Acura Coupes and Sedans 1986-1993 Repair Guide

Overhaul

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1986-89 INTEGRA



See Figures 1 through 16



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Fig. Fig. 1: Transaxle components-1986-89 Integra



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Fig. Fig. 2: Transaxle components-1986-89 Integra



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Fig. Fig. 3: Measuring clearance at the reverse idler gear-1986-89 Integra



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Fig. Fig. 4: Measuring clearance at the reverse shift fork-1986-89 Integra



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Fig. Fig. 5: Shaft identification-1986-89 Integra



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Fig. Fig. 6: Mainshaft components-1986-89 Integra



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Fig. Fig. 7: Countershaft components-1986-89 Integra



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Fig. Fig. 8: The longer teeth must be matched with the deeper grooves in the hub-1986-89 Integra



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Fig. Fig. 9: Check the mainshaft diameters at these points-1986-89 Integra



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Fig. Fig. 10: Check the countershaft diameters at these points-1986-89 Integra



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Fig. Fig. 11: Mainshaft assembly-1986-89 Integra



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Fig. Fig. 12: Countershaft assembly-1986-89 Integra



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Fig. Fig. 13: Shift arm holder assembly-1986-89 Integra



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Fig. Fig. 14: Install the detent balls and springs in the proper order-1986-89 Integra



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Fig. Fig. 15: Torque the cover bolts to 9 ft. lbs. (12 Nm) in the sequence shown-1986-89 Integra



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Fig. Fig. 16: Shifter components-1986-89 Integra


WARNING
The use of the correct special tools or their equivalent is REQUIRED for this procedure.

Cleanliness is an important factor in the overhaul of this guide transaxle. Before opening up the unit, the entire outside of the transaxle assembly should be cleaned, preferably with a high pressure washer such as a car wash spray unit. Dirt entering the transaxle internal parts will negate all the time and effort spent on the overhaul. During inspection and reassembly all parts should be thoroughly cleaned with solvent, then dried with compressed air. Wiping cloths and rags should not be used to dry parts.

Wheel bearing grease, long used to hold thrust washers and lubricate parts, should not be used. Lube seals with clean transaxle oil and use ordinary (unmedicated) petroleum jelly to hold the thrust washers. This will ease the assembly of seals, since it will not leave a harmful residue as grease often does. Do not use solvent on neoprene seals, if they are to be reused, or thrust washers.

Before installing bolts into aluminum parts, always dip the threads into clean transaxle oil. Antiseize compound can also be used to prevent bolts from galling the aluminum and seizing. Always use a torque wrench to keep from stripping the threads.The internal snaprings should be expanded and the external rings should be compressed using proper tools.

Transaxle
DISASSEMBLY
  1. Remove the transaxle end cover.
  2.  
  3. Install the mainshaft holder tool 07923-6890101. Shift the transaxle into reverse.
  4.  
  5. Remove the mainshaft and countershaft locknuts. The mainshaft locknut has left-hand threads.
  6.  
  7. Drive out the spring pin securing the 5th gear shift fork to the shaft.
  8.  
  9. Remove the mainshaft 5th gear, shift fork, synchro sleeve,hub ring and spring as an assembly.
  10.  
  11. Remove countershaft 5th gear.
  12.  
  13. Remove the 3 retaining screws, washers, springs and detent balls.
  14.  
  15. Remove the reverse light switch.
  16.  
  17. Remove the 13 housing bolts.
  18.  
  19. Loosen the housing by tapping on its edge with a soft hammer or mallet. To separate the transaxle housing from the clutch housing, remove the attachment from the bearing remover 07936-6340000, or equivalent, and screw the threaded end into the hole in the transmission housing. Expand the snapring while operating the bearing remover as a slide hammer.
  20.  
  21. Before removing the reverse shift fork, measure the clearance between the reverse shift fork and the 5th/reverse shift shaft pin. The specification is 0.05-0.50mm (0.002-0.020 in). If not within specification, measure the width of the slot in the reverse shift fork. The maximum width is 0.285 in. (7.25mm). Replace the fork if not within specification.
  22.  
  23. Measure the clearance between the reverse idler gear and the shift fork. The specification is 0.20-1.7mm (0.008-0.070 in). If not within specification, remove the fork and measure the distance between the shift fork pawls. The specification is 11.8-12.1mm (0.46-0.48 in.) Replace the shift fork if not within specification.
  24.  
  25. Remove the reverse shift fork/shift arm holder if not already removed.
  26.  
  27. Shift the transaxle into neutral. Remove the mainshaft bearing retainer plate.
  28.  
  29. Pull out the shift guide shaft.
  30.  
  31. Remove the reverse idler shaft and gear.
  32.  
  33. Pull the 3rd/4th and 1st/2nd shift shafts up, to shift into 4th and 2nd gears. Remove the 5th/reverse shift shaft by pulling it up while lifting the reverse shift fork.
  34.  
  35. Measure the clearance between the collar and shim on the selector arm shaft. The specification is 0.01-0.20mm (0.0004-0.0080 in). If not within specification, disassemble the shift arm holder and replace the shim. Selective shims are available in 0.008 in. (0.20mm) increments from 0.031-0.063 in. (0.80-1.60mm).
  36.  
  37. Measure the shift arm to shift guide clearance. The specification is 0.10-0.60mm (0.004-0.024 in). If not within specification, measure the width of the slot in the shift guide. The maximum width is 8.00mm (0.315 in). If wider than the maximum, replace the shift guide.
  38.  
  39. Measure the selector arm to interlock clearance. The specification is 0.70-0.25mm (0.002-0.030 in). If not within specification, measure the gap between the selector arm fingers. The maximum allowable gap is 10.15mm (0.40 in). If wider than specifications, replace the arm.
  40.  
  41. Measure the shift arm to shift rod guide clearance. The specification is (0.05-0.80mm 0.002-0.03 in). If not within specification measure the width of the slot in the shift rod guide. The maximum width is (12.0mm 0.47 in). If not within specification, replace the shift rod guide. If within specification, measure the width of the tab on the selector arm. The minimum width is 11.9mm (0.46 in). If it is too narrow, replace the arm.
  42.  
  43. Tilt the interlock and shift guide to the side and lift them out.
  44.  
  45. Remove the countershaft and mainshaft together as an assembly along with the 1st/2nd and 3rd/4th shift shafts. Inspect the shafts, especially the detent grooves for damage.
  46.  
  47. Remove the shift rod and boot. Inspect the rod for damage and the boot for rips.
  48.  
  49. Remove the differential assembly.
  50.  
  51. Remove the snapring in the transaxle housing. Drive out the axle seals from both housings.
  52.  
  53. Remove the bearing retainer plate.
  54.  
  55. Insert the bearing remover, or equivalent with attachment 07936-6890101 or 07736-A01000A into the countershaft bearing. Operate the slide hammer to remove the bearing.
  56.  
  57. Remove the oil barrier plate, wash thoroughly and reinstall. Unless the countershaft needle bearing is to be replaced, reinstall it.
  58.  
  59. Reinstall the bearing retainer plate, tighten the screw with an impact driver and stake the screw heads.
  60.  
  61. Remove the mainshaft bearing seal from the clutch housing. Do not remove the mainshaft bearing unless it rotates roughly and is to be replaced.
  62.  
  63. Remove the mainshaft and countershaft bearings from the transaxle housing by expanding each snapring and pushing the bearing out by hand. Do not remove the snaprings unless it is necessary to clean their grooves.
  64.  

Countershaft Assembly
CHECKING CLEARANCES

Before disassembling the countershaft assembly, perform the following measurements. If any measurement is not within specifications, disassemble the countershaft assembly and replace thrust washers as required.

