Component Disassembly & Reassembly: MAINSHAFT: Measurements

1. For all mainshaft measurement specifications, refer to MAINSHAFT SPECIFICATIONS  table. Measure clearance between 2nd and 3rd gears. See Fig 1 to 28. If clearance exceeds service limit, measure thickness of 3rd gear. If thickness of 3rd gear is less than service limit, replace 3rd gear.
2. Measure clearance between 4th gear and spacer collar. If clearance exceeds service limit, measure height "A" on spacer collar. If height "A" is greater than clearance specification, replace spacer collar. If height "A" is within specification, measure thickness of 4th gear. If thickness of 4th gear is less than service limit, replace 4th gear. If thickness of 4th gear is within service limit, replace 3rd/4th synchro hub.
3. Measure clearance between 5th gear and spacer collar. If clearance exceeds service limit, measure height "B" on spacer collar. If height "B" is greater than specification, replace spacer collar. If height "B" is within specification, measure thickness of 5th gear. If thickness of 5th gear is less than service limit, replace 5th gear. If thickness of 5th gear is within service limit, replace 5th/reverse synchro hub.

MAINSHAFT SPECIFICATIONS

Application			Specification
2nd-3rd Gear Clearance
Design Clearance			.002-.008" (.06-.21 mm)
Service Limit			.12" (.30 mm)
4th Gear/Spacer Collar Clearance
Design Clearance			.002-.008" (.06-.21 mm)
Service Limit			.12" (.30 mm)
5th Gear/Spacer Collar Clearance
Design Clearance			.002-.008" (.06-.21 mm)
Service Limit			.12" (.30 mm)
3rd Gear Thickness
1.7L
Design Thickness			1.375-1.377" (34.92-34.97 mm)
Service Limit			1.350" (34.3 mm)
1.8L
Design Thickness			1.355-1.357" (34.42-34.47 mm)
Service Limit			1.331" (33.8 mm)
4th Gear Thickness
1.7L
Design Thickness			1.237-1.239" (31.42-31.47 mm)
Service Limit			1.232" (31.3 mm)
1.8L
Design Thickness			1.217-1.219" (30.92-30.97 mm)
Service Limit			1.213" (30.8 mm)
5th Gear Thickness
Design Thickness			1.237-1.239" (31.42-31.47 mm)
Service Limit			1.232" (31.3 mm)
Spacer Collar Height "A"
Height			1.025-1.027 (26.03-26.08 mm)
Spacer Collar Height "B"
Height			1.025-1.027 (26.03-26.08 mm)

Fig 1: Exploded View Of Mainshaft & Countershaft (1 of 2)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Exploded View Of Mainshaft & Countershaft (2 of 2)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 3: Identifying Mainshaft Measuring Points (1 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 4: Identifying Mainshaft Measuring Points (2 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 5: Identifying Mainshaft Measuring Points (3 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 6: Identifying Mainshaft Measuring Points (4 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 7: Identifying Mainshaft Measuring Points (5 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 8: Identifying Mainshaft Measuring Points (6 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 9: Identifying Mainshaft Measuring Points (7 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 10: Identifying Mainshaft Measuring Points (8 of 8)

Courtesy of AMERICAN HONDA MOTOR CO., INC.

CAUTION: Remove synchro hub using a press and steel block. Use of jaw-type puller can cause damage to gear teeth.