Exploded View

WARNING: This page is about a different variant/trim than selected.

Fig 1: Exploded View Of Countershaft With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

Driver, 58 x 62 mm 070AD-PYZA100
Driver Handle, 40 mm I.D. 07746-0030100

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 countershaft reverse gear (A) with the needle bearing (B), and 1st gear (C) onto the countershaft (D).

Fig 2: Identifying Countershaft Reverse Gear, Needle Bearing, 1St Gear And Countershaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro cone fingers (C) with the holes (D) in 1st gear.

Fig 3: Identifying Triple Cone Synchro Assembly, Synchro Spring, Synchro Cone Fingers And Holes In 1st Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.

Fig 4: Identifying 1st/2nd Synchro Hub, Synchro Ring Fingers And Grooves
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 1st/2nd synchro sleeve (A) by aligning the slots of the 1st/2nd synchro sleeve and the 1st/2nd synchro hub (B). After installing, check the operation of the 1st/2nd synchro hub set.
NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.

Fig 5: Identifying 1st/2nd Synchro Sleeve And 1st/2nd Synchro Hub
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 1st/2nd synchro hub.

Fig 6: Identifying Triple Cone Synchro Assembly, Synchro Spring, Synchro Ring Fingers, Grooves And 1st/2nd Synchro Hub
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 2nd gear distance collar (A) with the needle bearing (B).

Fig 7: Identifying 2nd Gear Distance Collar And Needle Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).

Fig 8: Identifying 2nd Gear, Synchro Cone Fingers And Holes In 2nd Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 58 x 62 mm driver (C) and a press (D).
NOTE: Do not exceed the maximum pressure.

Fig 9: Supporting Countershaft And Pressing On 3rd Gear Using Driver And Press With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Press on 4th gear (A) using the 58 x 62 mm driver (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

Fig 10: Pressing On 4th Gear Using Driver And Press With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Press on 5th gear (A) using the 40 mm I.D. driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

Fig 11: Pressing On 5th Gear Using I.D. Driver Handle And Press With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Press on 6th gear (A) using the 40 mm I.D. driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

Fig 12: Pressing On 6th Gear Using I.D. Driver Handle And Press With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 35 mm shim (A), and temporarily press on the used ball bearing (B) using the 40 mm I.D. driver handle (C) and a press (D).
NOTE:
- Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.
- Make sure the ball bearing is installed in the correct direction.
  
  Fig 13: Pressing On Used Ball Bearing Using I.D. Driver Handle And Press
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the clearance between the ball bearing (A) and the 35 mm shim (B) with a feeler gauge (C).
Standard: 0.04- 0.10 mm (0.002- 0.003 in)

Fig 14: Measuring Clearance Between Ball Bearing And Shim Using Feeler Gauge
Courtesy of AMERICAN HONDA MOTOR CO., INC.

If the measured clearance in step 14 is not within the standard, select another suitable 35 mm shim from the table, then go to next step to replace the 35 mm shim and the ball bearing with new ones. If the measured clearance in step 14 is within the standard, go to the next step to replace only the ball bearing with a new one.

35 MM SHIM

Type	Thickness
A	0.87 mm (0.034 in)
AA	0.91 mm (0.036 in)
B	0.95 mm (0.037 in)
AB	0.99 mm (0.039 in)
C	1.03 mm (0.041 in)
AC	1.07 mm (0.042 in)
D	1.11 mm (0.044 in)
AD	1.15 mm (0.045 in)
E	1.19 mm (0.047 in)
AE	1.23 mm (0.048 in)
F	1.27 mm (0.050 in)
AF	1.31 mm (0.052 in)
G	1.35 mm (0.053 in)
AG	1.39 mm (0.055 in)
H	1.43 mm (0.056 in)
AH	1.47 mm (0.058 in)
J	1.51 mm (0.059 in)
AJ	1.55 mm (0.061 in)
K	1.59 mm (0.063 in)
AK	1.63 mm (0.064 in)
L	1.67 mm (0.066 in)
AL	1.71 mm (0.067 in)
M	1.75 mm (0.069 in)
AM	1.79 mm (0.070 in)
N	1.83 mm (0.072 in)
AN	1.87 mm (0.074 in)
P	1.91 mm (0.075 in)
AP	1.95 mm (0.077 in)
Q	1.99 mm (0.078 in)

Remove 6th gear with the ball bearing and the 35 mm shim using a press (see step 3).
Repeat step 12 to install 6th gear.
Install the correct 35 mm shim (A) and a new ball bearing (B) using the 40 mm I.D. driver handle (C) and a press (D).
NOTE:
- If necessary, replace the 35 mm shim with the correct one selected in step 15.
- Make sure the ball bearing is installed in the correct direction.
  
  Fig 15: Installing Shim And Ball Bearing Using I.D. Driver Handle And Press
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Recheck the clearance between the ball bearing and the 35 mm shim with a feeler gauge.
Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

Fig 16: Securely Clamping Countershaft Assembly In Bench Vise With Wood Blocks With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten a new special bolt (B) (left-hand threads).
NOTE: Apply new MTF to the bolt threads and flange.