If all measurements are within specifications, there is no reason to disassemble the countershaft assembly except in cases of physical damage.

  1. Measure the clearance between the 1st gear thrust washer and the shoulder on 1st gear. The specification is 0.001-0.003in. (0.03-0.08mm).
  2.  
  3. Measure the clearance between the shoulder on 3rd gear and the shoulder on 2nd gear. The specification is 0.001-0.007in. (0.03-0.18mm). If out of specification, measure the thickness of 2nd gear. The specification is 1.192-1.120 in. (30.30-30.47mm).
  4.  
  5. If any of the measurements are not within specifications, calculate the thickness needed to bring the measurement within the service limit before disassembling the unit.
  6.  

DISASSEMBLY
  1. Remove 5th gear.
  2.  
  3. Remove the ball bearing, 4th gear and the spacer collar.
  4.  
  5. Remove the 3rd gear, the needle bearing, spacer collar.
  6.  
  7. Remove 2nd gear.
  8.  
  9. Remove the synchro ring, spring, sleeve, hub, spring and ring.
  10.  
  11. Remove 1st gear.
  12.  
  13. Remove the needle bearing and the thrust washer.
  14.  

INSPECTION
  1. Inspect the needle bearing for wear or damage.
  2.  
  3. Check the clearance between each shift fork and its matching synchro sleeve. The specification is 0.014-0.039 in. (0.35-1.00mm). If the clearance exceeds the specification, measure the width of the groove in the synchro sleeve. The specification is 0.266-0.270 in. (6.75-6.85mm).
  4.  
  5. Inspect the gear teeth on all synchro hubs and sleeves for rounded corners, indicating wear.
  6.  
  7. Install each hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
  8.  
  9. Inspect the inside of the synchro ring and the synchro ring teeth and matching teeth on the gear for wear in the form of rounding.
  10.  
  11. Inspect the gear hub thrust and cone surfaces for wear.
  12.  
  13. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
  14.  
  15. Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is 0.016-0.029 in. (0.40-1.18mm). Remove the ring from the gear.
  16.  
  17. Inspect the oil passages for clogging. Inspect the splines on the countershaft for damage.
  18.  
  19. Measure the outside diameter of the bearing surface on the end opposite the threaded end. The specification is 1.297-1.300 in. (32.95-33.02mm).
  20.  
  21. Measure the outside diameter of the bearing surface in front of the countershaft gear. The specification is 1.336-1.339 in. (33.93-34.00mm).
  22.  
  23. Measure the outside diameter of the bearing surface nearest the threaded end. The specification is 0.981-0.984 in. (24.93-25.00mm).
  24.  
  25. Inspect the countershaft for run-out. The maximum allowable run-out is 0.002 in. (0.05mm). Replace the countershaft if any measurement is not within specification.
  26.  

ASSEMBLY

Clean all parts thoroughly with solvent and dry with compressed air. Lubricate all parts with oil before assembling.

Each synchro sleeve has 3 sets of longer teeth 120° apart that must be matched with the 3 sets of deeper grooves in the hub when assembled.

  1. Install the thrust washer and needle bearing.
  2.  
  3. Install 1st gear.
  4.  
  5. Install the synchro ring, spring, hub, sleeve, spring and ring.
  6.  
  7. Install 2nd gear.
  8.  
  9. Install the spacer collar, needle bearing and 3rd gear.
  10.  
  11. Install the spacer collar, 4th gear and 3rd gear.
  12.  
  13. Install 5th gear.
  14.  

Mainshaft
CHECKING CLEARANCES

Before disassembling the mainshaft assembly, perform the following measurements. If any measurement is not within specifications, disassemble the mainshaft assembly and replace thrust washers as required.

If all measurements are within specifications, there is no reason to disassemble the countershaft assembly, providing there is no damage to any of its components.

  1. Measure the clearance between the shoulder on 4th gear and the spacer collar. The specification is 0.001-0.007 in. (0.03-0.18mm). If out of specification, measure the thickness of 4th gear. The specification is 1.232-1.240 in. (31.30-31.47mm).
  2.  
  3. Measure the clearance between the shoulder on 3rd gear and the shoulder on 2nd gear. The specification is 0.001-0.007 in. (0.03-0.18mm). If out of specification, measure the thickness of 3rd gear. The specification is 1.232-1.240 (31.30-31.47mm).
  4.  
  5. Measure the clearance between the shoulder on 5th gear and the spacer collar. The specification is 0.001-0.005 in. (0.03-0.13mm). If out of specification, measure the thickness of 5th gear. The specification is 1.272-1.278 (32.30-32.47mm).
  6.  
  7. Measure the clearance between the 28mm spacer and the ball bearing. The specification is 0-0.004 in. (0-0.010mm). If not within specification, replace the spacer washer. Selective spacer washers are available in the following sizes:

    A - 0.074-0.075 in. (1.88-1.92mm)
     
    B - 0.076-0.078 in. (1.94-1.98mm)
     
    C - 0.079-0.080 in. (2.00-2.04mm)
     
    D - 0.081-0.082 in. (2.06-2.10mm)
     
    E - 0.083-0.084 in. (2.12-2.16mm)
     

  8.  

  1. If any of the measurements are not within specifications, calculate the thickness of washers needed to bring the measurement back within the serviceable limit before disassembling the unit.
  2.  

DISASSEMBLY
  1. Remove the synchro sleeve, hub, spring and ring.
  2.  
  3. Remove 5th gear.
  4.  
  5. Remove the needle bearing, spacer collar and mainshaft needle bearing.
  6.  
  7. Remove the spacer collar and needle bearing.
  8.  
  9. Remove 4th gear.
  10.  
  11. Remove the synchro ring, spring, sleeve, hub, spring and ring.
  12.  
  13. Remove 3rd gear and the needle bearing.
  14.  

INSPECTION
  1. Inspect the needle bearings for wear or damage.
  2.  
  3. Inspect the inside of the synchro rings for wear.
  4.  
  5. Install each hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
  6.  
  7. Inspect the synchro ring teeth and matching teeth on the gears for wear in the form of rounding.
  8.  
  9. Inspect the gear hub thrust and cone surfaces for wear.
  10.  
  11. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
  12.  
  13. Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is0.016-0.029 in. (0.40-1.18mm). Remove the ring from the gear.
  14.  
  15. Inspect the splines and gear teeth on the mainshaft for damage or excessive wear.
  16.  
  17. Inspect the oil passages for clogging.
  18.  
  19. Measure the outer diameter of the ball bearing contact area in front of 1st gear. The specification is 1.100-1.103 in. (27.95-28.12mm).
  20.  
  21. Measure the outer diameter of the 3rd gear needle bearing contact area. The specification is 1.257-1.260 in. (31.93-32.00mm).
  22.  
  23. Measure the outer diameter of the needle bearing contact area in front of the 5th synchro hub splines. The specification is 0.980-0.984 in. (24.93-25.00mm).
  24.  

ASSEMBLY
  1. Install the 3rd gear and the needle bearing.
  2.  
  3. Replace the synchro ring, spring, sleeve, hub, spring and ring.
  4.  
  5. Install 4th gear, the spacer collar and needle bearing.
  6.  
  7. Install the mainshaft needle bearing, spacer collar and needle bearing.
  8.  
  9. Install 5th gear, synchro sleeve, hub, spring and ring.
  10.  

Shift Arm Holder
DISASSEMBLY
  1. Remove the roll pin on the end of the shaft.
  2.  
  3. Remove the collar.
  4.  
  5. Remove the washer.
  6.  
  7. Remove the shim.
  8.  
  9. Remove the spring.
  10.  
  11. Remove the selector arm.
  12.  

