Countershaft Assembly: Reassembly

CAUTION:

Press the 3rd, 4th, and 5th gears on the countershaft without lubrication.
When installing the 3rd, 4th, and 5th gears, support the shaft on steel blocks and install the gears using a press.

NOTE: Refer to COUNTERSHAFT ASSEMBLY for reassembly sequence.

Install the needle bearing on the countershaft.

Fig 1: Identifying Needle Bearing And Countershaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Assemble the parts below as shown.
NOTE: Check that the fingers of the friction damper are securely set in the grooves of the 1st/2nd synchro hub.

Fig 2: Identifying Countershaft Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the parts on the countershaft.
Support the countershaft on a steel block as shown and install 3rd gear using the special tools and a press as shown.

Fig 3: Installing 3rd Gear Using Special Tools And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install 4th gear using the special tools and a press as shown.

Fig 4: Installing 4th Gear Using Special Tools And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install 5th gear using the special tools and a press as shown.

Fig 5: Installing 5th Gear Using Special Tools And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the bearings using the special tools and a press as shown.
CAUTION: Install the bearings with a maximum pressure of 7.8 kN (800 kgf, 5,786 lbf).

Fig 6: Installing Bearings Using Special Tools And Press
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Securely clamp the countershaft assembly in a bench vise with wood blocks.
LOCKNUT

108 → 0 → 108 N.m

(11.0 → 0 → 11.0 kgf.m, 79.6 → 0 → 79.6 lbf.ft)

Fig 7: Securing Clamp Countershaft Assembly In Bench Vise With Wood Blocks
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the spring washer, tighten the locknut, the stake the locknut tab into groove.