Countershaft 2nd Gear and 5th Gear Axial Clearance Inspection

Special Tools Required 

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

1. Slide the park gear (A) over the countershaft (B).
   Fig 1: Locating Park Gear And Countershaft

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2. Place the park gear (A) on press bases (B), and place a spacer (C) between the countershaft (D) and the press to prevent damaging the countershaft.
   Fig 2: Locating Park Gear, Press Bases, Spacer And Countershaft

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3. Install the park gear using a press.
4. Install the 53x57x20 mm needle bearing (A), 1st gear (B), 5th gear (C), the 42.5 x 52.5 x 2.5 mm thrust washer (D), the 5th gear collar (E), the 42.5 mm thrust shim (F), and 2nd gear (G) on the countershaft (H). Install 2nd gear and 5th gear in the direction shown.
   Fig 3: Locating 53x57x20 mm Needle Bearing, 1st Gear, 5th Gear And 42.5 x 52.5 x 2.5 mm Thrust Washer

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5. Install the ball bearing (A) over the countershaft (B), then press it into place using the 40 mm I.D. driver handle and the press.
   Fig 4: Installing Ball Bearing Over Countershaft

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6. Secure the final drive gear part of the countershaft in a bench vise with wood blocks, install the old lock bolt (A), and tighten it to 125 N.m (12.7 kgf.m, 92 lbf.ft). The lock bolt has left-hand threads.
   NOTE: After this procedure, remove wood chips that may be stuck to the gear.
   Fig 5: Locating Final Drive Gear Lock Bolt

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7. Measure the clearance between the 5th gear collar (A) and the 42.5 mm thrust shim (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.

   Standard: 0.04-0.10 mm (0.002-0.003 in) 

   Fig 6: Measuring Clearance Between 5th Gear Collar And 42.5 mm Thrust Shim With Feeler Gauge (1 Of 2)

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   Fig 7: Measuring Clearance Between 5th Gear Collar And 42.5 mm Thrust Shim With Feeler Gauge (2 Of 2)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. If the clearance is out of the standard, remove the 42.5 mm thrust shim and measure its thickness.
9. Select and install a new 42.5 mm thrust shim, then recheck the clearance.

   THRUST SHIM, 42.5 mm 

   THRUST SHIM THICKNESS REFERENCE CHART
   
   

   No.	Thickness
   A	1.82 mm (0.0717 in)
   B	1.86 mm (0.0732 in)
   C	1.90 mm (0.0748 in)
   D	1.94 mm (0.0764 in)
   E	1.98 mm (0.0780 in)
   F	2.02 mm (0.0795 in)
   G	2.06 mm (0.0811 in)
   H	2.10 mm (0.0827 in)
   I	2.14 mm (0.0843 in)
   J	2.18 mm (0.0858 in)
   K	2.22 mm (0.0874 in)
   L	2.26 mm (0.0890 in)