Exploded View

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

Fig 1: Exploded View Of Countershaft Assembly

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

Driver Handle, 40 mm I.D. 07746-0030100
Bearing Driver Attachment, 30 mm 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 1st gear distance collar (A) with the needle bearing (B) and 1st gear (C) on the countershaft (D).

Fig 2: Identifying Collar With Needle Bearing And 1st Gear On Countershaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the friction damper (A), the synchro ring (B), and the synchro spring (C) on 1st gear (D).

Fig 3: Identifying Friction Damper, Synchro Ring And Synchro Spring On 1st Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 countershaft.

Fig 4: Installing 1st/2nd Synchro Hub Onto Countershaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B). After installing, check the operation of the 1st/2nd synchro hub set (see SYNCHRO SLEEVE AND HUB INSPECTION AND REASSEMBLY ).
NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.

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

Fig 6: Installing Double Cone Synchro Assembly With Synchro Spring By Aligning Synchro Ring Fingers With 1st/2nd Synchro Hub Grooves
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 2nd gear distance collar (A) with the friction damper (B), then align the fingers (C) on the friction damper and the grooves (D) in the 1st/2nd synchro hub.

Fig 7: Installing 2nd Gear Distance Collar With Friction Damper By Aligning Fingers On Friction Damper And Grooves On 1st/2nd Synchro Hub
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the needle bearing (A), then install 2nd gear (B) by aligning the synchro cone fingers (C) with the grooves (D) in 2nd gear.

Fig 8: Installing Needle Bearing, 2nd Gear By Aligning Synchro Cone Fingers With Grooves On 2nd Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 40 mm driver handle (C) and a press (D).
NOTE: Do not exceed the maximum pressure.

Fig 9: Pressing On 3rd Gear Using Driver Handle And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Press on 4th gear (A) using the 40 mm driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

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

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

Fig 12: Pressing On 6th Gear Using Driver Handle And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 32 mm shim (A), and temporarily press on the used ball bearing (B) using the 40 mm driver handle (C), the 30 mm bearing driver attachment (D), and a press (E).
- Use any size of the 32 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 Ball Bearing Using Driver Handle, Bearing Driver Attachment And Press
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the clearance between the bearing (A) and the 32 mm shim (B) with a feeler gauge (C).
Standard: 0.04-0.10 mm (0.0016-0.0039 in)

Fig 14: Identifying Clearance Between Bearing And Shim
Courtesy of AMERICAN HONDA MOTOR CO., INC.

If the measured clearance in step 14 is not within the standard, select another suitable 32 mm shim from the table, then go to next step to replace the 32 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.

32 mm Shim

SHIM THICKNESS SPECIFICATIONS

Type	Thickness
A	1.56 mm (0.0614 in)
B	1.60 mm (0.0630 in)
C	1.64 mm (0.0646 in)
D	1.68 mm (0.0661 in)
E	1.72 mm (0.0677 in)
F	1.76 mm (0.0693 in)
G	1.80 mm (0.0709 in)
H	1.84 mm (0.0724 in)
J	1.88 mm (0.0740 in)
K	1.92 mm (0.0756 in)
L	1.96 mm (0.0772 in)
M	2.00 mm (0.0787 in)
N	2.04 mm (0.0803 in)
P	2.08 mm (0.0819 in)
Q	2.12 mm (0.0835 in)
R	2.16 mm (0.0850 in)
S	2.20 mm (0.0866 in)
T	2.24 mm (0.0882 in)
U	2.28 mm (0.0898 in)
V	2.32 mm (0.0913 in)

Remove 6th gear with the ball bearing and the 32 mm shim using a press (see step 3 ).
Repeat step 12 to install 6th gear.
Install the correct 32 mm shim (A) and a new ball bearing (B) using the 40 mm driver handle (C), the 30 mm bearing driver attachment (D), and a press (E).
NOTE:
- If necessary, replace the 32 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 Driver Handle, Bearing Driver Attachment And Press
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Recheck the clearance between the bearing and the 32 mm shim with a feeler gauge.
Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

Fig 16: Tightening Manual Transmission Bolt With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten a new special bolt (B) (left-hand threads).
NOTE: Apply MTF to the bolt threads and flange.