Countershaft Disassembly

Securely clamp the countershaft assembly in a bench vise with wood blocks.

Fig 1: Removing Countershaft Special Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the 20 mm special bolt (left-hand threads).
Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing.

Fig 2: Pressing Countershaft Out Of Ball Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the 35 mm shim and 6th gear.
Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 4th and 5th gear.

Fig 3: Pressing Countershaft Out Of 4th And 5th Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 2nd and 3rd gear.

Fig 4: Pressing Countershaft Out Of 2nd And 3rd Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the distance collar and needle bearing.
Remove the triple cone synchro assembly (A) and synchro spring (B).

Fig 5: Identifying Triple Cone Synchro Assembly And Synchro Spring
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the 1st/2nd synchro sleeve.
Remove the 1st/2nd synchro hub (A).

Fig 6: Identifying 1st/2nd Synchro Hub
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the synchro spring (A) and the triple cone synchro assembly (B).

Fig 7: Identifying Synchro Spring And Triple Cone Synchro Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove 1st gear (A), needle bearing (B), and countershaft reverse gear (C).

Fig 8: Identifying 1st Gear, Needle Bearing And Countershaft Reverse Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.