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Mainshaft Assembly Clearance Inspection

WARNING: This page is about a different variant/trim than selected.
  1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
    Fig 1: Measuring Clearance Between 2nd Gear And 3rd Gear Using Feeler Gauge
    G08066080Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).
    • If the clearance exceeds the service limit, go to step 3.
    • If the clearance is within the service limit, go to step  4.

    Standard: 0.06- 0.19 mm (0.002- 0.007 in) 

    Service Limit: 0.3 mm (0.011 in) 

  3. Measure the thickness of 3rd gear.
    • If the thickness is less than the service limit, replace 3rd gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.

    Standard: 23.89- 23.97 mm (0.9405- 0.9437 in) 

    Service Limit: 23.8 mm (0.937 in) 

    Fig 2: Measuring Thickness Of 3rd Gear
    G08066081Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Measure the clearance between 4th gear (A) and the 4th/5th gear distance collar (B) with a dial indicator (C).
    • If the clearance exceeds the service limit, go to step 5.
    • If the clearance is within the service limit, go to step  7.

    Standard: 0.06- 0.19 mm (0.0024- 0.0075 in) 

    Service Limit: 0.3 mm (0.012 in) 

    Fig 3: Measuring Clearance Between 4th Gear And 4th/5th Gear Distance Collar Using Dial Indicator
    G08066082Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Measure the length (1) of the 4th/5th gear distance collar as shown.
    • If the length (1) is not within the standard, replace the 4th/5th gear distance collar.
    • If the length (1) is within the standard, go to step 6.

    Standard: 22.53- 22.58 mm (0.8870- 0.8890 in) 

    Fig 4: Measuring Length Of 4th/5th Gear Distance Collar
    G08066083Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Measure the thickness of 4th gear.
    • If the thickness is less than the service limit, replace 4th gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.

    Standard: 22.39- 22.47 mm (0.8815- 0.8846 in) 

    Service Limit: 22.3 mm (0.878 in) 

    Fig 5: Measuring Thickness Of 4th Gear
    G08066084Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Measure the clearance between the 4th/5th gear distance collar (A) and 5th gear (B) with a dial indicator (C).
    • If the clearance exceeds the service limit, go to step 8.
    • If the clearance is within the service limit, go to step  10.

    Standard: 0.06- 0.19 mm (0.0024- 0.0075 in) 

    Service Limit: 0.3 mm (0.012 in) 

    Fig 6: Measuring Clearance Between 4th/5th Gear Distance Collar And 5th Gear Using Dial Indicator
    G08066085Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Measure the length (2) of the 4th/5th gear distance collar as shown.
    • If the length (2) is not within the standard, replace the 4th/5th gear distance collar.
    • If the length (2) is within the standard, go to step 9.

    Standard: 22.53- 22.58 mm (0.8870- 0.8890 in) 

    Fig 7: Measuring Length Of 4th/5th Gear Distance Collar
    G08066086Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Measure the thickness of 5th gear.
    • If the thickness is less than the service limit, replace 5th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and the 5th/6th synchro sleeve as a set.

    Standard: 22.39- 22.47 mm (0.8815- 0.8846 in) 

    Service Limit: 22.3 mm (0.878 in) 

    Fig 8: Measuring Thickness Of 5th Gear
    G08066087Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C). If the clearance exceeds the service limit, go to step 11.

    Standard: 0.06- 0.19 mm (0.0024- 0.0075 in) 

    Service Limit: 0.3 mm (0.012 in) 

    Fig 9: Measuring Clearance Between 6th Gear And Angular Ball Bearing Inner Race Using Dial Indicator
    G08066088Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Measure the length of the 6th gear distance collar.
    • If the length is not within the standard, replace the 6th gear distance collar.
    • If the length is within the standard, go to step 12.

    Standard: 26.03- 26.08 mm (1.0248- 1.0268 in) 

    Fig 10: Measuring Length Of 6th Gear Distance Collar
    G08066089Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Measure the thickness of 6th gear.
    • If the thickness is less than the service limit, replace 6th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and the 5th/6th synchro sleeve as a set.

    Standard: 25.89- 25.97 mm (1.0193- 1.0224 in) 

    Service Limit: 25.8 mm (1.016 in) 

    Fig 11: Measuring Thickness Of 6th Gear
    G08066090Courtesy of AMERICAN HONDA MOTOR CO., INC.
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