Reconditioning the gearbox of a Honda CRX involves several steps, including disassembly, inspection, cleaning, replacement of worn components, and reassembly. click here for more details on the download manual…..
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Below is a detailed guide on how to perform this task. Please note that this is a complex job that requires mechanical knowledge, specialized tools, and safety precautions.
### Tools and Equipment Needed
1. **Basic Hand Tools:**
– Socket set (metric sizes)
– Wrench set (metric sizes)
– Screwdrivers (flathead and Phillips)
– Pliers
– Hammer
– Torque wrench
2. **Specialized Tools:**
– Gear puller
– Snap ring pliers
– Transmission jack or support stand
– Measuring tools (calipers, micrometers)
3. **Replacement Parts:**
– Gaskets and seals
– Bearings (input, output, and intermediate)
– Synchronizers (if needed)
– Oil (specific to your gearbox type)
4. **Cleaning Supplies:**
– Brake cleaner
– Rags/shop towels
– Parts washer (optional)
5. **Safety Gear:**
– Gloves
– Safety glasses
– Dust mask (if necessary)
### Step-by-Step Process
#### 1. Preparation
– **Disconnect the Battery:** start by disconnecting the negative terminal of the battery to ensure safety.
– **Lift the Vehicle:** Use a hydraulic jack to lift the front of the CRX and support it with jack stands.
– **Drain the Gear Oil:** Remove the drain plug from the gearbox and allow the oil to drain completely into a suitable container.
#### 2. Remove the Gearbox
– **Disconnect Linkages:** Remove the gear linkage and shifter mechanism.
– **Remove Axles:** Unbolt the drive axles from the gearbox. You may need to use a pry bar to help remove them.
– **Support the Gearbox:** Use a transmission jack or support to hold the gearbox in place.
– **Unbolt the Gearbox:** Remove the bolts securing the gearbox to the engine. Carefully lower the gearbox from the vehicle.
#### 3. Disassemble the Gearbox
– **Clean the Exterior:** Clean the outside of the gearbox to prevent contamination during disassembly.
– **Remove the Bellhousing:** Unbolt and remove the bellhousing to access the internal components.
– **Remove the main Case:** Carefully separate the main case from the gearbox housing. Be cautious of any shims or spacers that may fall out.
– **Take Out the Gears and Shafts:** Remove the countershaft, input shaft, and other internal components. Use a gear puller if necessary to remove any stubborn gears.
#### 4. Inspection
– **Inspect Gears and Shafts:** Check for signs of wear, scoring, or damage. Measure the thickness of the gears and bearings to ensure they meet specifications.
– **Check Synchronizers:** Inspect synchronizers for wear. Replace them if necessary.
– **Inspect Bearings:** Check all bearings for smoothness and wear. Replace any that feel rough or are damaged.
#### 5. Cleaning
– **Clean Components:** Use brake cleaner and a parts washer to thoroughly clean all components. Remove any old gasket material and contaminants.
– **Dry Components:** Ensure all parts are dry before reassembly.
#### 6. Replace Worn Components
– **Install New Bearings:** Press new bearings into their respective locations. Use a bearing installer tool to avoid damage.
– **Replace Seals:** Install new seals in the gearbox where applicable.
– **Replace Gaskets:** Use new gaskets for the bellhousing and any other mating surfaces.
#### 7. Reassembly
– **Reassemble the Gearbox:** Carefully place the input and output shafts back into the gearbox. Ensure that all components are aligned correctly.
– **Install Gears:** Place gears back onto the shafts, ensuring they mesh correctly.
– **Reattach the Bellhousing:** Securely bolt the bellhousing back onto the gearbox.
#### 8. Installation
– **Reinstall the Gearbox:** Carefully lift the gearbox back into position. Align it with the engine
and secure it with bolts.
– **Reattach Axles and Linkages:** Reinstall the drive axles and reconnect the gear linkage.
– **Reconnect the Battery:** Reattach the negative terminal of the battery.
#### 9. Final Checks
– **Fill with Gear Oil:** Add the recommended type and amount of gear oil to the gearbox.
– **Check for Leaks:** start the engine and check for any leaks around the gearbox.
– **Test Drive:** Take the vehicle for a test drive to ensure everything is functioning properly.
### Conclusion
Reconditioning a gearbox is a labor-intensive process that requires attention to detail and proper tools. Make sure to follow the manufacturer’s specifications and guidelines throughout the process. If you are unsure about any step, it is advisable to consult with a professional mechanic or refer to a repair manual specific to the Honda CRX.
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