Exploded View - Transmission Housing

Fig 1: Exploded View Of Transmission Housing Replacement Components With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. 2WD: Remove the side cover (A) and O-ring (B).
   Fig 2: Identifying Side Cover & O-Ring

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. 4WD: Remove the transfer assembly (A), O-ring (B), and 10 x 20 mm dowel pin (C).
   Fig 3: Identifying Transfer Assembly, O-Ring & Dowel Pin

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Remove the detent bolts (A), the 12 mm sealing washers (B), the springs (D), the steel balls (E), the back-up light switch (F), and transmission hanger C.
   Fig 4: Identifying Detent Bolts, Springs, Steel Balls Washers & Back-Up Light Switch

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Remove the 20 mm bolt (A) and 20 mm washer (B).
   Fig 5: Identifying Bolt & Washer

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Remove the interlock bolt (A), then remove the change lever assembly (B) and 8 x 14 mm dowel pins (C).
   Fig 6: Identifying Interlock Bolt, Lever Assembly & Dowel Pins

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), and the sealing washers (D).
   Fig 7: Identifying Drain Plug, Filler Plug, Flange Bolt & Sealing Washers

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Remove the output shaft (countershaft) speed sensor (E), the plain washer (F), and the O-ring (G).
8. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
   Fig 8: Identifying Output Shaft Speed Sensor, Plain Washer & O-Ring

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Remove the 8 mm flange bolts with transmission hanger A and transmission hanger B.
10. Remove the 32 mm sealing cap (A).
    Fig 9: Identifying Sealing Cap

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C). Release the snap ring pliers, and remove the transmission housing and the three 14 x 20 mm dowel pins (D).
12. Remove the reverse lock cam (A).
    Fig 10: Identifying Reverse Lock Cam

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
13. Remove the reverse idler gear (A) and reverse gear shaft (B).
    Fig 11: Identifying Reverse Idler Gear & Reverse Gear Shaft

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Remove the reverse shift fork (A).
    Fig 12: Identifying Reverse Shift Fork

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
15. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).
    Fig 13: Identifying Mainshaft Assembly, Countershaft Assembly, Shift Fork Assembly & Clutch Housing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
16. Remove the 28 mm spring washer (E) and 28 mm washer (F).
17. Remove the differential assembly (A) and magnet (B).
    Fig 14: Identifying Differential Assembly & Magnet

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. Remove the oil gutter plate (A), the 72 mm shim (B), and oil guide plate M.
    Fig 15: Identifying Oil Gutter Plate & Oil Guide Plate

    Courtesy of AMERICAN HONDA MOTOR CO., INC.