - 7.6 mm (0.291 - 0.299 in)
lf the thickness of the shift fork fingers is not
within the standard, replace the shift fork with a
lf the thickness of the shift fork fingers is within
the standard, replace the synchro sleeve with a
new one.
3. Measure the clearance between the shift piece and
the shift fork shafts.
Standard: 0.2 - 0.5 mm (0.008 - 0.02 inl
Service Limit: 0.8 mm (0.03 inl
SHIFT PIECE
It the clearance is more than the service limit,
sure the width of the shift piece.
Standard: 11.9 - 12.0 mm (0.a69 - 0.a72 inl
lf the width of the shift piece is not within the
standard, replace lhe shift piece with a new one.
lf the width of the shift piece is within the stan-
dard. reolace the shift fork with a new one.
IFT FORK
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SHIFT PIECE

Mainshaft Assembly
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NOTE:
. The 3rd/4th and the 5th synchro hubs are installed with a press.
.Installtheangularball bearing with the thin-edged outer race facing the stop ring.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The
3rdl4th and the 5th synchro hubs, however, should be installed with a press before lubricating lhem.
SYNCHRO RINGInspection, page 13-35
ANGULARBALL BEARINGInspect tor weatano oporaron,Note the direction ofinstallation.818C1 .nd 818CS ongin$:In3tallation dot ils, p.go 13-27
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LSYNCHROSPRING
3RD GEARInspection,page 13-22
STOP RING
TAPEN RING
NEEDLE BEARINGInspect for wearano operaton,
SPACER
SYNCHRO RINGInspecton,page'13-35
SYNCHROSPRING
5TH/REVERSESYNCHRO HUB
sTH/REVEBSESYNCHRO SLEEVE
SYNCHROSPRING
SYNCHRO RINGrnspect|on,page 13-35
sTH GEARInspection,page 13-24
SPACERCOLLAR
4TH GEARInspect|on,page 13-23
BEARINGInspect for wearano operaaron.
NEEOLE BEARING
ano operal|on.
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13-21

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Mainshaft Assembly
Glearance Inspection
NOTE: lf replacement is required, always replace the
svnchro sleeve and the svnchro hub as a set.
'L Measure the clearance between 2nd and 3rd qears.
Standard: 0.05 - 0.21 mm (0.002 - 0.C08 in)
Service Limit: 0.3 mm 10,01 inl
13-22
Engine Type818C1.818C5818B 1
Standard34.92 - 34.97 mm
{l.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. It the clearance is more than the service limit, mea-
sure the thickness of 3rd gear.
li 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

4.
Measure the clearance between 4th qear and the
spacer colar.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 in)
Service Limit:0.3 mm (0.01 in)
4TH GEAR
SPACER COLLAR
lf the clearance is more than the service limit, mea-
sure distance A on the spacer collar.
Standard: 26.03 - 25.08 mm (1.025 - 1.027 in)
SPACER COLLAR
Engine Type818C1, B'l8C581881
Standard31 .42 - 31.47 mm
(1 .237 - 1.239 inl
30.92 - 30.97 mm
11 .211 - 1.2'tg inl
Service Limit31.3 mm
11.232 inl
30.8 mm
(1.213 in)
5. lf distance @ is not within the standard, replace the
spacer collar with a new one. lf distance @ is within
the 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, replace the 3rd/4th synchro hub with a new
one.
(cont'd)
13-23

Mainshaft Assembly
Clearance Inspection (cont'dl
Measure the clearance between sth qear and
50acer collar.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 in)
S€rvica limit: 0.3 mm {0.012 inl
the8. lf distance (9 is not within the standard, replace the
spacer collar with a new one.
lf distance @ is within the standard, measure the
thickness of sth gear.
Standard: 31.42 -31.17 mm (1.237 - 1.239 inl
Service Limit:31.3 mm {1.232 inl
7.lf the clearance is more than the service limit, mea-
sure distance @ on the spacer collar.
Stsndard: 26.03 - 26.08 mm (1.025 - 1.027 in)
lf the thickness of sth gear is less than the ser-
vice limit, replace 5th gear with a new one.
lf the thickness of sth gear is within the service
limit, replace the 5th svnchro hub with a new
one.
SPACER COI-LAR
sTH GEAR
5TH GEAR

Disassembly
1. Remove the ball bearing using a bearing puller as
shown.
BEARING PULLERlCommerciallyrv.ilable)
BALL BEARING
CAUTION: Remove th€ synchro hubs using a press
and the stsel blocks as shown. Use ot a jaw.type
puller can cause damage to the gear teeth.
Support sth gear on steel blocks, and press the
mainshaft out of the sth synchro hub, as shown.
sTH SYNCHRO HUB
sTH GEAR
3.Support 3rd gear on steel blocks, and press the
mainshaft out of the 3rd/4th synchro hub, as shown.

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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.