INSPECTION
  1. Inspect the spring, shim and washer for deformation and rust.
  2.  
  3. Inspect the hole in the center of the holder for wear.
  4.  
  5. Inspect the selector arm for wear or bending.
  6.  
  7. Inspect the roll pin bore for expansion.
  8.  

ASSEMBLY
  1. Install the selector arm to the shaft on the holder.
  2.  
  3. Install the spring making sure to engage the ends correctly.
  4.  
  5. Install the chosen selective shim, if changed.
  6.  
  7. Install the washer.
  8.  
  9. Install the collar and roll pin.
  10.  

Transaxle
ASSEMBLY
  1. Install the mainshaft bearing to the clutch housing if it was removed. Install a new seal.
  2.  
  3. Install the mainshaft and countershaft bearings to the transaxle housing.
  4.  
  5. Install the shift rod with the detent notches facing downward. Install the spring and detent ball. Push the detent ball in and install the rod fully.
  6.  
  7. Install the shift rod guide and torque the bolt 22 ft. lbs (30 Nm).
  8.  
  9. Hook the selector arm into the shift rod guide and install the shift arm holder. Torque the longer bolts to 11 ft. lbs. (15 Nm) and the shorter bolt to 9 ft. lbs (12 Nm).
  10.  
  11. Install the differential assembly in the clutch housing.
  12.  
  13. Install the mainshaft, countershaft, 1st/2nd shift shaft, 3rd/4th shift shaft and both forks together as an assembly.
  14.  
  15. Lift the mainshaft and install the interlock into the selector arm. Place the shift rod in neutral.
  16.  
  17. Hook the interlock into the selector arm, 1st/2nd shift shaft and 3rd/4th shift shaft. Hook the shift guide into the shift arm.
  18.  
  19. Install the 5th/reverse shift shaft and hook its pin into the reverse shift fork slot.
  20.  
  21. Install the shift guide shaft so it bottoms securely in the clutch housing hole. The end of the shaft should not extend more than 1 / 2 in. (13mm) above the interlock. Do not continue until this measurement is correct.
  22.  
  23. Install the mainshaft bearing retainer plate. Tighten the bolts to 21 ft. lbs (28 Nm).
  24.  
  25. Install the reverse idler gear and shaft.
  26.  
  27. Install the reverse light switch with a new washer.
  28.  
  29. Thoroughly clean and dry the mating surfaces of the transaxle and clutch housings and install a new gasket to the clutch housing.
  30.  
  31. Shift the transaxle into 3rd gear. Install the transaxle housing, being careful to line up shafts. The shift guide shaft must seat in the blind hole in the transaxle housing. Do not force the installation.
  32.  
  33. Tighten the bolts to 21 ft. lbs (28 Nm).
  34.  
  35. Install the detent balls, new washers, springs and retaining bolts. Torque the bolts to 16 ft. lbs (22 Nm).
  36.  
  37. Install the countershaft 5th gear with the dished side facing down. Install the spring washer with the dished surface facing 5th gear.
  38.  
  39. Install the spacer collar and needle bearing on the mainshaft.
  40.  
  41. Install mainshaft 5th gear.
  42.  
  43. Install the synchro ring, spring, hub and sleeve on the mainshaft.
  44.  
  45. Install the 5th shift fork onto the synchro sleeve and install the roll pin.
  46.  
  47. Install the spring washer with the dished surface facing the synchro hub.
  48.  
  49. Install the mainshaft holder tool 07923-6890101, then shift the transaxle into reverse.
  50.  
  51. Install the mainshaft and countershaft locknuts. Tighten them one at a time to 65 ft. lbs. (90 Nm), loosen the nut, then retorque to the same setting. Stake the locknuts in place after the procedure is complete.
  52.  

The mainshaft locknut has left-hand threads.

  1. Clean the mating surfaces of the housing and the end cover. Install the end cover with a new gasket. Tighten the bolts to 9 ft. lbs. (12 Nm).
  2.  
  3. Install the snapring into the axle opening in the transaxle housing, aligning the lug on the snapring with the slot in the housing.
  4.  
  5. Lubricate and install new axle seals using driver 07749-0010000 and attachment 07947-6110500.
  6.  

1989-93 INTEGRA



See Figures 17 through 42



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Fig. Fig. 17: Shifter components-1986-89 Integra



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Fig. Fig. 18: Shifter components-1986-90 Legend



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Fig. Fig. 19: Shifter components-1991-93 Legend



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Fig. Fig. 20: Transaxle components-1986-89 Integra



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Fig. Fig. 21: Remove these components before separating the housing-1986-89 Integra



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Fig. Fig. 22: Remove the snapring beneath the sealing bolt-1986-89 Integra



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Fig. Fig. 23: Remove the thrust shim and oil guide plate-1986-89 Integra



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Fig. Fig. 24: Remove the oil gutter by prying the hook-1986-89 Integra



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Fig. Fig. 25: Reverse shift fork measurements-1986-89 Integra



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Fig. Fig. 26: Change holder components-1986-89 Integra



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Fig. Fig. 27: Tape the spines on the shaft before removing-1986-89 Integra



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Fig. Fig. 28: Remove the chamber plate-1986-89 Integra



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Fig. Fig. 29: Shift rod components-1986-89 Integra



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Fig. Fig. 30: Shift fork components-1986-89 Integra



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Fig. Fig. 31: Mainshaft components-1986-89 Integra



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Fig. Fig. 32: Mainshaft measurement points-1986-89 Integra



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Fig. Fig. 33: Countershaft components-1986-89 Integra



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Fig. Fig. 34: Countershaft measurement points-1986-89 Integra



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Fig. Fig. 35: Bend the tabs down on the bearing retainer plate-1986-89 Integra



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Fig. Fig. 36: Measure this height to the top of the 28mm thrust washer-1986-89 Integra



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Fig. Fig. 37: Measure the distance between the inner race to the housing surface-1986-89 Integra



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Fig. Fig. 38: Measuring the thrust clearance-1986-89 Integra



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Fig. Fig. 39: Assembling the shift rod-1986-89 Integra



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Fig. Fig. 40: Install the chamber plate-1986-89 Integra



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Fig. Fig. 41: Install the gear assembly with the 28mm spring washer concave face towards the gears-1986-89 Integra



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Fig. Fig. 42: Install these components with new washers-1986-89 Integra

