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Home >> Honda >> 2007 >> Element SC, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission >> Countershaft Reassembly >> Special Tools Required

Special Tools Required

NOTE: Refer to EXPLODED VIEW , as needed, during this procedure.
  1. Clean all parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces.
  2. Install the 1st gear distance collar (A) with the needle bearing (B), and 1st gear (C) onto the countershaft (D).
    Fig 1: Identifying 1st Gear Distance Collar, Needle Bearing, 1st Gear & Countershaft
    G00485815Courtesy of AMERICAN HONDA MOTOR CO., INC.
  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: Identifying Triple Cone Synchro Assembly, Synchro Cone Fingers, Grooves In 1st Gear & Synchro Spring
    G05449482Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.
    Fig 3: Aligning Synchro Ring Fingers
    G00487422Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B). After installing, check the operation of the 1st/2nd synchro hub set.
    NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown below.
    Fig 4: Identifying Reverse Gear & 1st/2nd Synchro Hub
    G00487423Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 1st/2nd synchro hub.
    Fig 5: Identifying Triple Cone Synchro Assembly, Synchro Spring & Synchro Ring Fingers
    G05449484Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Install the 2nd gear distance collar (A) and the friction damper (B) by aligning the friction damper fingers (C) with the grooves (D) in the 1st/2nd synchro hub.
    Fig 6: Identifying 2nd Gear Distance Collar, Friction Damper & Friction Damper Fingers
    G05449485Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Install the needle bearing (A).
    Fig 7: Identifying Needle Bearing
    G00487424Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves (C) in 2nd gear.
  10. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 40 mm inner driver handle (C) and a press (D).
    NOTE: Do not exceed the maximum pressure.
    Fig 8: Pressing 3rd Gear
    G05449487Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Press on 4th gear (A) using the 40 mm inner driver handle (B) and a press (C).
    NOTE: Do not exceed the maximum pressure.
    Fig 9: Pressing 4th Gear
    G05449488Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Press on 5th gear (A) using the 40 mm driver handle (B) and a press (C).
    NOTE: Do not exceed the maximum pressure.
    Fig 10: Pressing 5th Gear
    G05449489Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install the distance collar (A), the 35 mm shim (B), and temporarily press on the used old ball bearing (C) using the 40 mm I.D. driver handle (D), the 30 mm bearing driver attachment (E), and a press (F).
    NOTE:
    • Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.
    • Make sure the ball bearing is installed in the correct direction.
    Fig 11: Identifying Distance Collar, Shim, Old Ball Bearing, Driver Handle, Bearing Driver Attachment & Press
    G00487425Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. 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 12: Measuring Clearance Between Old Bearing & Shim With Feeler Gauge
    G05449491Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. If the measured clearance in step  14 is not within the standard, select another suitable 35 mm shim from the table below, then go to next step to replace the 35 mm shim and the ball bearing with new ones. If the measured clearance in step  14 is within the standard, go to the next step to replace only the ball bearing with a new one.

    35 mm Shim 

    SHIM THICKNESS CHART

    Type 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.)
  16. Remove the ball bearing and the 35 mm shim using a press (see step  3 ).
  17. Install the correct 35 mm shim (A) and new ball bearing (B) using the 40 mm I.D. driver handle (C), the 30 mm inner bearing driver attachment (D), and a press (E).
    NOTE:
    • If necessary, replace the 35 mm shim with the correct one selected in step  15.
    • Make sure the ball bearing is installed in the correct direction.
    Fig 13: Pressing Countershaft Out Of Ball Bearing
    G00487426Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Check the clearance between the ball bearing and the 35 mm shim with a feeler gauge.
  19. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
    Fig 14: Countershaft Assembly With Torque Specifications
    G05449494Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Tighten the new special bolt (B) (left-hand threads).
    NOTE: Apply new MTF to the bolt threads and flange.
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