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 MTF to all contact surfaces.

If any of the items listed were replaced, do the differential carrier bearing preload adjustment before reassembling the transmission (see TRANSMISSION DISASSEMBLY ).
- Transmission housing
- Clutch housing
- Differential carrier
- Spacer
- Differential carrier bearing and outer race
Press a new 16 x 23 x 5 mm dust seal (A) flush with the transmission housing surface, then install the change lever (B), the shift arm (C), the 8 mm spring washer (D), and the 8 mm special bolt (E).
NOTE: Be sure to install the spring washer in the direction shown.

Fig 1: Dust Seal, Change Lever, Shift Arm, Spring Washer, Breather Cap And Bolt With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the breather cap (F) with the arrow on the cap toward the front of the vehicle.
Select the proper size 87 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
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the oil pump outer rotor (A), the oil pump inner rotor (B), and the oil pump plate (C).

Fig 3: Oil Pump Plate, Oil Pump Outer Rotor And Inner Rotor With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the oil gutter plate (A).

Fig 4: Identifying Oil Gutter Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer output shaft assembly (A).

Fig 5: Identifying Transfer Output Shaft Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the differential assembly (A) and the oil pump shaft (B).

Fig 6: Identifying Differential Assembly And Oil Pump Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 64 mm spring washer (A).
NOTE: Be sure to install the spring washer in the direction shown.

Fig 7: Identifying Spring Washer, Mainshaft Splines, Countershaft And Shift Fork Assembly
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply tape to the mainshaft splines (B) to protect the seal. Install the mainshaft and the countershaft (C) with the shift fork assembly (D) as an assembly.
NOTE: Do not apply tape thick to damage the oil seal.
Press a new 14 x 20 x 4 mm dust seal (A) flush with the clutch housing surface, then install the select lever (B), the select arm (C), a new 5 x 22 mm spring pin (D), and a new 3 x 22 mm spring pin (E).
NOTE: Make the seams (F) of the 5 x 22 mm and 3 x 22 mm spring pin are opposite side.

Fig 8: Identifying Dust Seal, Lever, Arm, Seams And Spring Pins
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Set the select return spring (A), the 8 x 50 mm pin (B), and the interlock (C) as shown.

Fig 9: Identifying Interlock, Return Spring And Pin
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the shift piece (A) and the shift piece shaft (B).

Fig 10: Identifying Shift Piece And Shift Piece Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Assemble the 25 mm thrust needle bearings (A), the 25 mm thrust washers (B), the reverse idler gear shaft assembly (C), and the reverse shift fork (D) (see REVERSE IDLER GEAR SHAFT ASSEMBLY DISASSEMBLY/REASSEMBLY ).

Fig 11: Identifying Thrust Needle Bearings, Thrust Washers, Reverse Idler Gear Shaft Assembly, Reverse Shift Fork And Spring Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 36 mm spring washer (E) to the reverse idler gear shaft assembly.
NOTE: Be sure to install the spring washer in the direction shown.
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 12: Installing Reverse Idler Gear Shaft Assembly Into Hole Of Clutch Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the reverse shift lever (A) and the 8x50 mm pin (B).

Fig 13: Identifying Reverse Shift Lever And Pin
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install oil guide pipe A, the oil guide pipe (B), and the magnet (C).
NOTE: Clean the magnet anytime the transmission is disassembled.

Fig 14: Identifying Oil Guide Pipe And Magnet
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Clean any dirt and oil from the transmission housing sealing surface.
Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the clutch housing mating surface of 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 15: Identifying Clutch Housing Mating Surface Of Transmission Housing
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the three 14 x 20 mm dowel pins (A).

Fig 16: Dowel Pins, Shift Arm, Groove Of Shift Piece, Change Lever And Snap Ring With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).
While expanding the 75 mm snap ring (E) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.
Make sure the 75 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 1.67- 9.42 mm (0.066- 0.371 in)
Install a new O-ring (F) and the transmission case cap (G).
NOTE: Check the operation of the change lever and the select lever.
Install the 10 mm flange bolts finger-tight, with transmission hanger B and the clutch line bracket (A).

Fig 17: Identifying Clutch Line Bracket And Transmission Hanger
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the 10 mm flange bolts in a crisscross pattern in several steps.
Specified Torque: 10 x 1.25 mm 44 N.m (4.5 kgf.m, 33 lbf.ft)

Fig 18: Identifying Flange Bolts With Tightening Sequence
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the drain plug (A) with a new sealing washer (B).

Fig 19: Sealing Washer, Fluid Check Bolt And Drain Plug With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the fluid check bolt (C) with a new sealing washer (D) by finger-tight.
Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolts (A), then install the steel balls (B), the 22.0 mm detent ball spring (C), the 27.4 mm detent ball spring (D), and the detent bolts.

Fig 20: Steel Balls, Detent Ball Spring, Detent Bolts, O-Rings, Input Shaft (Mainshaft) And Output Shaft (Countershaft) Speed Sensor With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the input shaft (mainshaft) speed sensor (E), the output shaft (countershaft) speed sensor (F), and new O-rings (G).
Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolts (A), then install the steel balls (B), the 22.0 mm detent ball spring (C), the 26.1 mm detent ball spring (D), the 27.4 mm detent ball spring (E), and the detent bolts.

Fig 21: Steel Balls, Detent Ball Springs, Detent Bolts, Filler Plug And Sealing Washer With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the filler plug (F) with a new sealing washer (G) by finger-tight.
Clean any dirt or oil from the reverse lockout solenoid sealing surface.
Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the transmission housing mating surface of the reverse lockout solenoid. 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 22: Identifying Transmission Housing Mating Surface Of Reverse Lockout Solenoid
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the select lock pin spring (B), the select lock pin (C), and the reverse lockout solenoid (D).

Fig 23: Transmission Hanger, Lock Pin Spring, Lock Pin, Reverse Lockout Solenoid And Threads Of Back-Up Light Switch With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply liquid gasket, (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the threads of the back-up light switch (E), and install it in the transmission housing.
Install transmission hanger A.
Install the oil pump strainer (A), the strainer set spring (B), and the strainer cover (C) with a new O-ring (D).
NOTE: Clean the strainer anytime the transmission is disassembled.

Fig 24: Oil Pump Strainer, Strainer Set Spring, Strainer Cover And O-Ring With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.