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Transmission Reassembly

WARNING: This page is about a different variant/trim than selected.
NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces.
  1. Press the new dust seal (A) into the transmission housing surface, then install the change lever (B), shift arm (C), 8 mm spring washer (D), and 8 mm special bolt (E).
    Fig 1: Dust Seal, Change Lever, Shift Arm And Spring Washer With Torque Specifications
    G05458712Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Select the proper size 82 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see MAINSHAFT THRUST CLEARANCE ADJUSTMENT  ). Install it into the transmission housing (B).
    Fig 2: Identifying Shim And Transmission Housing
    G05458713Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the oil pump outer rotor (A), oil pump inner rotor (B), and oil pump plate (C).
    Fig 3: Oil Pump Outer Rotor, Oil Pump Inner Rotor And Oil Pump Plate With Torque Specifications
    G05458714Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the differential assembly (A) and oil pump shaft (B).
    Fig 4: Identifying Differential Assembly And Oil Pump Shaft
    G05458715Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the 64 mm spring washer (A). Note the installation direction of the 64 mm spring washer.
    Fig 5: Identifying Mainshaft Splines, Countershaft And Shift Fork Assembly
    G05458716Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Apply tape to the mainshaft splines (B) to protect the seal. Install the mainshaft and countershaft (C) into the shift fork assembly (D) as an assembly.
  7. Press the new dust seal (A) into the clutch housing surface, then install the select lever (B), select arm (C), new 5 mm spring pin (D), and new 3 mm spring pin (E).
    Fig 6: Identifying Dust Seal, Select Lever, Select Arm And Spring Pin
    G05458717Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Set the select return spring (A), 8 x 50 mm pin (B), and interlock (C) as shown.
    Fig 7: Identifying Select Return Spring, Pin And Interlock
    G05458718Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Install the shift piece (A) and shift piece shaft (B).
    Fig 8: Identifying Shift Piece And Shift Piece Shaft
    G05458719Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the 33 mm spring washer (A). Note the installation direction of the spring washer.
    Fig 9: Identifying Thrust Needle Bearings, Reverse Idler Gear Shaft Assembly And Reverse Shift Fork
    G05458720Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Install the 20 mm thrust needle bearings (B), 20 mm thrust washers (C), reverse idler gear shaft assembly (D), and reverse shift fork (E) as an assembly.
  12. Slide the reverse idler gear shaft assembly (A) on the rib (B) of the clutch housing, then install it into the hole (C) of the clutch housing.
    Fig 10: Installing Reverse Idler Gear Shaft Assembly
    G05458721Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install the reverse shift lever (A), and 8 x 50 mm pin (B).
    Fig 11: Identifying Reverse Shift Lever And Pin
    G05458722Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the oil guide pipe A, oil guide pipe B, and magnet (C).
    Fig 12: Identifying Oil Guide Pipes And Magnet
    G05458723Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Clean any dirt and oil from the transmission housing sealing surface.
  16. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the transmission housing and the clutch housing. Install the component within 5 minutes of applying the liquid gasket.
    NOTE:
    • If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
    • If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
      Fig 13: Identifying Mating Surface Of Transmission Housing
      G05458724Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Install the three 14x20 mm dowel pins (A).
    Fig 14: Shift Arm, Shift Piece And Change Lever With Torque Specifications
    G05458725Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).
  19. While expanding the 75 mm snap ring (E) of the countershaft ball bearing with snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Then release the pliers, and push down the housing unit it bottoms and the snap ring snaps in place in the counter shaft ball bearing snap ring groove.
  20. Make sure the 75 mm snap ring is securely seated in the groove of the countershaft bearing.
    Fig 15: Identifying Snap Ring Dimension
    G05458726Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Install the new 37.7 mm O-ring (F) and transmission case cap (G).
    NOTE: Check the operation of the change lever and select lever.
  22. Install transmission hanger A, transmission hanger B, 8 mm flange bolt (C), and the 10 mm flange bolts, finger-tight.
    Fig 16: Transmission Hanger And Flange Bolt With Torque Specifications
    G05458727Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Tighten the 10 mm flange bolts in a crisscross pattern in several steps.
    Fig 17: Tightening Sequence Of Flange Bolts With Torque Specifications
    G05458728Courtesy of AMERICAN HONDA MOTOR CO., INC.
  24. Install the oil check bolt (A), new 6 mm washer (B), drain plug (C), and new 14 mm washer (D).
    Fig 18: Oil Check Bolt, Washer And Drain Plug With Torque Specifications
    G05458729Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Apply liquid gasket, P/N 08718-0001 evenly to the set screws (A), then install the set screws, 22.0 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and new O-rings (G). Install the component within 5 minutes of applying the liquid gasket.
    NOTE:
    • If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
    • If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
      Fig 19: Steel Balls, Input Shaft (Mainshaft) Speed Sensor And Output Shaft (Countershaft) Speed Sensor With Torque Specifications
      G05458730Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Apply liquid gasket, P/N 08718-0001 evenly to the set screws (A), then install the set screws, 22.0 mm spring (B), 26.1 mm spring (C), 27.4 mm springs (D), steel balls (E), 20.0 mm washer (F), and clutch line bracket (G). Install the filler plug (H) finger-tight. Install the component within 5 minutes of applying the liquid gasket.
    NOTE:
    • If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
    • If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
      Fig 20: Steel Balls, Washer, Clutch Line Bracket And Filler Plug With Torque Specifications
      G05458731Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. Clean any dirt or oil from the reverse lockout solenoid sealing surface.
  28. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the reverse lockout solenoid and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.
    NOTE:
    • If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
    • If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
      Fig 21: [Identifying Mating Surface Of Reverse Lockout Solenoid]
      G05458732Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. Install the transmission harness bracket (A) and the reverse lockout solenoid (B).
    Fig 22: Transmission Harness Bracket, Back-Up Light Switch And Reverse Lockout Solenoid With Torque Specifications
    G05458733Courtesy of AMERICAN HONDA MOTOR CO., INC.
  30. Apply liquid gasket, P/N 08718-0001 evenly to the threads of the back-up light switch (C), and install the switch in the transmission housing. Install the component within 5 minutes of applying the liquid gasket.
    NOTE:
    • If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
    • If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
  31. Install the strainer cover (A), new O-ring (B), strainer set spring (C), and oil pump strainer (D).
    Fig 23: Strainer Cover, O-Ring, Strainer Set Spring And Oil Pump Strainer With Torque Specifications
    G05458734Courtesy of AMERICAN HONDA MOTOR CO., INC.
  32. Adjust the differential carrier bearing preload (see CARRIER BEARING PRELOAD ADJUSTMENT  ).
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