Transmission Reassembly

WARNING: This page is about a different variant/trim than selected.

NOTE: Prior to reassembly, clean all parts in solvent, dry them, and apply MTF to any contact surfaces.

Install the magnet (A) and the differential assembly (B).
NOTE: Clean the magnet anytime the transmission is disassembled.

Fig 1: Identifying Magnet (A) And Differential Assembly (B)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 28 mm spring washer (A) and the 28 mm washer (B) over the ball bearing (C).
NOTE: Be sure to install the spring washer in the direction shown.

Fig 2: Installing Spring Washer (A) And Washer (B) Over Ball Bearing (C)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply tape to the mainshaft splines (D) to protect the seal. Install the mainshaft assembly (E) and the countershaft assembly (F) with the shift fork assembly (G), as an assembly.
NOTE: Do not apply tape thick to damage the oil seal.
Install the reverse shift fork (A).

Fig 3: Reverse Shift Fork (A) With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the reverse idler gear (A) and the reverse idler gear shaft (B) by aligning the mark (C) on the clutch housing with the reverse idler gear shaft hole (D).

Fig 4: Identifying Reverse Idler Gear (A) And Reverse Idler Gear Shaft (B) By Aligning Mark (C)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the baffle plate (A).

Fig 5: Identifying Baffle Plate (A)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see MAINSHAFT THRUST CLEARANCE ADJUSTMENT ). Install the oil gutter plate (B), oil guide plate M, and the 72 mm shim into the transmission housing (C).

Fig 6: Identifying Oil Gutter Plate (B), Oil Guide Plate M, And Shim Into Transmission Housing (C)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Clean any dirt or oil from the transmission housing sealing surface.
Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 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 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 7: Identifying Liquid Gasket
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the three 14x20 mm dowel pins (A).

Fig 8: Dowel Pins (A), Snap Ring (C) And Snap Ring (C) With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Place the transmission housing on the clutch housing, making sure to line up the shafts.
While expanding the 72 mm snap ring (C) 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.
NOTE: Install the 32 mm sealing cap (D) after setting in the 72 mm snap ring.
Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing.
Dimension as installed: 3.3-6.0 mm (0.13-0.24 in)

Fig 9: Identifying Snap Ring (A)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, or 08718-0009) to the threads of the 32 mm sealing cap, and install it on the transmission housing.
Install the 8 mm flange bolts finger-tight with transmission hanger A, transmission hanger B, and the harness bracket (C).

Fig 10: Identifying Transmission Hanger A, Transmission Hanger B, And Harness Bracket (C)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
Specified Torque: 8 x 1.25 mm 27 IM-m (2.8 kgf-m, 20 Ibf-ft)

Fig 11: Identifying Flange Bolts Tightening Sequence
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Clean any dirt or oil from the change lever assembly sealing surface.
Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
- If 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 12: Identifying Liquid Gasket
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 8x14 mm dowel pins (A) and the change lever assembly (B).

Fig 13: Dowel Pins (A) And Change Lever Assembly (B) With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, or 08718-0009) to the threads of the interlock bolt (C), and install it on the transmission housing.
Install the filler plug (A) with a new washer finger-tight, and install the drain plug (B) and the 10 mm flange bolt (C) with new sealing washers (D).

Fig 14: Filler Plug (A), Drain Plug (B) And Flange Bolt (C) With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply MTF to a new O-ring (E), then install the O-ring, the plain washer (F), and the output shaft (countershaft) speed sensor (G).
Install the steel balls (A), the detent ball springs (B), and the detent bolts (C) with new 12 mm sealing washers (D).

Fig 15: Steel Balls (A), Detent Ball Springs (B), And Detent Bolts (C) With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 20 mm bolt (E) with a new 20 mm sealing washer (F).
Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, or 08718-0009) to the threads of the back-up light switch (G), and install it in the transmission housing.