  1. Remove the reverse light switch, the transaxle hanger, set bolts, springs and balls. Remove the reverse idler shaft bolt and washer.
  2.  
  3. Remove the bolts from the transaxle housing. Loosen them in a diagonal pattern a few threads at a time. Do not remove the housing from the transaxle yet.
  4.  
  5. Remove the 32mm sealing bolt from the rear of the transaxle housing. Reaching into the hole, expand the snapring on the countershaft ball bearing and remove it from its groove.
  6.  
  7. Remove the transaxle housing from the clutch housing.
  8.  
  9. Remove the thrust shim snapring and the oil guide from the housing.
  10.  
  11. Remove the 16mm sealing bolt.
  12.  
  13. Remove the oil gutter plate from the transaxle housing.
  14.  
  15. Before removing the reverse shift fork, measure the clearance between the reverse shift fork and the 5th/reverse shift piece pin. The specification is 0.002-0.018 in. (0.05-0.45mm) on the reverse side and 0.016-0.035 in. (0.40-0.90mm) on the 5th side. If beyond specification, measure the width of the L-groove in the reverse shift fork. The maximum width is 0.285 in. (7.25mm) on the reverse side and 0.303 in. (7.70mm) on the 5th side. Replace the fork if beyond specifications.
  16.  
  17. Measure the clearance between the reverse idler gear and the shift fork. The specification is 0.020-0.071 in. (0.50-1.8mm). If beyond specification, remove the fork and measure the distance between the shift fork pawls. The specification is 0.512-0.524 in. (13.0-13.3mm). Replace the shift fork if beyond specifications.
  18.  
  19. Remove the reverse shift fork if it was not removed in the previous step. Remove the reverse idler shaft and reverse idler gear from the the clutch housing.
  20.  
  21. Check the clearance between the shift piece and the shift arm. The service limit is 0.024 in. (0.6mm). If the clearance exceeds this measurement, check the width of the shift piece groove. The standard width is 0.319-0.329 in. (8.1-8.2mm).
  22.  
  23. Check the clearance between the select arm and the interlock. The service limit is 0.020 in. (0.5mm). If the clearance exceeds this measurement, check the width of the interlock. The standard width is 0.390-0.394 in. (9.9-10.0mm).
  24.  
  25. Check the clearance between the select arm and the thrust shim. The standard size is 0.0004-0.008 in. (0.01-0.20mm). If the clearance exceeds this measurement, install a thrust shim to bring the measurement to specification. Thrust shims are available from 0.031 in. (0.8mm) through 0.063 in. (1.6mm) in 5 steps.
  26.  
  27. Check the clearance between the shift arm and the change piece. The service limit is 0.031 in. (0.8mm). If the clearance exceeds this measurement, check the width of the change piece groove. The standard width is 0.465-0.472 in. (11.8-12.0mm).
  28.  
  29. Check the clearance between the select arm and the change piece. The service limit is 0.020 in. (0.5mm). If the clearance exceeds this measurement, check the width of the change piece groove. The standard width is 0.474-0.478 in. (12.05-12.15mm).
  30.  
  31. Remove the mainshaft and countershaft assemblies along with the shift fork assembly with thrust washer. Wrap tape around the splines to prevent damage to the seal if not replacing.
  32.  
  33. Remove the differential assembly from the clutch housing. Remove the chamber plate next to the bearings.
  34.  
  35. Check the synchro clearance at the shift fork fingers. The service limit is 0.039 in. (1.0mm). If the clearance is excessive, check the width of the shift fork fingers. The standard size is 0.291-0.295 in. (7.4-7.5mm)
  36.  
  37. Check the clearance between the shift piece and the shift fork shafts. The service limit is 0.031 in. (0.8mm). If the clearance exceeds this measurement, check the width of the shift piece. The standard width is 0.469-0.472 in. (11.9-12.0mm).
  38.  
  39. Measure the clearance between 2nd and 3rd gear. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.350 in. (34.3mm) with the B17A1 engine and 1.331 in. (33.8mm) with the B18A1 engine.
  40.  
  41. Measure the clearance between 4th gear and the spacer collar. The service limit is 0.0118 in. (0.3mm). The standard width of the 4th gear side of the spacer collar is 1.025-1.027 in. (26.03-26.08mm). The service limit of 4th gear width is 1.232 in. (31.3mm) for the B17A1 engine and 1.213 in. (30.8mm) for the B18A1 engine.
  42.  
  43. Measure the clearance between 5th gear and the spacer collar. The service limit is 0.0118 in. (0.3mm). The standard width of the 5th gear side of the spacer collar is 1.025-1.027 in. (26.03-26.08mm). The service limit of 5rd gear width is 1.232 in. (31.3mm).
  44.  
  45. Check the clearance between 1st gear and the 60mm thrust shim. The service clearance should be 0.0016-0.0047 in. (0.04-0.12mm). Correct with a shim, available from 0.0768 in. (1.95mm) to 0.0827 in. (2.10mm) in 16 steps.
  46.  
  47. Measure the distance between 2nd and 3rd gear. The service clearance should be 0.002-0.0047 in. (0.05-0.12mm). Correct with a new spacer collar available in 2 widths, 1.1425-1.1433 in. (29.02-29.04mm) and 1.1445-1.1453 in. (29.07-29.09mm).
  48.  
  49. Disassemble the mainshaft. Inspect the mainshaft for bearing surface wear. The bearing surface A service diameter limit of 1.0996 in. (27.93mm). The bearing surface B service diameter limit of 1.4933 in. (37.930mm). The bearing surface C service diameter limit of 1.0999 in. (27.940mm). Replace if any of the measurements are below these limits.
  50.  
  51. Disassemble the countershaft. Inspect the countershaft for bearing surface wear. The bearing surface A service diameter limit of 0.9819 in. (24.940mm). The bearing surface B service diameter limit of 1.4539 in. (36.930mm). The bearing surface C service diameter limit of 1.2972 in. (32.950mm). Replace if any of the measurements are below these limits.
  52.  
  53. Check the run-out of the mainshaft and countershaft. If the run-out exceeds the service limit of 0.0020 in. (0.05mm), replace the shaft.
  54.  
  55. Remove the mainshaft bearing and oil seal from the clutch side of the clutch housing.
  56.  
  57. Remove the retaining plate and countershaft needle bearing from the clutch housing using the adjustable bearing remover 07736-A01000A or equivalent and a slide hammer.
  58.  
  59. Remove the differential oil seals.
  60.  
  61. Remove the 72mm thrust shim and the oil guide plate.
  62.  
  63. Install the 3/4 synchro hub, spacer collar, 5th synchro hub, collar, 28mm thrust washer and ball bearing on the mainshaft. Make sure the clutch side ball bearing is not installed on the mainshaft. Install the assembly in the transaxle case.
  64.  
  65. Measure the distance between the end of the transaxle case and the top of 28mm thrust washer. Make the measurement at 3 places, average the results and record the final answer.
  66.  
  67. Measure the distance between the end of the clutch housing and the bearing inner race. Make the measurement at 3 places, average the results and record the final answer.
  68.  
  69. Add the results of the 2 measurements and subtract 0.039 in. (1.0mm). Use this as the shim thickness for the 72mm shim. Shims are available from 0.0236 in. (0.60mm) through 0.0709 in. (1.80mm) in 41 equal steps.
  70.  
  71. Install the selected shim(s) in the transaxle case.
  72.  
  73. Install the spring washer on the mainshaft, concave side facing mainshaft 1st gear.
  74.  
  75. Install the mainshaft in the clutch housing.
  76.  
  77. Clean all dirt from the mating surfaces of the transaxle and clutch housings and install the transaxle housing to the clutch housing. Torque the 8mm bolts to 20 ft. lbs. (28 Nm) and 10mm bolts to 33 ft. lbs. (45 Nm).
  78.  
  79. Tap the mainshaft with a plastic hammer.
  80.  
  81. Install the collar and shaft holder of the mainshaft thrust clearance inspection tool 07GAJ-PG20101 to the mainshaft and tighten the 3 Allen bolts into the groove below the splines. Make sure they are positioned correctly and not digging into the splines.
  82.  
  83. Position a dial indicator so the pin rests on the outer circumference of the tip of the mainshaft.
  84.  
  85. Turn the bolt clockwise and read the clearance.
  86.  

Do not turn the bolt more than 60° after the needle of the dial indicator has stopped increasing.

  1. The clearance specification for is 0.004-0.007 in. (0.11-0.18mm). If the clearance is not within specifications, repeat the entire procedure. Do not continue until the correct clearance has been obtained.
  2.  
  3. When the correct clearance has been obtained, disassemble the transaxle and assemble the mainshaft and countershaft completely.
  4.  

