Manual Transmission Disassembly and Reassembly (M/T) (2016 2017 2018): Reassembly

NOTE: 

• Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
• Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Differential Assembly and Magnet - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Install the differential assembly (A). 2. Install the magnet (B). NOTE: Clean the magnet anytime the transmission is disassembled.

2. Mainshaft, Countershaft, and Shift Fork Assembly - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Install the 64 mm spring washer (A). NOTE: Be sure to install the spring washer in the direction shown. 2. Apply a thin layer of tape to the mainshaft splines (B) to protect the oil seal. NOTE: Do not apply too much tape as it will damage the oil seal. 3. Install the mainshaft and the countershaft (C) with the shift fork assembly (D) as an assembly.

3. Shift Piece - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Set the shift piece shaft (A), the shift piece (B), the interlock (C) the select return spring (D), the shift piece collar (E), and the 8 x 50 mm pin (F) as shown.

4. Reverse Idler Gear Shaft Assembly - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Assemble the reverse idler gear shaft assembly (A) and the reverse shift fork (B). 2. Install the 33 mm spring washer (C). NOTE: Be sure to install the spring washer in the direction shown.

   Courtesy of HONDA, U.S.A., INC.

   3. Slide the reverse idler gear shaft assembly (A) on the rib (B) of the clutch housing, then install it into the hole (C) of the clutch housing.

   Courtesy of HONDA, U.S.A., INC.

   4. Align the mark (A) on the clutch housing with the reverse gear holder hole (B).

5. Baffle Plate - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Install the baffle plate (A).

6. Reverse Shift Holder - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Install the reverse shift holder (A).

7. Oil Gutter Plate B - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Install oil gutter plate B.

8. Oil Guide Plate M, 72 mm Shim, and Oil Gutter Plate A - Install

   Courtesy of HONDA, U.S.A., INC.

   1. Select the proper size 72 mm shim (B) according to the measurements made during the Mainshaft Thrust Clearance Adjustment 2. Install oil guide plate M and the 72 mm shim. 3. Install oil gutter plate A.

9. Oil Guide Plate C - Install

   Courtesy of HONDA, U.S.A., INC.

   1. While expanding the 72 mm snap ring (A) using the snap ring pliers, install oil guide plate C.

10. Transmission Housing - Install

    Courtesy of HONDA, U.S.A., INC.

    1. Clean any dirt and oil from the sealing surface of the transmission housing and the clutch housing. 2. Apply liquid gasket (P/N 08C70- K0334M) evenly to the clutch housing mating surface of the transmission housing. Install the component within 4 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

    Courtesy of HONDA, U.S.A., INC.

    3. Install the 14 x 20 mm dowel pins (A). 4. Place the transmission housing on the clutch housing, making sure to line up the shafts. NOTE: When installing the transmission housing to the clutch housing, push the 72 mm snap ring (B) towards the direction pointed by the arrow shown in the picture to make sure to place the 72 mm snap ring properly without holding it between the transmission housing and the countershaft ball bearing.

    Courtesy of HONDA, U.S.A., INC.

    5. While expanding the 72 mm snap ring (A) on the countershaft ball bearing using the snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the snap ring groove of the countershaft ball bearing.

    Courtesy of HONDA, U.S.A., INC.

    6. Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing. Dimension  as installed:

    3.3-6.0 mm (0.130-0.236 in)

    Courtesy of HONDA, U.S.A., INC.

    7. Make sure oil guide plate C is positioned on the transmission housing as shown.

    Courtesy of HONDA, U.S.A., INC.

    8. Clean any dirt and oil from the sealing surface of the 32 mm sealing cap (A) and the transmission housing. 9. Apply liquid gasket (P/N 08C70- K0334M) evenly to the threads of the 32 mm sealing cap. Install the component within 5 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

    Courtesy of HONDA, U.S.A., INC.

    10. Install the 8 mm flange bolts finger-tight with the clutch line bracket (A).

    Fig 1: Tightening Flange Bolts In Crisscross Pattern In Serveral Steps

    Courtesy of HONDA, U.S.A., INC.

    11. Tighten the 8 mm flange bolts in a crisscross pattern in several steps. Specified Torque:

    27 N.m (2.8 kgf.m, 20 lbf.ft)

    Courtesy of HONDA, U.S.A., INC.

    12. Install the drain plug (A) with a new 20 mm sealing washer (B).

    Courtesy of HONDA, U.S.A., INC.

    13. Install the 8 mm flange bolt (A) with a new 8 mm packing (B) finger-tight.

    Courtesy of HONDA, U.S.A., INC.

    14. Apply liquid gasket (P/N 08C70- K0334M) to the thread of the detent bolt (A). Install the component within 5 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. 15. Install the steel ball (B), the 26.0 mm detent ball spring (C), and the detent bolt. 16. Install the oil check bolt (D) with a new 6 mm sealing washer (E) finger-tight.

    Courtesy of HONDA, U.S.A., INC.

    17. Apply MTF to a new O-ring (A). 18. Install the output shaft (countershaft) speed sensor (B), the plain washer (C), and the O-ring.

    Courtesy of HONDA, U.S.A., INC.

    19. Clean any dirt and oil from the sealing surface of the back-up light switch (A) and the transmission housing. 20. Apply liquid gasket (P/N 08C70- K0334M) to the threads of the back-up light switch. Install the back-up light switch within 4 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

    Courtesy of HONDA, U.S.A., INC.

    21. Apply liquid gasket (P/N 08C70- K0334M) to the thread of the detent bolts (A). Install the component within 4 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. 22. Install the steel balls (B), the 26.0 mm detent ball springs (C), and the detent bolts. 23. Install the filler plug (D) finger-tight.

    Courtesy of HONDA, U.S.A., INC.

    24. Clean any dirt and oil from the sealing surface of the change lever assembly and the transmission housing. 25. Apply liquid gasket (P/N 08C70- K0334M) evenly to the transmission housing mating surface of the change lever assembly. Install the component within 4 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

    Courtesy of HONDA, U.S.A., INC.

    26. Install the 8 x 10 mm dowel pins (A) and the change lever assembly (B).

    Courtesy of HONDA, U.S.A., INC.

    27. Apply liquid gasket (P/N 08C70- K0334M) to the thread of the detent bolts (A). Install the component within 5 minutes of applying the liquid gasket. NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket. 28. Install the steel balls (B), the 26.0 mm detent ball spring (C), the 23.4 mm detent ball spring (D), and the detent bolts.

    Courtesy of HONDA, U.S.A., INC.

    29. Check the position of the breather cap mark (A) as shown. 30. Check that the transmission shifts into all gears smoothly.

    Courtesy of HONDA, U.S.A., INC.

    31. Install the neutral position sensor (A) and a new O-ring (B). 32. Install the release bearing and the release fork.(Refer to "Release Bearing and the Release Fork - Install " in "Clutch Removal and Installation.")