It seems that the intermediate shaft has a little play in it on the drivers side. It does make a clicking sound when applying the brakes at low speeds and whan you hit some roughness in the road. I have already replaced the axle and that is not the problem. I have checked the complete suspension and brakes, so this is the only thing left.
I was just wondering if anyone has done a rebuild before, and what is all envolved?

TIA

 

I can only think of two reasons for this happening.
1. The bracket on the intermediate shaft that holds it on the back of the motor is not staying in one spot or the three bolts have worked there way loose somehow
2. You have a loose rear mount and everytime u step on the brakes the motor moves and makes the clicking noise

just my .02 cents could be wrong

 

Good points but all of those things have been checked.

 

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Are you sure the int.shaft is making the clicking noise when you apply the brakes?

Perhaps its a brake component making that sound..

 

I put the car up on jack stands and when you move the wheel around (back and forth rolling) the axle has a little play in it at that joint of the interm. shaft, the shaft doesnt actually move but the axle side does.

As stated above I have already check the brakes and sus.

 

Did you check your control arms, cambers etc.. You when the car is on a jack stand the whole front hangs. You said the car makes noises when you hit bumps, its probablly the u-shape thing( I forgot what's the name) where you install the camber kit, its probablly hitting the frame! Check that, that's pennies worth> this happened to me before because my car was to low plus my swap weighed the car down> therefore I installed new springs, shocks and camber kit!

 

Quick Question? Are the halfshafts for 92 and up civics shorter than the 90-93 integra shorter? Because i have a halfshaft that is waaaay shorter than the 90-93 teg halfshaft i used on my swap in my 88-91 hatch.