To assemble:
  1. Install the differential assembly in the clutch housing.
  2.  
  3. Install the mainshaft and countershaft bearings in the clutch housing.
  4.  
  5. Install the spring washer to the bottom of the mainshaft and install the mainshaft, countershaft and shift forks together as as assembly.
  6.  
  7. Install the change holder, shift piece and interlock.
  8.  
  9. Install the reverse idler gear and idler gear shaft in the clutch housing. Install the reverse shift fork in the clutch housing. Make sure the pin is engaged with the slot in the fork. Torque the bolts to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the oil guide plate and selected shim(s) into the transaxle housing.
  12.  
  13. Install the oil gutter plate in the transaxle housing. Bend the hook into place and torque the 16mm sealing bolt to 22 ft. lbs. (30 Nm).
  14.  
  15. Thoroughly clean and dry the mating surfaces of the transaxle and clutch housings. Apply sealant, part number 08718-550000 or equivalent to the clutch housing.
  16.  
  17. Install the transaxle housing to the clutch housing, being careful to line up the shafts.
  18.  
  19. Install the snapring to the countershaft ball bearing through the hole at the top of the transaxle housing. Install the 32mm sealing bolt and torque to 18 ft. lbs. (25 Nm).
  20.  
  21. Torque the housing 8mm bolts to 20 ft. lbs. (28 Nm) in the proper sequence.
  22.  
  23. Install the reverse idler shaft bolt with new washer. Torque the bolt to 40 ft. lbs. (55 Nm).
  24.  
  25. Install the reverse light switch and new washer. Install the transmission hanger and set screws with springs and balls. Torque to 16 ft. lbs. (22 Nm).
  26.  

1986-90 LEGEND



See Figures 43 through 62



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Fig. Fig. 43: Transaxle components-1986-1990 Legend



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Fig. Fig. 44: Remove these components-1986-1990 Legend



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Fig. Fig. 45: Remove the reverse idler shaft bolt and bracket-1986-1990 Legend



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Fig. Fig. 46: Remove the snapring-1986-1990 Legend



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Fig. Fig. 47: Shift arm assembly-1986-1990 Legend



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Fig. Fig. 48: Measure this height-1986-1990 Legend



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Fig. Fig. 49: Measure this height-1986-1990 Legend



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Fig. Fig. 50: Checking the thrust clearance-1986-1990 Legend



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Fig. Fig. 51: Mainshaft components-1986-1990 Legend



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Fig. Fig. 52: Countershaft components-1986-1990 Legend



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Fig. Fig. 53: Measure these points on the mainshaft-1986-1990 Legend



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Fig. Fig. 54: Measure these points on the countershaft-1986-1990 Legend



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Fig. Fig. 55: Shift rod assembly-1986-1990 Legend



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Fig. Fig. 56: Replace the detent ball-1986-1990 Legend



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Fig. Fig. 57: Install the shift rod guide-1986-1990 Legend



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Fig. Fig. 58: Install the shift arm holder-1986-1990 Legend



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Fig. Fig. 59: Torque the housing bolts in this order-1986-1990 Legend



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Fig. Fig. 60: Replace the idler shaft bolt-1986-1990 Legend



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Fig. Fig. 61: Replace the components-1986-1990 Legend



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Fig. Fig. 62: Replace the 32mm sealing bolt-1986-1990 Legend

  1. Remove the reverse light switch and neutral switch.
  2.  
  3. Remove the ball spring setting screw and washer. Remove the spring and detent ball from the transaxle housing.
  4.  
  5. Remove the reverse idler shaft bolt.
  6.  
  7. Remove the bolts attaching the transaxle housing to the clutch housing.
  8.  
  9. Remove the 32mm sealing bolt. The 16mm sealing bolt does not have to be removed to disassemble the transaxle.
  10.  
  11. Reach into the hole and expand the countershaft ball bearing snapring, removing it from the groove.
  12.  
  13. Separate the transaxle housing from the clutch housing.
  14.  
  15. Remove the thrust shim(s) and oil guide plate from the transaxle housing.
  16.  
  17. Before removing the reverse shift fork, measure the clearance between the reverse shift fork and the 5th/reverse shift pin. The specification is 0.002-0.020 in. (0.05-0.50mm). If beyond specification, measure the width of the L-groove in the reverse shift fork. The maximum width is 0.285 in. (7.25mm). Replace the fork if beyond specifications.
  18.  
  19. Measure the clearance between the reverse idler gear and the shift fork. The specification is 0.020-0.071 in. (0.50-1.8mm). If beyond specification, remove the fork and measure the distance between the shift fork pawls. The specification is 0.512-0.524 in. (13.0-13.3mm). Replace the shift fork if beyond specifications.
  20.  
  21. Remove the reverse shift fork if it was not removed in the previous step. Remove the reverse idler shaft, washer and reverse idler gear from the the clutch housing.
  22.  
  23. Measure the clearance between the shift arm and the shift guide. The specification is 0.008-0.022 in. (0.20-0.55mm). If the clearance is not within specifications, measure the width of the groove in the shift guide. The maximum width is 0.323 in. (8.20mm). Replace the shift guide if the width is beyond specification.
  24.  
  25. Remove the shift arm assembly from the clutch housing.
  26.  
  27. Remove the mainshaft and countershaft assemblies together with the shift fork assembly.
  28.  
  29. Remove the differential assembly. Remove the shift rod guide.
  30.  
  31. Remove the detent ball and spring from the clutch housing.
  32.  
  33. Remove the shift rod and boot from the clutch housing.
  34.  
  35. Remove the roll pin, clip and shift joint end from the shift rod.
  36.  
  37. Remove the mainshaft bearing and oil seal from the clutch side of the clutch housing.
  38.  
  39. Remove the countershaft bearing retaining plate from the clutch housing. Remove the magnetic plate.
  40.  
  41. Remove the countershaft needle bearing from the clutch housing using the adjustable bearing remover 07736-A01000A and a slide hammer.
  42.  
  43. Remove the differential oil seals.
  44.  
  45. Disassemble the shift fork shafts. Remove the roll pin from the 5th/reverse shift guide. Remove the 5th and 3rd/4th shift forks from the shaft. Remove the 1st/2nd shift fork from its shaft.
  46.  
  47. Inspect the shift fork bores for scoring and excessive wear. Inspect the shift fork pawls for cracks and wear. Inspect the shafts for scoring, damage and excessive wear.
  48.  
  49. Install the 1st/2nd shift fork on its shaft. Install the 5th and 3rd/4th shift forks on the shaft. Install the roll pin.
  50.  
  51. Remove the shift shaft. Remove the shift arm holder from the shift guide. Remove the shift guide.
  52.  
  53. Inspect the springs for deformation and rust. Inspect the shift arm holder for scoring and pitting. Inspect the shift guide for wear.
  54.  
  55. Measure the width of the groove in the change piece. The maximum width is 0.522 in. (13.25mm). If not within specification, replace the change piece.
  56.  
  57. Measure the clearance between the interlock and the change piece. The specification is 0.002-0.020 in. (0.05-0.50mm). If the clearance is not within specifications, measure the outside diameter of the interlock. The specification is 0.474-0.478 in. (12.05-12.15mm). If not within specification, replace the interlock.
  58.  
  59. Assemble the shift guide and interlock. Engage the shift arm holder with the shift guide. Install the shift shaft.
  60.  

Before disassembling the mainshaft assembly, perform the following measurements. If any measurement is not within specifications, disassemble the mainshaft assembly and replace parts as required. If all measurements are within specifications, there is no reason to disassemble the mainshaft assembly, providing there is no damage to any of its components.

