Countershaft Idler Gear and 4th Gear Axial Clearance Inspection

WARNING: This page is about a different car, the 2013 Honda Odyssey, 2012 Honda Odyssey, and 2011 Honda Odyssey. However, it is still accessible from the selected car via links, so may be relevant.

Install the 40.5 mm cotters (A), 2nd gear (B), the thrust needle bearing (C), the needle bearing (D), the idler gear (E), the thrust needle bearing (F), the original thickness 61 mm washer (G), 1st gear (H), 4th gear (I), the 50.8 mm collar (J), the original thickness 50.8 mm washer (K), the 42.2 mm cotters (L), the cotter retainer (M), and the snap ring (N) on the countershaft (0). Install the 40.5 mm cotters, the idler gear, 1st gear, and 4th gear in the direction shown.

Fig 1: Identifying Cotters, 2nd Gear, Thrust Needle Bearing, Needle Bearing, Idler Gear, Thrust Needle Bearing, Washer And 1st Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Insert a feeler gauge (A) as thick as possible between the 50.8 mm collar (B) and the 50.8 mm washer (C).

Fig 2: Inserting Feeler Gauge Between Collar And Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Set a dial indicator (A) on the idler gear (B).

Fig 3: Setting Dial Indicator On Idler Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the idler gear axial clearance in at least three places while moving the idler gear. Use the average as the actual clearance.
Standard: 0.005-0.040 mm (0.00020-0.00157 in)

Fig 4: Measuring Idler Gear Axial Clearance
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the clearance is out of the standard, remove the 61 mm washer and measure its thickness.

Select and install a new washer, then recheck the clearance.

WASHER, 61 mm

WASHER THICKNESS SPECIFICATION

No.	Thickness
A	1.525 mm (0.06004 in)
B	1.505 mm (0.05925 in)
C	1.485 mm (0.05846 in)
D	1.465 mm (0.05768 in)
E	1.445 mm (0.05689 in)
F	1.425 mm (0.05610 in)
G	1.405 mm (0.05531 in)

Measure the clearance between the 50.8 mm collar (A) and the 50.8 mm washer (B) with the feeler gauge (C) in at least three places. Use the average as the actual clearance.
Standard: 0.005-0.040 mm (0.001-0.001 in) A B

Fig 5: Measuring Clearance Between Collar And Washer With Feeler Gauge
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the clearance is out of the standard, remove the 50.8 mm washer and measure its thickness.

Select and install a new washer, then recheck the clearance.

WASHER, 50.8 mm

WASHER THICKNESS SPECIFICATION

No.	Thickness
A	1.91 mm (0.0752 in)
B	1.93 mm (0.0760 in)
C	1.95 mm (0.0768 in)
D	1.97 mm (0.0776 in)
E	1.99 mm (0.0783 in)
F	2.01 mm (0.0791 in)
G	2.03 mm (0.0799 in)
H	2.05 mm (0.0807 in)
I	2.07 mm (0.0815 in)
J	2.09 mm (0.0823 in)
K	2.11 mm (0.0831 in)
L	2.13 mm (0.0839 in)
M	2.15 mm (0.0846 in)
N	2.17 mm (0.0854 in)
O	2.19 mm (0.0862 in)
P	2.21 mm (0.0870 in)
Q	2.23 mm (0.0878 in)
R	2.25 mm (0.0886 in)
S	2.27 mm (0.0894 in)
T	2.29 mm (0.0902 in)
U	2.31 mm (0.0909 in)
V	2.33 mm (0.0917 in)
W	2.35 mm (0.0925 in)
X	2.37 mm (0.0933 in)
Y	2.39 mm (0.0941 in)
Z	2.41 mm (0.0949 in)
AA	2.43 mm (0.0957 in)
AB	2.45 mm (0.0965 in)