Exploded View

Fig 1: Exploded View Of Countershaft Components With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver, 56 x 62 mm 070AD-PYZA100
• Driver, 40 mm I.D. 07746-0030100

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the countershaft reverse gear (A), needle bearing (B), and 1st gear (C) onto the countershaft (D).
   Fig 2: Identifying Reverse Gear (A), Needle Bearing (B), 1st Gear (C) And Countershaft (D)

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3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 1st gear (C), then install the synchro spring (D).
   Fig 3: Identifying Synchro Assembly (A), Synchro Cone Fingers (B), 1st Gear (C) And Synchro Spring (D)

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4. Install the 1st/2nd synchro hub (A) by aligning the outer synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).
   Fig 4: Installing 1st/2nd Synchro Hub (A) By Aligning Synchro Ring Fingers (B) With Synchro Hub Grooves (C)

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5. Install the 1st/2nd synchro sleeve.
6. Install the synchro spring (A).
   Fig 5: Identifying Synchro Spring (A), Synchro Assembly (B), Synchro Ring Fingers (C) And 1st/2nd Synchro Hub (D)

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7. Install the triple cone synchro assembly (B) by aligning the outer synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
8. Install the distance collar and needle bearing.
9. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).
   Fig 6: Installing 2nd Gear (A) By Aligning Synchro Cone Fingers (B) With 2nd Gear Holes (C)

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10. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the special tool and a press (C).
    Fig 7: Identifying Countershaft (A), 3rd Gear (B), Special Tool And Press (C)

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11. Install 4th gear (A) using the special tool and a press (B).
    Fig 8: Installing 4th Gear (A) Using Special Tool And Press (B)

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12. Install 5th gear (A) using the special tool and a press (B).
    Fig 9: Installing 5th Gear (A) Using Special Tool And Press (B)

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13. Install 6th gear (A) using the special tool and a press (B).
    Fig 10: Installing 6th Gear (A) Using Special Tool And Press (B)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Install the 35 mm shim (A) and the old ball bearing (B) using the special tool and a press (C).
    Fig 11: Installing Shim (A) And Ball Bearing (B) Using Special Tool And Press (C)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 12: Measuring Clearance Between Bearing (A) And Shim (B) With Feeler Gauge (C)

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16. If the clearance is more than the standard, select a new shim from the following table.

    35 mm Shim 

    35 MM SHIM - SPECIFICATION TABLE
    
    

    	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 (0.059 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 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the old ball bearing.
    Fig 13: Identifying 6th Gear (A), Steel Blocks (B), Press (C) And Attachment (D)

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18. If a new 35 mm shim was selected in step 16, install the shim, and recheck the clearance.
19. Install 6th gear (A) using the special tool and a press (B).
    Fig 14: Installing 6th Gear (A) Using Special Tool And Press (B)

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20. Install the 35 mm shim (A) and new bearing (B) using the special tool and a press (C).
    Fig 15: Installing Shim (A) And Bearing (B) Using Special Tool And Press (C)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
21. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
    Fig 16: Clamping Countershaft Assembly In Bench Vise With Wood Blocks (A) With Torque Specifications

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22. Tighten the new 20 mm special bolt (B) (left-hand threads).