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Exploded View

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Fig 1: Exploded View Of Countershaft Assembly With Torque Specifications
G05458676Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

NOTE: Refer to the Exploded View (See Fig 1), as needed, during this procedure.
  1. Clean all parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces.
  2. Install the countershaft reverse gear (A), needle bearing (B), and 1st gear (C) onto the countershaft (D).
    Fig 2: Identifying Countershaft Reverse Gear, Needle Bearing, 1st Gear And Countershaft
    G05458677Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 1st gear (C), then install the synchro spring (D).
    Fig 3: Identifying Triple Cone Synchro Assembly, Synchro Cone Fingers, 1st Gear And Synchro Spring
    G05458678Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the 1st/2nd synchro hub (A) by aligning the outer synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).
    Fig 4: Identifying 1st/2nd Synchro Hub, Outer Synchro Ring Fingers And 1st/2nd Synchro Hub
    G05458679Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the 1st/2nd synchro sleeve.
  6. Install the synchro spring (A).
    Fig 5: Identifying Triple Cone Synchro Assembly, Outer Synchro Ring Fingers And 1st/2nd Synchro Hub
    G05458680Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Install the triple cone synchro assembly (B) by aligning the outer synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
  8. Install the distance collar and needle bearing.
  9. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).
    Fig 6: Installing 2nd Gear
    G05458681Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the 52 x 62 mm driver (C) and a press (D).
    Fig 7: Installing 3rd Gear
    G05458682Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Install 4th gear (A) using the 52 x 62 mm driver (B) and a press (C).
    Fig 8: Installing 4th Gear
    G05458683Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. install 5th gear (A) using the 52 x 62 mm driver (B) and a press (C).
    Fig 9: Installing 5th Gear
    G05458684Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install 6th gear (A) using the 40 mm I.D. driver (B) and a press (C).
    Fig 10: Installing 6th Gear
    G05458685Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the 35 mm shim (A) and the old ball bearing (B) using the 40 mm I.D. driver (C) and a press (D).
    Fig 11: Installing Ball Bearing
    G05458686Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

    Standard: 0.04-0.10 mm (0.0016-0.0039 in.) 

    Fig 12: Measuring Clearance Between Old Bearing And Shim
    G05458687Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step  15 is within the standard, replace only the ball bearing.

    35 mm Shim 

    SHIM THICKNESS SPECIFICATION

      Part Number Thickness
    A 23981 -PPP-000 0.87 mm (0.034 in.)
    AA 23981-PPP-900 0.91 mm (0.036 in.)
    B 23982-PPP-000 0.95 mm (0.037 in.)
    AB 23982-PPP-900 0.99 mm (0.039 in.)
    C 23983-PPP-000 1.03 mm (0.041 in.)
    AC 23983-PPP-900 1.07 mm (0.042 in.)
    D 23984-PPP-000 1.11 mm (0.044 in.)
    AD 23984-PPP-900 1.15 mm (0.045 in.)
    E 23985-PPP-000 1.19 mm (0.047 in.)
    AE 23985-PPP-900 1.23 mm (0.048 in.)
    F 23986-PPP-000 1.27 mm (0.050 in.)
    AF 23986-PPP-900 1.31 mm (0.052 in.)
    G 23987-PPP-000 1.35 mm (0.053 in.)
    AG 23987-PPP-900 1.39 mm (0.055 in.)
    H 23988-PPP-000 1.43 mm (0.056 in.)
    AH 23988-PPP-900 1.47 mm (0.058 in.)
    J 23989-PPP-000 1.51 mm (0.059 in.)
    AJ 23989-PPP-900 1.55 mm (0.061 in.)
    K 23990-PPP-000 1.59 mm (0.063 in.)
    AK 23990-PPP-900 1.63 mm (0.064 in.)
    L 23991-PPP-000 1.67 mm (0.066 in.)
    AL 23991-PPP-900 1.71 mm (0.067 in.)
    M 23992-PPP-000 1.75 mm (0.069 in.)
    AM 23992-PPP-900 1.79 mm (0.070 in.)
    N 23993-PPP-000 1.83 mm (0.072 in.)
    AN 23993-PPP-900 1.87 mm (0.074 in.)
    P 23994-PPP-000 1.91 mm (0.075 in.)
    AP 23994-PPP-900 1.95 mm (0.077 in.)
    Q 23995-PPP-000 1.99 mm (0.078 in.)
  17. Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the old ball bearing.
    Fig 13: Pressing Countershaft Out Of Old Ball Bearing
    G05458688Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. If a new 35 mm shim was selected in step  16, install the shim, and recheck the clearance.
  19. Install 6th gear (A) using the 40 mm I.D. driver (B) and a press (C).
    Fig 14: Installing 6th Gear
    G05458689Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Install the 35 mm shim (A) and new bearing (B) using the 40 mm I.D. driver (C) and a press (D).
    Fig 15: Installing Shim And Bearing
    G05458690Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
    Fig 16: Tightening Countershaft Special Bolt With Torque Specifications
    G05458691Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Tighten the new 20 mm special bolt (B) (left-hand threads).
    NOTE: Apply new MTF to the bolt threads and flanges.
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