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Home >> Acura >> 1996 >> Integra L4-1834cc 1.8L DOHC PFI >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Manual Transaxle Overhaul >> Part 1

Part 1



TRANSMISSION HOUSING
Removal

NOTE:
- If the transmission housing or clutch housing are replaced, the bearing preload must be adjusted (B18C1 engine).
- Place the clutch housing an two pieces of wood thick enough to keep the mainshaft from the hitting the workbench.

1. Remove the back-up light switch.
2. Remove the transmission hanger B.





3. Remove the set screws, the springs, and the steel balls.





4. Remove the reverse idler gear shaft bolt.





5. Loosen the transmission housing attaching bolts in a crisscross pattern in several steps, then remove them
6. Remove the 32 mm sealing bolt.





7. Expand the snap ring on the countershaft ball bearing and remove it from the groove using a pair of snap ring pliers.
8. Separate the transmission housing from the clutch housing, and wipe it clean of the sealant.





9. Remove the 72 mm thrust shim and the oil guide plate from the transmission housing.





10. Remove the 16 mm sealing bolt and the oil gutter plate.

REVERSE CHANGE HOLDER, REVERSE IDLER GEAR
Clearance Inspection





1. Measure the clearance between the reverse change holder and the 5th/reverse shift piece pin.





2. If the clearance are not within the standard, measure the width of the grooves in the reverse change holder.
- If the width of the grooves are not within the standard, replace the reverse change holder with a new one.
- If the width of the grooves are within the standard, replace the 5th/reverse shift piece with a new one.





3. Measure the clearance between the reverse idler gear and the reverse change holder.





4. If the clearance is more than the service limit, measure the width of the reverse change holder.
- If the width is not within the standard, replace the reverse change holder with a new one.
- If the width is within the standard, replace the reverse idler gear with a new one.

Removal





1. Remove the reverse change holder.





2. Remove the reverse idler gear and the reverse idler gear shaft, and the washer (B18C1).

CHANGE HOLDER ASSEMBLY
Clearance Inspection





1. Measure the clearance between the shift piece and the shift arm holder.





2. If the clearance is more than the service limit, measure the width of the groove in the shift piece.
- If the width of the groove is not within the standard, replace the shift piece with a new one.
- If the width of the groove is within the standard, replace the shift arm holder with a new one.





3. Measure the clearance between the select arm and the interlock.





4. If the clearance is more than the service limit, measure the width of the interlock.
- If the width is not within the standard, replace the interlock with a new one.
- If the width is within the standard, replace the select arm with a new one.





5. Measure the clearance between the select arm and the 10 mm shim.





6. If the clearance is not within the standard, select and install the appropriate 10 mm shim for the correct clearance from the chart above.





7. Measure the clearance between the shift arm holder and the change piece.





8. If the clearance is more than the service limit, measure the groove of the change piece.
- If the groove is not within the standard, replace the change piece with a new one.
- If the groove is within the standard, replace the shift arm holder with a new one.





9. Measure the clearance between the select arm and the change piece.





10. If the clearance is more than the service limit, measure the width of the change piece.
- If the width is not within the standard, replace the change piece with a new one.
- If the width is within the standard, replace the select arm with a new one.

Removal





1. Remove the shift piece shaft, then remove the shift piece and the interlock.





2. Remove the change holder assembly.

Disassembly/Reassembly





Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.


MAINSHAFT, COUNTERSHAFT, SHIFT FORK
Removal
1. Remove the mainshaft and the countershaft assemblies with the shift forks from the clutch housing.

NOTE: Tape the mainshaft spline before removing the mainshaft and the countershaft assemblies.





2. Remove the spring washer and the washer.





3. Remove the differential assembly from the clutch housing.





4. Remove the chamber plate.

SHIFT ROD
Removal
1. Remove the shift rod boots.
2. Remove the change piece attaching bolt and the spring washer.
3. Remove the set screw, then remove the spring and the steel ball.
4. Remove the shift rod, then remove the change piece.





5. Remove the oil seal.

SHIFT FORK ASSEMBLY





Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts

Clearance Inspection

NOTE: The synchro sleeve and the synchro hub should be replaced as a set.





1. Measure the clearance between each shift fork and its matching synchro sleeve.





2. If the clearance is more than the service limit, measure the thickness of the shift fork fingers.
- If the thickness of the shift fork fingers is not within the standard, replace the shift fork with a new one.
- If 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.





4. If the clearance is more than the service limit, measure the width of the shift piece.
- If the width of the shift piece is not within the standard, replace the shift piece with a new one.
- If the width of the shift piece is within the standard, replace the shift fork with a new one.



MAINSHAFT ASSEMBLY





Index

NOTE:
- The 3rd/4th and the 5th synchro hubs are installed with a press.

Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd/4th and the 5th synchro hubs, however, should be installed with a press before lubricating them.

Clearance Inspection

NOTE: If replacement is required, always replace the synchro sleeve and the synchro hub as a set.





1. Measure the clearance between 2nd and 3rd gears.





2. If the clearance is more than the service limit, measure the thickness of 3rd gear.
- If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
- If the thickness of 3rd gear os within the service limit, replace the 3rd/4th Syncro hub with a new one.





3. Measure the clearance between 4th gear and the spacer collar.





4. If the clearance is more than the service limit, measure distance (A) on the spacer collar.





5. If distance (A) is not within the standard, replace the spacer collar with a new one. If distance (A) is within the standard, measure the thickness of 4th gear.
- If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
- If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.





6. Measure the clearance between 5th gear and the spacer collar.





7. If the clearance is more than the service limit, measure distance (B) on the spacer collar.





8. If distance (B) is not within the standard, replace the spacer collar with a new one.
If distance (B) is within the standard, measure the thickness of 5th gear.
- If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.
- If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.

Disassembly





1. Remove the ball bearing using a bearing puller as shown.

CAUTION: Remove the synchro hubs using a press and the steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.





2. 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.

Inspection





1. Inspect the gear surfaces and the bearing surfaces for wear and damage, then measure the mainshaft at points A, B, and C.
- If any parts of the mainshaft are less than the service limit, replace mainshaft with a new one.





2. Inspect for runout.

Standard: 0.02 mm (13.0008 inch) max.
Service Limit: 0.05 mm 0D.002 inch)

NOTE: Support the mainshaft at both ends as shown.

If the runout is more than the service limit, replace the mainshaft with a new one.

Reassembly

CAUTION:
- Press the 3rd/4th and the 5th synchro hubs on the mainshaft without lubrication.
- When installing the 3rd/4th and the 5th synchro hubs, support the mainshaft on the steel blocks, and install synchro hubs using a press.
- Install the 3rd/4th and the 5th synchro hubs with a maximum pressure of 19.6 kN (2,000 kgf, 14,466 lbs.).





NOTE: Refer to image for reassembly sequence.





1. 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.





2. Install the 5th synchro hub using the special tools and a press as shown.





3. Install the ball bearing using the special tools and a press as shown.

NOTE: Install the ball bearing with the tapered end facing down.
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