Exploded View

Fig 1: Exploded View Of Countershaft

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver, 40 mm I.D. 07746-0030100
• Attachment, 25 mm I.D. 07746-0030200
• Attachment, 30 mm I.D. 07746-0030300
• Attachment, 35 mm I.D. 07746-0030400

1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install 1st gear, its bearing, and the friction damper on the shaft.
3. Install the 1st gear double cone synchro (A) and synchro spring (B) on the shaft.
   Fig 2: Installing 1ST Gear Double Cone Synchro And Synchro Spring On Shaft

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4. Align the fingers (A) on the friction damper with the grooves (B) on the 1st/2nd synchro hub (C), then install the 1st/2nd synchro hub onto the shaft.
   Fig 3: Aligning Fingers On Friction Damper With Grooves On 1ST/2ND Synchro Hub

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5. Install the reverse gear (A), synchro spring (B), and double cone synchro (C) on the shaft.
   Fig 4: Installing Reverse Gear, Synchro Spring, And Double Cone Synchro On Shaft

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6. Install the distance collar (A) and friction damper (B), then align the fingers (C) on the friction damper and grooves (D) in the 1st/2nd synchro hub.
   Fig 5: Aligning Fingers On Friction Damper And Grooves In 1ST/2ND Synchro Hub

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Install the needle bearing and 2nd gear (A), then align the holes (B) on 2nd gear with the fingers (C) on the double cone synchro.
   Fig 6: Aligning Holes On 2ND Gear With Fingers On Double Cone Synchro

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8. Install 3rd gear (A) using the special tools and a press (B).
   Fig 7: Installing 3RD Gear

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9. Install 4th gear (A) using the special tools and a press (B).
   Fig 8: Installing 4TH Gear

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10. Install 5th gear (A) using the special tools and a press (B).
    Fig 9: Installing 5TH Gear

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11. Install the ball bearing (A) using the special tools and a press (B).
    Fig 10: Installing Ball Bearing

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12. Install the ball bearing (A) using the special tools and a press (B).
    Fig 11: Installing Ball Bearing

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13. Install the 22 mm spring washer (A) and 22 mm locknut (B).
    Fig 12: Installing Spring Washer And Locknut

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Securely clamp the countershaft assembly in a bench vise with wood blocks.
15. Torque the new locknut to 108 N.m (11.0 kgf. m, 79.6 lbf. ft), then loosen it, and torque it again to the same value. Stake the locknut tab into the groove.