  1. Push down on the bearing race with a suitable socket and measure the clearance between 2nd and 3rd gears. The specification is 0.002-0.012 in. (0.06-0.30mm). If not within specifications, disassemble the mainshaft and inspect 3rd gear.
  2.  
  3. Measure the clearance between 4th gear and the spacer collar. The specification is 0.002-0.012 in. (0.06-0.30mm). If not within specifications, disassemble the mainshaft and inspect 4th gear and the spacer collar.
  4.  
  5. Measure the clearance between 5th gear and the spacer collar. The specification is 0.002-0.012 in. (0.06-0.30mm). If not within specifications, disassemble the mainshaft and inspect 5th gear and the spacer collar.
  6.  
  7. Remove the ball bearing from the end of the mainshaft.
  8.  
  9. Remove the 5th synchro hub, sleeve, spring and ring.
  10.  
  11. Remove 5th gear.
  12.  
  13. Remove the first needle bearing, spacer collar and the second needle bearing.
  14.  
  15. Remove 4th gear.
  16.  
  17. Remove the 3/4 synchro sleeve, first ring, first spring, hub, second spring and second ring.
  18.  
  19. Remove 3rd gear and the needle bearing.
  20.  
  21. Inspect the needle bearings for wear or damage. Inspect the inside of the synchro rings for wear.
  22.  
  23. Install each hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
  24.  
  25. Inspect the synchro ring teeth and matching teeth on the gears for wear in the form of rounding.
  26.  
  27. Inspect the gear hub thrust and cone surfaces for wear.
  28.  
  29. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
  30.  
  31. Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is 0.016-0.043 in. (0.40-1.10mm). Remove the ring from the gear.
  32.  
  33. Inspect the splines and gear teeth on the mainshaft for damage or excessive wear.
  34.  
  35. Inspect the oil passages for clogging.
  36.  
  37. If the clearance between 2nd and 3rd gears was not within specification, measure the thickness of 3rd gear from the flat side to the top of the coned side. The specification is 1.390-1.396 in. (35.30-35.47mm). If the reading is not within specification, replace the gear; if it is within specification, replace the synchro hub.
  38.  
  39. If the clearance between 4th gear and the spacer collar was not within specification, measure the length of the 4th gear half of the spacer collar. The specification is 1.024-1.027 in. (26.01-26.08mm). If the reading is not within specification, replace the spacer collar; if it is not within specification, measure the thickness of 4th gear from the flat side to the top of the coned side. The specification is 1.312-1.318 in. (33.33-33.47mm). If the reading is not within specification, replace the gear; if it is within specification, replace the synchro hub.
  40.  
  41. If the clearance between 5th gear and the spacer collar was not within specification, measure the length of the 5th gear half of the spacer collar. The specification is 1.024-1.027 in. (26.01-26.08mm). If the reading is not within specification, replace the spacer collar; if it is not within specification, measure the thickness of 5th gear from the flat side to the top of the coned side. The specification is 1.252-1.259 in. (31.80-31.97mm). If the reading is not within specification, replace the gear; if it is within specification, replace the synchro hub.
  42.  
  43. Measure the outer diameter of the ball bearing contact area in front of 1st gear. The specification is 1.100-1.102 in. (27.94-27.99mm).
  44.  
  45. Measure the outer diameter of the 3rd gear contact area. The specification is 1.493-1.496 in. (37.93-38.00mm).
  46.  
  47. Measure the outer diameter of the needle bearing contact area behind the 5th synchro hub splines. The specification is 1.100-1.102 in. (27.94-27.99mm).
  48.  
  49. Inspect the mainshaft for run-out. The maximum allowable run-out is 0.0019 in. (0.05mm). Replace the mainshaft if any measurement is not within specifications.
  50.  

If the selective mainshaft shims located above the oil guide plate in the transaxle housing are to be changed, do not assemble the mainshaft until that procedure is completed.

  1. Install the needle bearing and 3rd gear.
  2.  
  3. Install the first synchro ring, first spring, hub, second spring, second spring, second ring and 3/4 synchro sleeve.
  4.  
  5. Install 4th gear.
  6.  
  7. Install the first needle bearing, spacer collar and second needle bearing.
  8.  
  9. Install 5th gear.
  10.  
  11. Install the 5th synchro ring, spring, sleeve and hub.
  12.  
  13. Install the ball bearing.
  14.  
  15. If they have not already been removed, remove the thrust shim(s), and oil guide plate from the transaxle housing.
  16.  
  17. Install the 3/4 synchro hub, spacer collar, 5th synchro hub and ball bearing on the mainshaft. Make sure the clutch side ball bearing is not installed on the mainshaft. Install the assembly in the transaxle case.
  18.  
  19. Measure the distance between the end of the transaxle case and the top of mainshaft 1st gear. Make the measurement at 3 places, average the results and record the final answer.
  20.  
  21. Install the clutch housing side bearing (without the spring washer) into the mainshaft and install the clutch housing on the transaxle housing temporarily. Measure the distance between the end of the clutch housing and the bearing inner race. Make the measurement at 3 places, average the results and record the final answer.
  22.  
  23. To select the proper shim(s), add the 2 measurements and subtract 0.0366 in. (0.93mm). This is the size shim to use. Select a shim or combination of shims that fall within the range of the minimum and maximum answers to the formulas. Shims are available from 0.0472 in. (1.20mm) through 0.0933 in. (2.37mm) in 40 steps.
  24.  

Do not use more than 2 thrust shims.

  1. Install the selected shim(s) in the transaxle case.
  2.  
  3. Install the spring washer on the mainshaft, concave side facing mainshaft 1st gear.
  4.  
  5. Install the mainshaft in the clutch housing.
  6.  
  7. Clean all dirt from the mating surfaces of the transaxle and clutch housings and install the transaxle housing to the clutch housing with several bolts spaced evenly around the housing.
  8.  
  9. Tap the mainshaft with a plastic hammer.
  10.  
  11. Install the collar and shaft holder of the mainshaft thrust clearance inspection tool 07GAJ-PG20101 to the mainshaft and tighten the 3 allen bolts into the groove below the splines. Make sure they are positioned correctly and not digging into the splines.
  12.  
  13. Position a dial indicator so the pin rests on the outer circumference of the tip of the mainshaft.
  14.  
  15. Turn the bolt clockwise and read the clearance.
  16.  

Do not turn the bolt more than 60 degrees after the needle of the dial indicator has stopped increasing.

  1. The clearance specification is 0.0039-0.0063 in. (0.10-0.16mm). If the clearance is not within specifications, repeat the entire procedure. Do not continue until the correct clearance has been obtained.
  2.  
  3. When the correct clearance has been obtained, disassemble the transaxle and assemble the mainshaft completely.
  4.  

Before disassembling the countershaft assembly, perform the following measurements. If any measurement is not within specifications, disassemble the assembly and replace parts as required. If all measurements are within specifications, there is no reason to disassemble the countershaft assembly, providing there is no damage to any of its components.

