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Mainshaft Assembly Clearance Inspection

NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set.
  1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
    Fig 1: Pushing Down On Mainshaft
    G05458630Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).
    • If the clearance is more than the service limit, go to step 3.
    • If the clearance is within the service limit, go to step  4.

      Standard: 0.06-0.19 mm (0.002-0.007 in.) 

      Service Limit: 0.3 mm (0.01 in.) 

  3. Measure the thickness of 3rd gear.
    • If the thickness is less than the service limit, replace 3rd gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub and 3rd/4th synchro sleeve as a set.

      Standard: 23.89-23.97 mm (0.941 -0.944 in.) 

      Service Limit: 23.8 mm (0.94 in.) 

      Fig 2: Identifying Thickness Of 3rd Gear
      G05458631Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C).
    • If the clearance is more than the service limit, go to step 5.
    • If the clearance is within the service limit, go to step  7.

      Standard: 0.06-0.19 mm (0.002-0.007 in.) 

      Service Limit: 0.3 mm (0.01 in.) 

      Fig 3: Measuring Clearance Between 4th Gear And Distance Collar
      G05458632Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Measure the length (1) of the 4th gear side distance collar as shown.
    • If the length (1) is not within the standard, replace the distance collar.
    • If the length (1) is within the standard, go to step 6.

      Standard: 22.53-22.58 mm (0.887-0.889 in.) 

      Fig 4: Identifying Length Of 4th Gear Side Distance Collar
      G05458633Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Measure the thickness of 4th gear.
    • If the thickness is less than the service limit, replace 4th gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub and 3rd/4th synchro sleeve as a set.

      Standard: 22.39-22.47 mm (0.881-0.885 in.) 

      Service Limit: 22.3 mm (0.88 in.) 

      Fig 5: Identifying Thickness Of 4th Gear
      G05458634Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C).
    • If the clearance is more than the service limit, go to step 8.
    • If the clearance is within the service limit, go to step  10.

      Standard: 0.06-0.19 mm (0.002-0.007 in.) 

      Service Limit: 0.3 mm (0.01 in.) 

      Fig 6: Measuring Clearance Between Distance Collar And 5th Gear
      G05458635Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Measure the length (2) of the 5th gear side distance collar as shown.
    • If the length (2) is not within the standard, replace the distance collar.
    • If the length (2) is within the standard, go to step 9.

      Standard: 22.53-22.58 mm (0.887-0.889 in.) 

      Fig 7: Identifying Length Of 5th Gear Side Distance Collar
      G05458636Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Measure the thickness of 5th gear.
    • If the thickness is less than the service limit, replace 5th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and 5th/6th synchro sleeve as a set.

      Standard: 22.39-22.47 mm (0.881-0.885 in.) 

      Service Limit: 22.3 mm (0.88 in.) 

      Fig 8: Identifying Thickness Of 5th Gear
      G05458637Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 11.

    Standard: 0.13-0.26 mm (0.005-0.010 in.) 

    Service Limit: 0.35 mm (0.01 in.) 

    Fig 9: Measuring Clearance Between 6th Gear And Angular Ball Bearing Inner Race
    G05458638Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Measure the length of the distance collar.
    • If the length is less than the standard, replace the distance collar.
    • If the length is within the standard, go to step 12.

      Standard: 24.03-24.08 mm (0.946-0.948 in.) 

      Fig 10: Identifying Length Of Distance Collar
      G05458639Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Measure the thickness of 6th gear.
    • If the thickness is less than the service limit, replace 6th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and 5th/6th synchro sleeve as a set.

      Standard: 23.82-23.90 mm (0.937-0.940 in.) 

      Service Limit: 23.75 mm (0.94 in.) 

      Fig 11: Identifying Thickness Of 6th Gear
      G05458640Courtesy of AMERICAN HONDA MOTOR CO., INC.
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