Countershaft Assembly Clearance Inspection

NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.

Measure the clearance between 2nd gear (A) and the countershaft (B) with a dial indicator.
- If the clearance is more than the service limit, go to step 2.
- If the clearance is within the service limit, go to step 3.
Standard: 0.04-0.17 mm {0.002-0.007 in.)

Service Limit: 0.3 mm (0.012 in.)

Fig 1: Measuring Clearance Between 2nd Gear And Countershaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the thickness of 2nd gear.
- If the thickness is less than the service limit, replace 2nd gear.
- If the thickness is within the service limit, replace the 1st/2nd synchro hub and sleeve.
Standard: 32.88-32.96 mm (1.294-1.298 in.)

Service Limit: 32.76 mm (1.290 in.)

Fig 2: Measuring Thickness Of 2nd Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the clearance between 1st gear (A) and the distance collar (B). with a dial indicator.
- If the clearance is more than the service limit, go to step 4.
- If the clearance is within the service limit, go to step 6.
Standard:

2000-2003 models: 0.04-0.22 mm (0.002-0.009 in.)

2004-2008 models: 0.04-0.17 mm (0.002-0.007 in.)

Service Limit: 0.3 mm (0.012 in.)

Fig 3: Measuring Clearance Between 1st Gear And Distance Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure distance (1) on the distance collar.
- If distance (1) is not within the standard, replace the distance collar.
- If distance (1) is within the standard, go to step 5.
Standard: 28.03-28.08 mm (1.104-1.106 in.)

Fig 4: Measuring Distance (1) On Distance Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the thickness of 1st gear.
- If the thickness is less than the service limit, replace 1st gear.
- If the thickness is within the service limit, replace the 1st/2nd synchro hub and sleeve.
Standard:

2000-2003 models: 31.18-31.26 mm (1.228-1.231 in.)

2004-2008 models: 27.88-27.96 mm (1.098-1.101 in.)

Service Limit:

2000-2003 models: 31.06 mm (1.223 in.)

2004-2008 models: 27.76 mm (1.093 in.)

Fig 5: Measuring Thickness Of 1st Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the clearance between reverse gear (A) and the distance collar (B) with a dial indicator. If the clearance is more than the service limit, go to step 7.
Standard: 0.04-0.22 mm (0.002-0.009 in.)

Service Limit: 0.3 mm (0.012 in.)

Fig 6: Measuring Clearance Between Reverse Gear And Distance Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure distance (2) on the distance collar.
- If distance (2) is not within the standard, replace the distance collar.
- If distance (2) is within the standard, go to step 8.
Standard: 25.53-25.58 mm (1.005-1.007 in.)

Fig 7: Measuring Distance On Distance Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the thickness of reverse gear.
- If the thickness is less than the service limit, replace reverse gear.
- If the thickness is within the service limit, replace the reverse synchro hub and sleeve.
Standard: 26.38-26.46 mm (1.039-1.042 in.)

Service Limit: 26.26 mm (1.034 in.)

Fig 8: Measuring Thickness Of Reverse Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.