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Countershaft Assembly Clearance Inspection

NOTE: Before inspection, make sure the special bolt is tightened to the specified torque (see EXPLODED VIEW  ).
  1. Measure the clearance between 1st gear (A) and the distance collar (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step  2.

    Standard: 0.06-0.16 mm (0.002-0.006 in.) 

    Service Limit: 0.25 mm (0.010 in.) 

    Fig 1: Measuring Clearance Between 1st Gear & Distance Collar With Feeler Gauge
    G05449469Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Measure the length of the 1st gear distance collar as shown below.
    • If the length is not within the standard, replace the 1st gear distance collar.
    • If the length is within the standard, go to step  3.

    Standard: 23.03-23.08 mm (0.907-0.909 in.) 

    Fig 2: Identifying Length Of Distance Collar
    G00487427Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. 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 reverse gear as a set.

    Standard: 22.92-22.97 mm (0.902-0.904 in.) 

    Service Limit: 22.87 mm (0.900 in.) 

    Fig 3: Identifying Thickness Of 1st Gear
    G05449471Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step  5.

    Standard: 0.06-0.16 mm (0.002-0.006 in.) 

    Service Limit: 0.25 mm (0.010 in.) 

    Fig 4: Measuring Clearance Between 2nd Gear & 3rd Gear With Feeler Gauge
    G05449472Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Measure the length of the distance collar.
    • If the length is not within the standard, replace the distance collar.
    • If the length is within the standard, go to step  6.

    Standard: 28.03-28.08 mm (1.104-1.106 in.) 

    Fig 5: Identifying Length Of Distance Collar
    G05449473Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. 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 reverse gear as a set.

    Standard: 27.92-27.97 mm (1.099-1.101 in.) 

    Service Limit: 27.87 mm (1.097 in.) 

    Fig 6: Identifying Thickness Of 2nd Gear
    G05449474Courtesy of AMERICAN HONDA MOTOR CO., INC.
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