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Transaxle Reassembly

NOTE: Letter references in parenthesis in the following steps are found in illustrations.
NOTE: Refer to exploded views as needed during the following procedures. See Figure and Figure .
  1. Install the magnet and differential assembly. See Figure .
  2. Install the 28-mm spring washer (A) and 28-mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer. See Figure .
  3. Apply vinyl tape to the mainshaft splines to protect the seal. Install the mainshaft (A) and countershaft (B) into the shift forks (C), and install them as an assembly. See Figure .
  4. Install the reverse shift fork.
  5. Install the reverse idler gear (A) and reverse gear shaft (B) by aligning the mark (C) with reverse gear shaft hole (D). See Fig 1 .
  6. Install the reverse lock cam.
  7. Select the proper size 72-mm shim according to the measurements made during the MAINSHAFT THRUST CLEARANCE  under TRANSAXLE ADJUSTMENTS. Install the oil gutter plate, oil guide plate "M", and 72-mm shim into the transaxle housing. See Figure .
    8. NOTE: If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transaxle with oil.
  8. Remove the dirt and oil from the transaxle housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.
  9. Install the 14 x 20 mm dowel pins (E). See Figure .
  10. Set the tapered cone ring as shown. See Figure . Place the transaxle housing over the clutch housing, being careful to line up the shafts.
  11. Lower the transaxle housing the rest of the way as you expand the 72-mm snap ring. Release the snap ring so it seats in the groove of the countershaft bearing.
  12. Check that the 72-mm snap ring is securely seated in the groove of the countershaft bearing. With snap ring installed, gap between snap ring ends should be .13-.24" (3.30-6.00 mm).
  13. Apply gasket sealer to the threads of the 32-mm sealing cap (A), and install it on the transaxle housing. See Figure .
  14. Install the transaxle hanger "A", the transaxle hanger "B", and the 8-mm flange bolts finger-tight. See Figure .
  15. Tighten the 8-mm flange bolts in a crisscross pattern in several steps to specification. See TORQUE SPECIFICATIONS  . See Fig 2 .
    16. NOTE: If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transaxle with oil.
  16. Remove the dirt and oil from the shift lever cover sealing surface. Apply gasket sealer to the sealing surface.
  17. Install the 8 x 14 mm dowel pins, clutch line clip bracket, and change lever assembly.
  18. Apply gasket sealer to the threads of the interlock bolt, and install it on the transaxle housing.
  19. Install the drain plug, filler plug, and 10-mm flange bolt with new washers.
  20. Install the detent bolts, springs, and steel balls with new washers.
  21. Apply gasket sealer to the threads of the back-up light switch, and install it on the transaxle housing.
  22. Install the VSS and "O" ring. Install 10 x 20 mm dowel pin (C) , "O" ring (B) and transfer assembly (A). See Figure .
Fig 1: Aligning Reverse Gear Shaft
G00079094Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 2: Transaxle Housing Bolt Tightening Pattern
G00079093Courtesy of AMERICAN HONDA MOTOR CO., INC.
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