Exploded View

Fig 1: Exploded View Of Countershaft With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

Driver, 40 mm I.D. 07746-0030100
Attachment, 30 mm I.D. 07746-0030300

NOTE: Refer to the EXPLODED VIEW , as needed, during this procedure.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
Install the distance collar and needle bearing onto the countershaft.
Install the 1st gear.
Install the triple cone synchro assembly (A) by aligning the synchro ring fingers (B) with the grooves in 1st gear (C), then install the synchro spring (D).

Fig 2: Identifying Triple Cone Synchro Assembly, Synchro Ring Fingers, 1st Gear And Synchro Spring
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Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).

Fig 3: Identifying 1st/2nd Synchro Hub, Synchro Ring Fingers And 1st/2nd Synchro Hub
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Install reverse gear.
Install the synchro spring (A).

Fig 4: Identifying Synchro Spring
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Install the triple cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves in the 1st/2nd synchro hub (D).

Fig 5: Identifying Distance Collar, Friction Damper, Friction Damper Fingers And 1st/2nd Synchro Hub
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Install the needle bearing.
Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves (C) in 2nd gear.

Fig 6: Identifying 2nd Gear, Synchro Cone Fingers And Grooves
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Support the countershaft (A) on steel blocks, then install 3rd gear (B) using the 40 mm I.D. driver (C) and a press (D).
NOTE: Do not exceed the maximum pressure.

Fig 7: Identifying Countershaft, 3rd Gear, I.D. Driver And Press
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Install 4th gear (A) using the 40 mm I.D. driver (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

Fig 8: Identifying 4th Gear, I.D. Driver And Press
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Install 5th gear (A) using the 40 mm I.D. driver (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

Fig 9: Identifying 5th Gear, I.D. Driver And Press
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Install 6th gear (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).
NOTE: Do not exceed the maximum pressure.

Fig 10: Identifying 6th Gear, I.D. Driver, I.D. Attachment And Press
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Install the 35 mm shim and the old ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).

Fig 11: Identifying Ball Bearing, I.D. Driver, I.D. Attachment And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure 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: Identifying Bearing, Shim And Feeler Gauge
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If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 16 is within the standard, replace only the ball bearing.

35 mm Shim

SHIM THICKNESS CHART

	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 (0.060 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.)

Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the ball bearing.

Fig 13: Identifying 6th Gear, Steel Blocks, Press And Attachment
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If necessary, install the 35 mm shim selected in step 18.
Install 6th gear (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).
NOTE: Do not exceed the maximum pressure.

Fig 14: Identifying 6th Gear, I.D. Driver, I.D. Attachment And Press
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Install the new ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D), then recheck the clearance.

Fig 15: Identifying Ball Bearing, I.D. Driver, I.D. Attachment And Press
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Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

Fig 16: Bench Vise With Wood Blocks With Torque Specifications
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Tighten the new special bolt (B) (left-hand threads).