  1. Clamp the countershaft assembly in a vise using 2 pieces of wood to protect the shaft.
  2.  
  3. Torque the locknut to 80 ft. lbs. (110 Nm), loosen it, then retorque it to the 80 ft. lbs. (110 Nm).
  4.  
  5. Measure the clearance between 1st gear and the thrust washer. The specification is 0.002-0.007 in. (0.04-0.18mm). If not within specifications, disassemble the countershaft assembly and select the thrust washer that will bring the clearance within specifications.
  6.  
  7. Measure the clearance between 3rd gear and 2nd gear. The specification is 0.001-0.007 in. (0.03-0.18mm). If not within specifications, disassemble the countershaft assembly and select the spacer collar that will bring the clearance within specifications.
  8.  
  9. Remove the locknut and lock washer.
  10.  
  11. Remove the ball bearing.
  12.  
  13. Remove the first needle bearing, 5th, 4th, 3rd and 2nd gears and the second needle bearing.
  14.  
  15. Remove the first friction damper and spacer collar.
  16.  
  17. Remove the first synchro ring, first spring, reverse gear, second spring and second ring.
  18.  
  19. Remove the second friction damper.
  20.  
  21. Remove 1st gear, needle bearing and thrust washer.
  22.  
  23. Inspect the needle bearings for wear or damage.
  24.  
  25. Inspect the inside of the synchro rings for wear.
  26.  
  27. Install the hub in its mating sleeve and check for freedom of movement. If replacement is required, replace them as an assembly.
  28.  
  29. Inspect the synchro ring teeth and matching teeth on the gears for wear.
  30.  
  31. Inspect the gear hub thrust and cone surfaces for wear.
  32.  
  33. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks.
  34.  
  35. Place the synchro ring on the matching gear cone and rotate it until it stops. The ring to gear clearance specification is 0.016-0.043 in. (0.40-1.10mm). Remove the ring from the gear.
  36.  
  37. Inspect the oil passages in the countershaft for clogging.
  38.  
  39. Measure the outer diameter of the needle bearing contact area. The specification is 1.297-1.300 in. (32.95-33.02mm).
  40.  
  41. Measure the outer diameter of the low gear contact area below the splines. The specification is 1.572-1.575 in. (39.93-40.00mm).
  42.  
  43. Measure the outer diameter of the ball bearing surface near the threaded end of the shaft. The specification is 0.982-0.984 in. (24.94-25.00mm).
  44.  
  45. Measure the run-out of the countershaft. The maximum allowable run-out is 0.0019 in. (0.05mm). Replace the countershaft if any measurement is not within specification.
  46.  
  47. Install the selected thrust washer, needle bearing and 1st gear.
  48.  
  49. Install the friction damper.
  50.  
  51. Install the first synchro ring, first spring, reverse gear, second spring and second ring.
  52.  
  53. Install the friction damper.
  54.  
  55. Install the needle bearing, 2nd, 3rd, 4th and 5th gears and the other needle bearing.
  56.  
  57. Install the ball bearing.
  58.  
  59. Install the lock washer and locknut. Torque the locknut to 80 ft. lbs. (110 Nm), loosen it, then retorque it to the 80 ft. lbs. (110 Nm).
  60.  

To assemble:
  1. Position the shift rod guide and install the dust seal and boot.
  2.  
  3. Install the shift rod with the detents and holes facing up. Install the roll pin and clip that holds the change joint end.
  4.  
  5. Apply grease to the detent ball and spring and install. Torque the bolt to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the shift rod guide mounting bolt and washer. Torque the bolt to 22 ft. lbs. (30 Nm).
  8.  
  9. Install the differential assembly.
  10.  
  11. Install the mainshaft bearing and new seal and countershaft bearing in the clutch housing.
  12.  
  13. Install the spring washer to the bottom of the mainshaft and install the mainshaft, countershaft and shift forks together as as assembly.
  14.  
  15. Install the shift arm holder assembly. Torque the 6mm bolt to 7 ft. lbs. (12 Nm), the 8mm bolt to 21 ft. lbs. (28 Nm) and the special flange bolt to 11 ft. lbs. (15 Nm).
  16.  
  17. Measure the height of the protruding end of the shift shaft after mounting the shift arm holder. The height should be 0.44-0.46 in. (11.3-11.7mm). Do not proceed until this specification is met.
  18.  
  19. Install the reverse idler gear, washer and idler gear shaft in the clutch housing. Make sure the tab in the bottom of the shaft is aligned with the groove in the housing.
  20.  
  21. Install the reverse shift fork in the clutch housing. Make sure the pin is engaged with the slot in the fork. Torque the bolts to 11 ft. lbs. (15 Nm).
  22.  
  23. Install the oil guide plate and selected shim(s) into the transaxle housing.
  24.  
  25. Thoroughly clean and dry the mating surfaces of the transaxle and clutch housings. Apply sealant (Honda part number 08718-550000, or equivalent) to the clutch housing.
  26.  
  27. Install the transaxle housing to the clutch housing, being careful to line up the shafts.
  28.  
  29. Install the snapring to the countershaft ball bearing through the hole at the top of the transaxle housing.
  30.  
  31. Torque the bolts in the proper sequence to 33 ft. lbs. (45 Nm).
  32.  
  33. Install the 32mm bolt.
  34.  
  35. Install the reverse idler shaft bolt with new washer and torque to 40 ft. lbs. (55 Nm). Install the hook and torque the mounting bolt to 18 ft. lbs. (24 Nm).
  36.  
  37. Install the reverse light switch and neutral switch, if equipped. Replace the sealing washers when installing each switch.
  38.  
  39. Install the 9.5mm detent ball, spring, new washer and setting screw. Torque the setting screw to 24 ft. lbs. (33 Nm).
  40.  

1991-93 LEGEND



See Figures 63 through 71



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Fig. Fig. 63: Remove the transaxle cover in the order shown-1991-93 Legend



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Fig. Fig. 64: Check these diameters on the mainshaft-1991-93 Legend



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Fig. Fig. 65: Check these diameters on the countershaft-1991-93 Legend



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Fig. Fig. 66: Torque the bolts in this sequence to 37 ft. lbs. (50 Nm)-1991-93 Legend



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Fig. Fig. 67: Install the bolts into the correct locations-1991-93 Legend



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Fig. Fig. 68: Assemble 5th gear-1991-93 Legend



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Fig. Fig. 69: Assemble the transaxle cover-1991-93 Legend



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Fig. Fig. 70: Components of the transaxle-1991-93 Legend



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Fig. Fig. 71: Components of the transaxle-1991-93 Legend

  1. Remove the transaxle and drain the fluid.
  2.  
  3. Remove the transaxle cover to expose 5th gear. Remove 5th gear and the transaxle housing. Remove the bearings from the housing.
  4.  
  5. Disassemble the mainshaft. Inspect the mainshaft for bearing surface wear. The needle bearing surface A service diameter limit of 1.0996 in. (27.93mm). The needle bearing surface B service diameter limit of 1.4935 in. (37.935mm). The needle bearing surface C service diameter limit of 1.2181 in. (30.94mm). The ball bearing surface D service diameter limit of 1.0999 in. (27.937mm). Replace if any of the measurements are below these limits.
  6.  
  7. Disassemble the countershaft. Inspect the countershaft for bearing surface wear. The needle bearing surface A service diameter limit of 1.2972 in. (32.95mm). The ball bearing surface B service diameter limit of 1.2570 in. (31.928mm). The needle bearing surface C service diameter limit of 1.0999 in. (27.937mm). Replace if any of the measurements are below these limits.
  8.  
  9. Check the run-out of the mainshaft and countershaft. If the run-out exceeds the service limit of 0.0020 in. (0.05mm), replace the shaft.
  10.  
  11. Check the reverse shift holder lever clearance at the shaft and fork. If there is greater than 0.0315 in. (0.8mm) clearance, check the lever width. The lever width should be 0.504-0.512 in. (12.80-13.00mm). Replace the lever if worn and replace the shaft or fork.
  12.  
  13. Check the clearance between the shift forks and the synchro sleeve. The clearance should not exceed 0.3937 in. (1.0mm). If there is excessive clearance, check the width of the shift fork. The reverse fork fingers should be 0.252-0.260 in. (6.4-6.6mm). The shift fork fingers should be 0.2913-0.2992 in. (7.4-7.6mm).
  14.  
  15. Check the clearance of the oil pump rotors. The outer rotor clearance limit should be 0.0071 in. (0.18mm). The inner rotor clearance limit should be 0.008 in. (0.2mm). The rotor to housing clearance limit should be 0.0087 in. (0.22mm).
  16.  
  17. Assemble the mainshaft and countershaft and install in the clutch housing. Hold the mainshaft and shift the synchro sleeve into 1st gear. Tighten the locknut.
  18.  
  19. Measure the clearance between 3rd gear and the mainshaft. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.2331 in. (31.32mm).
  20.  
  21. Measure the clearance between 4th gear and the distance collar. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.1543 in. (29.32mm).
  22.  
  23. Measure the clearance between 5th gear and the distance collar. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.1543 in. (29.32mm).
  24.  
  25. Check the clearance between 1st gear and the 60mm thrust shim. The service clearance should be 0.0016-0.0047 in. (0.04-0.10mm). Correct with a shim, available from 0.0559 in. (1.42mm) to 0.0606 in. (1.54mm) in four steps.
  26.  
  27. Measure the distance between 2nd and 3rd gear. The service clearance should be 0.0016-0.0047 in. (0.04-0.10mm). Correct with a new spacer collar available in 2 widths, 1.4201-1.4209 in. (36.07-36.09mm) and 1.4185-1.4193 in. (36.03-36.05mm).
  28.  

