Exploded View

Fig 1: Exploded View Of Countershaft

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver handle 07746-0030100
• Attachment, 30 mm I.D. 07746-0030300

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the distance collar, needle bearing, and 1st gear onto the countershaft.
3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the grooves in 1st gear (C), then install the synchro spring (D).
   Fig 2: Installing Triple Cone Synchro Assembly

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4. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).
   Fig 3: Installing First/Second Synchro Hub

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5. Install the reverse gear.
6. Install the synchro spring (A).
   Fig 4: Installing Synchro Spring

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7. Install the triple cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
8. Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves in the 1st/2nd synchro hub (D).
   Fig 5: Installing Distance Collar And Friction Damper

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9. Install the needle bearing.
10. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).
    Fig 6: Installing Second Gear

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11. Support the countershaft (A) on steel blocks, then install 3rd gear (B) using the special tool and a press (C). Do not exceed the maximum pressure.
    Fig 7: Installing Third Gear

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12. Install 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
    Fig 8: Installing Fourth Gear

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13. Install 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
    Fig 9: Installing Fifth Gear

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14. Install the distance collar (A), 35 mm shim, and old ball bearing (B) using the special tools and a press (C).
    Fig 10: Installing Distance Collar, 35mm Shim And Old Ball Bearing

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15. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

    Standard: 0.04-0.10 mm (0.0016-0.0039 in.) 

    Fig 11: Measuring Clearance Between Old Bearing And Shim

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 15 is within the standard, replace only the ball bearing.
    35 MM SHIM SPECIFICATIONS
    
    

    	Part Number	Thickness
    A	23981-PPP-000	0.87 mm (0.034 in.)
    AA	23981-PPP-900	0.91 mm (0.036 in.)
    B	23982-PPP-000	0.95 mm (0.037 in.)
    AB	23982-PPP-900	0.99 mm (0.039 in.)
    C	23983-PPP-000	1.03 mm (0.041 in.)
    AC	23983-PPP-900	1.07 mm (0.042 in.)
    D	23984-PPP-000	1.11 mm (0.044 in.)
    AD	23984-PPP-900	1.15 mm (0.045 in.)
    E	23985-PPP-000	1.19 mm (0.047 in.)
    AE	23985-PPP-900	1.23 mm (0.048 in.)
    F	23986-PPP-000	1.27 mm (0.050 in.)
    AF	23986-PPP-900	1.31 mm (0.052 in.)
    G	23987-PPP-000	1.35 mm (0.053 in.)
    AG	23987-PPP-900	1.39 mm (0.055 in.)
    H	23988-PPP-000	1.43 mm (0.056 in.)
    AH	23988-PPP-900	1.47 mm (0.058 in.)
    J	23989-PPP-000	1.51 mm (0.060 in.)
    AJ	23989-PPP-900	1.55 mm (0.061 in.)
    K	23990-PPP-000	1.59 mm (0.063 in.)
    AK	23990-PPP-900	1.63 mm (0.064 in.)
    L	23991-PPP-000	1.67 mm (0.066 in.)
    AL	23991-PPP-900	1.71 mm (0.067 in.)
    M	23992-PPP-000	1.75 mm (0.069 in.)
    AM	23992-PPP-900	1.79 mm (0.070 in.)
    N	23993-PPP-000	1.83 mm (0.072 in.)
    AN	23993-PPP-900	1.87 mm (0.074 in.)
    P	23994-PPP-000	1.91 mm (0.075 in.)
    AP	23994-PPP-900	1.95 mm (0.077 in.)
    Q	23995-PPP-000	1.99 mm (0.078 in.)

17. Support the ball bearing (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 12: Removing Countershaft Out Of Ball Bearing

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18. If necessary, install the 35 mm shim selected in step 16, then recheck the clearance.
19. Install the distance collar (A), 35 mm shim, and new ball bearing (B) using the special tools and a press (C).
    Fig 13: Installing Distance Collar, 35mm Shim, And New Ball Bearing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
20. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
    Fig 14: Identifying Tightening Torque Of Countershaft Assembly Bolt

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21. Tighten the new special bolt (B) (left-hand threads).