Secondary Shaft 2nd Gear and 5th Gear Axial Clearance Inspection

Special Tools Required 

Driver Handle, 40 mm I.D. 07746-0030100

1. Slide the idler gear (A) over the secondary shaft (B) in the direction shown.
   Fig 1: Sliding Idler Gear Over Secondary Shaft

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Place the idler gear (A) on press bases (B), and place a spacer (C) between the secondary shaft (D) and a press to prevent damaging the secondary shaft.
   Fig 2: Placing Idler Gear On Press Bases

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Install the idler gear using the press.
4. Install the 49 x 66 x 3 mm thrust needle bearing (A), the 45 x 50 x 25 mm needle bearing (B), 5th gear (C), the 49 x 66 x 3 mm thrust needle bearing (D), and the 5th gear collar (E) on the secondary shaft (F).
   Fig 3: Installing Idler Gear Using Press

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Press the 5th gear collar into place using the driver handle and the press.
   Fig 4: Pressing 5th Gear Collar

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. Install the 2nd/5th clutch (A) and the 2nd gear collar (B) on the secondary shaft (C).
   Fig 5: Installing 2nd/5th Clutch And 2nd Gear Collar On Secondary Shaft

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Install the ball bearing (A) over the secondary shaft (B), then press it into place using the driver handle and the press.
   Fig 6: Installing Ball Bearing Over Secondary Shaft

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. Secure the idler gear (A) on the secondary shaft (B) in a bench vise with wood blocks, install the old lock bolt (C), and tighten it to 78 N.m (8.0 kgf.m, 58 lbf.ft).
   NOTE: After this procedure, remove wood chips that may be stuck to the gear.
   Fig 7: Securing Idler Gear On Secondary Shaft In Bench Vise With Torque Specifications

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Measure the clearance between the 2nd gear collar (A) and the ball bearing (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.

   Standard: 0.05-0.12 mm (0.0020-0.0047 in) 

   Fig 8: Measuring Clearance Between 2nd Gear Collar And Ball Bearing With Feeler Gauge

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
10. If the clearance is out of the standard, remove the 2nd gear collar and measure its height (A).
    Fig 9: Removing 2nd Gear Collar

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Select and install a new 2nd gear collar, then recheck the clearance.

    2ND GEAR COLLAR 

    2ND GEAR COLLAR REFERENCE CHART
    
    

    No.	Height (A)
    A	32.89 mm (1.2949 in)
    B	32.94 mm (1.2968 in)
    C	32.99 mm (1.2988 in)
    D	33.04 mm (1.3008 in)
    E	33.09 mm (1.3028 in)
    F	33.14 mm (1.3047 in)
    G	33.19 mm (1.3067 in)
    H	33.24 mm (1.3087 in)