Intermediary Shaft 3rd Gear Axial Clearance Inspection

Special Tools Required 

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

1. Install the 3rd clutch (A), the original thickness 53 mm splined washer (B), the 30 x 52 x 3 mm thrust needle bearing (C), the needle bearing (D), the intermediary shaft 3rd gear (E), and the 30 x 52 x 3 mm thrust needle bearing (F) on the intermediary shaft (G). Do not install the O-rings during inspection.
   Fig 1: Identifying Intermediary Shaft 3rd Gear Components

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
   Fig 2: Installing Intermediary Shaft 4th Gear Using 40 I.D. Driver Handle And Press

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Install the intermediary shaft 4th gear (H) using the 40 mm I.D. driver handle and a press.
3. Install the cotters (I), the cotter retainer (J), and the snap ring (K).
4. Set a dial indicator (A) on the intermediary shaft 3rd gear (B).
   Fig 3: Setting Dial Indicator On Intermediary Shaft 3rd Gear

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Measure the intermediary shaft 3rd gear axial clearance in at least three places while moving the intermediary shaft 3rd gear. Use the average as the actual clearance.

   Standard: 0.005-0.045 mm (0.00020-0.00177 in) 

   Fig 4: Measuring Intermediary Shaft 3rd Gear Axial Clearance

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. If the clearance is out of the standard, remove the 53 mm splined washer and measure its thickness.
7. Select and install a new 53 mm splined washer, then recheck the clearance.

   SPLINED WASHER, 53 mm 

   SPLINED WASHER THICKNESS SPECIFICATION
   
   

   No.	Thickness
   A	3.995 mm (0.15728 in)
   B	4.015 mm (0.15807 in)
   C	4.035 mm (0.15886 in)
   D	4.055 mm (0.15965 in)
   HI	4.075 mm (0.16043 in)
   F	4.095 mm (0.16122 in)
   G	4.115 mm (0.16201 in)
   H	4.135 mm (0.16279 in)
   I	4.155 mm (0.16358 in)
   J	4.175 mm (0.16437 in)
   K	4.195 mm (0.16516 in)
   L	4.215 mm (0.16594 in)
   M	4.235 mm (0.16673 in)
   N	4.255 mm (0.16752 in)