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Home >> Honda >> 2021 >> HR-V EX-L, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1 (Manual Transaxle (M/T) - Testing & Troubleshooting) >> Repair Procedures, Tests >> Countershaft Disassembly, Reassembly, and Inspection(M/T) (2016 2017 2018) >> Reassembly

Countershaft Disassembly, Reassembly, and Inspection(M/T) (2016 2017 2018): Reassembly

WARNING: This page is about a different car, the 2018 Honda HR-V, 2017 Honda HR-V, and 2016 Honda HR-V. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:  Refer to the Exploded View as needed during this procedure.

  1. Countershaft - Reassemble
    GHH437171Courtesy of HONDA, U.S.A., INC.
    		 1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

    2. Install the countershaft reverse gear (A).

    3. Install the needle bearing (B).

    4. Install 1st gear (C).
    GHH437172Courtesy of HONDA, U.S.A., INC.
    		 5. Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro cone fingers (C) with the holes (D) in 1st gear.
    GHH437173Courtesy of HONDA, U.S.A., INC.
    		 6. Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.
    GHH437174Courtesy of HONDA, U.S.A., INC.
    		 7. Install the 1st/2nd synchro sleeve (A) by aligning the slots of the 1st/2nd synchro sleeve and the 1st/2nd synchro hub (B).

    NOTE:  Make sure to align the slots in the 1st/2nd synchro hub as shown.

    8. Check the operation of the 1st/2nd synchro hub set.
    GHH437175Courtesy of HONDA, U.S.A., INC.
    		 9. Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 1st/2nd synchro hub.
    GHH437176Courtesy of HONDA, U.S.A., INC.
    		 10. Install the 2nd gear distance collar (A) with the needle bearing (B).
    GHH437177Courtesy of HONDA, U.S.A., INC.
    		 11. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).
    GHH437178Courtesy of HONDA, U.S.A., INC.
    		 12. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 58 x 62 mm driver and a press (C).
    NOTE:  Do not exceed the maximum pressure.
    GHH437179Courtesy of HONDA, U.S.A., INC.
    		 13. Press on 4th gear (A) using the 58 x 62 mm driver and a press (B).
    NOTE:  Do not exceed the maximum pressure.
    GHH437180Courtesy of HONDA, U.S.A., INC.
    		 14. Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B).
    NOTE:  Do not exceed the maximum pressure.
    GHH437181Courtesy of HONDA, U.S.A., INC.
    		 15. Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B).
    NOTE:  Do not exceed the maximum pressure.
    GHH437182Courtesy of HONDA, U.S.A., INC.
    		 16. Install the 35 mm shim (A), and temporarily press on the used ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (C).
    NOTE: 
    • Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.
    • Make sure the ball bearing is installed in the correct direction.
    GHH437183Courtesy of HONDA, U.S.A., INC.
    		 17. Measure the clearance between the ball bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

    18. If the measured clearance in step 17 is not within the standard, select another suitable 35 mm shim from the table, then go to next step to replace the 35 mm shim and the ball bearing with new ones. If the measured clearance in step 17 is within the standard, go to the next step to replace only the ball bearing with a new one.

    35 mm Shim 

    19. Remove 6th gear with the ball bearing and the 35 mm shim using a press.

    20. Repeat step 15 to install 6th gear.
    Type  Thickness 
    A 0.87 mm (0.0343 in)
    AA 0.91 mm (0.0358 in)
    B 0.95 mm (0.0374 in)
    AB 0.99 mm (0.0390 in)
    C 1.03 mm (0.0406 in)
    AC 1.07 mm (0.0421 in)
    D 1.11 mm (0.0437 in)
    AD 1.15 mm (0.0453 in)
    E 1.19 mm (0.0469 in)
    AE 1.23 mm (0.0484 in)
    F 1.27 mm (0.0500 in)
    AF 1.31 mm (0.0516 in)
    G 1.35 mm (0.0532 in)
    AG 1.39 mm (0.0547 in)
    H 1.43 mm (0.0563 in)
    AH 1.47 mm (0.0579 in)
    J 1.51 mm (0.0594 in)
    AJ 1.55 mm (0.0610 in)
    K 1.59 mm (0.0626 in)
    AK 1.63 mm (0.0642 in)
    L 1.67 mm (0.0657 in)
    AL 1.71 mm (0.0673 in)
    M 1.75 mm (0.0689 in)
    AM 1.79 mm (0.0705 in)
    N 1.83 mm (0.0720 in)
    AN 1.87 mm (0.0736 in)
    P 1.91 mm (0.0752 in)
    AP 1.95 mm (0.0768 in)
    Q 1.99 mm (0.0783 in)
    Standard:  0.04-0.10 mm (0.0016-0.0039 in) 
    GHH437184Courtesy of HONDA, U.S.A., INC.
    		 21. Install the correct 35 mm shim (A) and a new ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (C).
    NOTE: 
    • If necessary, replace the 35 mm shim with the correct one selected in step 18.
    • Make sure the ball bearing is installed in the correct direction.

    22. Recheck the clearance between the ball bearing and the 35 mm shim with a feeler gauge.
    GHH437185Courtesy of HONDA, U.S.A., INC.
    		 23. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

    24. Tighten a new special bolt (B) (left-hand threads).

    NOTE:  Apply new MTF to the bolt threads and flange.
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