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Home › Acura › 2009 › CSX Base, Automatic › Repair and Diagnosis › Transmission › Manual Trans › 5-Speed Manual Transmission › Speed Manual Transmission › Countershaft Reassembly › Exploded View

Exploded View

Fig 1: Exploded View Of Countershaft
G06266037Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

NOTE: Refer to the EXPLODED VIEW , as needed, during this procedure.
  1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
  2. Install the distance collar, the needle bearing, and 1st gear onto the countershaft.
  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: Aligning Synchro Cone Fingers With Grooves In 1st Gear
    G06266038Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).
    Fig 3: Aligning Synchro Ring Fingers With Grooves In 1st/2nd Synchro Hub
    G06266039Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the reverse gear.
  6. Install the synchro spring (A).
    Fig 4: Identifying Synchro Spring
    G06266040Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Install the triple cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
  8. Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves in the 1st/2nd synchro hub (D).
    Fig 5: Aligning Synchro Ring Fingers With Grooves In 1st/2nd Synchro Hub
    G06266041Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Install the needle bearing.
  10. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).
    Fig 6: Aligning Synchro Cone Fingers With Grooves In 2nd Gear
    G06266042Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the 40 mm I.D. driver (C) and a press (D).
    NOTE: Do not exceed the maximum pressure.
    Fig 7: Installing 3rd Gear With Torque Specifications
    G06266043Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Install 4th gear (A) using the 40 mm I.D. driver (B) and a press (C).
    NOTE: Do not exceed the maximum pressure.
    Fig 8: Installing 4th Gear With Torque Specifications
    G06266044Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Install 5th gear (A) using the 40 mm I.D. driver (B) and a press (C).
    NOTE: Do not exceed the maximum pressure.
    Fig 9: Installing 5th Gear With Torque Specifications
    G06266045Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Install the distance collar (A), 35 mm shim, and old ball bearing (B) using the 40 mm I.D. driver (C), 30 mm I.D. attachment (D), and a press (E).
    Fig 10: Installing Distance Collar
    G06266046Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Measure 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 11: Measuring Clearance Between Old Bearing And Shim
    G06266047Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 15 is within the standard, replace only the ball bearing.

    35 mm Shim 

    THICKNESS SPECIFICATION

      Part Number Thickness
    A 23981-PPP-000 0.87 mm (0.0343 in.)
    AA 23981-PPP-900 0.91 mm (0.0358 in.)
    B 23982-PPP-000 0.95 mm (0.0374 in.)
    AB 23982-PPP-900 0.99 mm (0.0390 in.)
    C 23983-PPP-000 1.03 mm (0.0406 in.)
    AC 23983-PPP-900 1.07 mm (0.0421 in.)
    D 23984-PPP-000 1.11 mm (0.0437 in.)
    AD 23984-PPP-900 1.15 mm (0.0453 in.)
    E 23985-PPP-000 1.19 mm (0.0469 in.)
    AE 23985-PPP-900 1.23 mm (0.0484 in.)
    F 23986-PPP-000 1.27 mm (0.0500 in.)
    AF 23986-PPP-900 1.31 mm (0.0516 in.)
    G 23987-PPP-000 1.35 mm (0.0531 in.)
    AG 23987-PPP-900 1.39 mm (0.0547 in.)
    H 23988-PPP-000 1.43 mm (0.0563 in.)
    AH 23988-PPP-900 1.47 mm (0.0579 in.)
    J 23989-PPP-000 1.51 mm (0.0594 in.)
    AJ 23989-PPP-900 1.55 mm (0.0610 in.)
    K 23990-PPP-000 1.59 mm (0.0626 in.)
    AK 23990-PPP-900 1.63 mm (0.0642 in.)
    L 23991-PPP-000 1.67 mm (0.0657 in.)
    AL 23991-PPP-900 1.71 mm (0.0673 in.)
    M 23992-PPP-000 1.75 mm (0.0689 in.)
    AM 23992-PPP-900 1.79 mm (0.0705 in.)
    N 23993-PPP-000 1.83 mm (0.0720 in.)
    AN 23993-PPP-900 1.87 mm (0.0736 in.)
    P 23994-PPP-000 1.91 mm (0.0752 in.)
    AP 23994-PPP-900 1.95 mm (0.0768 in.)
    Q 23995-PPP-000 1.99 mm (0.0783 in.)
  17. Support the ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing.
    Fig 12: Supporting Ball Bearing On Steel Blocks
    G06266048Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. If necessary, install the 35 mm shim selected in step 16, then recheck the clearance.
  19. Install the distance collar (A), the 35 mm shim, and the new ball bearing (B) using the 40 mm I.D. driver (C), 30 mm I.D. attachment (D), and a press (E).
    Fig 13: Installing Distance Collar
    G06266049Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
    Fig 14: Clamping Countershaft Assembly In Bench Vise With Torque Specifications
    G06266050Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Tighten the new special bolt (B) (left-hand threads).
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