To assemble:
  1. Install the mainshaft, countershaft and the reverse gear shaft. Install the transaxle housing using liquid gasket on the mating surfaces. Torque the bolts in sequence.
  2.  
  3. Install the bearings. Check that the snaprings are seated in the grooves.
  4.  
  5. Install 5th gear. The thread on the countershaft is lefthand.
  6.  
  7. Install the transaxle cover using liquid gasket on the mating surfaces and thread sealant on the bolts.
  8.  

VIGOR



See Figures 72 through 89



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Fig. Fig. 72: Transaxle components-Vigor



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Fig. Fig. 73: Transaxle components-Vigor



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Fig. Fig. 74: Removal order of 5th gear-Vigor



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Fig. Fig. 75: Removal order of the transaxle housing-Vigor



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Fig. Fig. 76: Checking the clearance of the reverse shift holder-Vigor



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Fig. Fig. 77: Checking clearance between the reverse idler and holder-Vigor



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Fig. Fig. 78: Checking clearance between the select arm and change piece-Vigor



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Fig. Fig. 79: Checking clearance between the shift arm and change piece-Vigor



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Fig. Fig. 80: Checking clearance between the shift fork and the shift piece-Vigor



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Fig. Fig. 81: Disassembly of the mainshaft-Vigor



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Fig. Fig. 82: Check the mainshaft diameters at these locations-Vigor



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Fig. Fig. 83: Mainshaft assembly-Vigor



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Fig. Fig. 84: Disassemble the countershaft-Vigor



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Fig. Fig. 85: Check the countershaft diameters at these points-Vigor



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Fig. Fig. 86: Assemble the oil pump-Vigor



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Fig. Fig. 87: Use new washers when assembling-Vigor



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Fig. Fig. 88: Torque the housing bolts in this sequence to 21 ft. lbs. (28 Nm)-Vigor



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Fig. Fig. 89: Torque the cover bolts in this sequence to 21 ft. lbs. (28 Nm)-Vigor

  1. Remove the transaxle from the vehicle.
  2.  
  3. Remove the transaxle cover, 5th gear and the housing cover. Loosen all bolts in a diagonal pattern to reduce warping.
  4.  
  5. Check the clearance between 5th/reverse shift piece pin and the reverse shift holder. The service limit for A is 0.02 in. (0.5mm) and the service limit for B is 0.04 in. (1.0mm). If the clearance is too great, check the L groove in the reverse shift holder. The service limit for the width of A is 0.278-0.285 in. (7.05-7.25mm) and the service limit for B is 0.29-0.30 in. (7.4-7.7mm).
  6.  
  7. Check the clearance between the reverse idler gear and the reverse shift holder. The service limit is 0.07 in. (1.7mm). If the clearance exceeds the service limit, check the width of the reverse shift holder groove. The service limit is 0.55-0.56 in. (14.0-14.3mm).
  8.  
  9. Check the clearance between the change piece and the select arm. The service limit is 0.02 in. (0.5mm). If the clearance exceeds this limit, check the width of the select arm. The select arm service width is 0.46-0.47 in. (11.8-12.0mm).
  10.  
  11. Check the clearance between the change piece and the shift arm. The service limit is 0.02 in. (0.5mm). If the clearance exceeds this limit, check the width of the select arm. The select arm service width is 0.50-0.51 in. (12.8-13.0mm).
  12.  
  13. Check the clearance between the shift piece and the shift forks. Also check the clearance between the 5th/reverse shift piece and the shift piece. The service limit is 0.03 in. (0.7mm). If the clearance exceeds this limit, check the width of the select arm. The select arm service width is 0.469-0.472 in. (11.9-12.0mm).
  14.  
  15. Check the clearance between the shift piece and the shift arm. The service limit is 0.02 in. (0.6mm). If the clearance exceeds this limit, replace the change holder.
  16.  
  17. Disassemble the mainshaft and countershaft from the housing.
  18.  
  19. Disassemble the mainshaft. Inspect the mainshaft for bearing surface wear. The needle bearing surface A service diameter limit of 1.0996 in. (27.93mm). The needle bearing surface B service diameter limit of 1.4146 in. (35.930mm). The ball bearing surface C service diameter limit of 1.1394 in. (28.940mm). Replace if any of the measurements are below these limits.
  20.  
  21. Disassemble the countershaft. Inspect the countershaft for bearing surface wear. The needle bearing surface A service diameter limit of 1.2972 in. (32.95mm). The needle bearing surface B service diameter limit of 1.7295 in. (43.930mm). The needle bearing surface C service diameter limit of 1.0996 in. (27.930mm). The ball bearing surface C service diameter limit of 0.9815 in. (24.930mm). Replace if any of the measurements are below these limits.
  22.  
  23. Check the run-out of the mainshaft and countershaft. If the run-out exceeds the service limit of 0.0020 in. (0.05mm), replace the shaft. Assemble the mainshaft and countershaft.
  24.  
  25. Measure the clearance between 3rd gear and the mainshaft. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.097 in. (27.85mm).
  26.  
  27. Measure the clearance between 4th gear and the distance collar. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.372 in. (34.85mm).
  28.  
  29. Measure the clearance between 5th gear and the distance collar. The service limit is 0.0118 in. (0.3mm). The service limit of 3rd gear width is 1.234 in. (31.35mm).
  30.  
  31. Check the clearance between 1st gear and the 60mm thrust shim. The service clearance should be 0.002-0.004 in. (0.05-0.11mm). Correct with a shim, available from 0.0768 in. (1.95mm) to 0.0835 in. (2.12mm) in 6 steps.
  32.  
  33. Measure the distance between 2nd and 3rd gear. The service clearance should be 0.01 in. (0.30mm). If the clearance exceeds this limit, check the width of 2nd gear. The service width is 1.333 in. (33.85mm).
  34.  

To assemble:
  1. Replace the bearings in the clutch housing. Stake the screws to lock. Replace the oil seals.
  2.  
  3. Check the clearance of the oil pump rotors. The outer rotor clearance limit should be 0.009 in. (0.22mm). The inner rotor clearance limit should be 0.008 in. (0.2mm). The rotor to housing clearance limit should be 0.008 in. (0.20mm).
  4.  
  5. Check the width of the shift fork fingers. The width should be 0.29-0.30 in. (7.4-7.6mm)
  6.  
  7. Assemble the mainshaft and countershaft assemblies in the clutch housing. Install the transaxle housing to the clutch housing and torque the bolts in order to 21 ft. lbs. (28 Nm). Use liquid gasket on the mating surfaces.
  8.  
  9. Install new bearings in the transaxle housing. Install 5th gear and torque the mainshaft locknut to 108 ft. lbs. (150 Nm) and the countershaft locknut to 94 ft. lbs. (130 Nm). Stake the locknuts.
  10.  
  11. Install the transaxle cover. Use liquid gasket at the mating surfaces and torque the bolts in sequence to 21 ft. lbs. (28 Nm).
  12.  

 
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