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Mainshaft Assembly Clearance Inspection

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  1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
    Fig 1: Identifying Bearing Inner Race With An Appropriate Sized Socket (A), And Push Down On Mainshaft (B)
    G07768225Courtesy 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: 0.06-0.16 mm (0.0024-0.0063 in) 

    Service Limit: 0.25 mm (0.0098 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: 23.92-23.97 mm (0.9417-0.9437 in) 

    Service Limit: 23.80 mm (0.9370 in) 

    Fig 2: Identifying Bearing Inner Race With An Appropriate Sized Socket And Push Down On Mainshaft
    G07768226Courtesy 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: 0.06-0.16 mm (0.0024-0.0063 in) 

    Service Limit: 0.25 mm (0.0098 in) 

    Fig 3: Identifying Clearance Is Within Service Limit
    G07768227Courtesy 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: 24.03-24.08 mm (0.9461 -0.9480 in) 

    Fig 4: Identifying Length (1) Of 4Th/5Th Gear
    G07768228Courtesy 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: 23.92-23.97 mm (0.9417-0.9437 in) 

    Service Limit: 23.80 mm (0.9370 in) 

    Fig 5: Identifying Thickness Of 4Th Gear
    G07768229Courtesy 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: 0.06-0.16 mm (0.0024-0.0063 in) 

    Service Limit: 0.25 mm (0.0098 in) 

    Fig 6: Identifying Clearance Between 4Th/5Th Gear Distance Collar (A) And 5Th Gear (B) With A Dial Indicator (C)
    G07768230Courtesy 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: 24.03-24.08 mm (0.9461 -0.9480 in) 

    Fig 7: Identifying Length (2) Of 4Th/5Th Gear
    G07768231Courtesy 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: 23.92-23.97 mm (0.9417-0.9437 in) 

    Service Limit: 23.80 mm (0.9370 in) 

    Fig 8: Identifying Thickness Of 5Th Gear
    G07768232Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Measure the clearance between 6th gear (A) and the angular ball bearing (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 11.

    Standard: 0.15-0.25 mm (0.0059-0.0098 in) 

    Service Limit: 0.34 mm (0.0134 in) 

    Fig 9: Identifying Clearance Between 6Th Gear (A) And Angular Ball Bearing (B) With A Feeler Gauge (C)
    G07768233Courtesy 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: 24.03-24.08 mm (0.9461 -0.9480 in) 

    Fig 10: Identifying Length Of 6Th Gear Distance Collar
    G07768234Courtesy 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: 23.83-23.88 mm (0.9382-0.9402 in) 

    Service Limit: 23.71 mm (0.9335 in) 

Fig 11: Identifying Thickness Of 6Th Gear
G07768235Courtesy of AMERICAN HONDA MOTOR CO., INC.
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