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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: Pushing Mainshaft
    G06950737Courtesy 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: 0.06-0.21 mm (0.0024-0.0083 in) 

      Service Limit: 0.30 mm (0.0118 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: 27.02-27.07 mm (1.0638-1.0657 in) 

      Service Limit: 26.95 mm (1.0610 in) 

      Fig 2: Identifying 3rd Gear Thickness
      G06950738Courtesy 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: 0.28 mm (0.0110 in) 

      Fig 3: Measuring Clearance Between 4th Gear And 4th/5th Gear Distance Collar Using Dial Indicator
      G06950739Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Measure distance (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: 22.53-22.56 mm (0.8870-0.8882 in) 

      Fig 4: Identifying 4th/5th Gear Distance Collar Distance
      G06950740Courtesy 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: 25.52-25.57 mm (1.0047-1.0067 in) 

      Service Limit: 25.45 mm (1.0020 in) 

      Fig 5: Identifying 4th Gear Thickness
      G06950741Courtesy 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: 0.06-0.14 mm (0.0024-0.0055 in) 

      Service Limit: 0.23 mm (0.0091 in) 

      Fig 6: Measuring Clearance Between 4th/5th Gear Distance Collar And 5th Gear Using Dial Indicator
      G06950742Courtesy 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: 22.53-22.56 mm (0.8870-0.8882 in) 

      Fig 7: Identifying 4th/5th Gear Distance Collar Length
      G06950743Courtesy 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: 22.42-22.47 mm (0.8827-0.8846 in) 

      Service Limit: 22.35 mm (0.8799 in) 

      Fig 8: Identifying 5th Gear Thickness
      G06950744Courtesy 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: 0.06-0.16 mm (0.0024-0.0063 in) 

    Service Limit: 0.25 mm (0.0098 in) 

    Fig 9: Identifying Clearance Between 6th Gear And Angular Ball Bearing Inner Race
    G06950745Courtesy 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 not within the standard, go to step  12.

      Standard: 24.03-24.08 mm (0.9461-0.9480 in) 

      Fig 10: Identifying 6th Gear Distance Collar Length
      G06950746Courtesy 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: 23.92-23.97 mm (0.9417-0.9437 in) 

      Service Limit: 23.85 mm (0.9390 in) 

      Fig 11: Identifying 6th Gear Thickness
      G06950747Courtesy of AMERICAN HONDA MOTOR CO., INC.
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