Transmission Reassembly
- Drive oil seal into clutch housing, set shift rod guide and install shift rod with detent hole up. Install boot so that hole faces downward when transmission is mounted on vehicle. Grease and install steel detent ball and spring; tighten spring retaining bolt to 16 ft. lbs. (22 N.m). Install bolt and washer holding change piece. Tighten change piece bolt to 22 ft. lbs. (30 N.m).
- Install differential assembly in clutch housing. Install thrust shim and snap ring. Install transmission housing. Install and torque housing bolts. Ensure differential assembly is bottomed in housing. Measure clearance between thrust shim and outer race in housing. Maximum clearance is .00394" (.10 mm). If not within limits, select proper shim from DIFFERENTIAL THRUST SHIM THICKNESS
table.DIFFERENTIAL THRUST SHIM THICKNESS
Part Number Thickness 41441-PL3-B00 .03937" (1.0 mm) 41442-PL3-B00 .04331" (1.1 mm) 41443-PL3-B00 .04724" (1.2 mm) 41444-PL3-B00 .05118" (1.3 mm) 41446-PL3-B00 .05512" (1.4 mm) 41447-PL3-B00 .05906" (1.5 mm) 41447-PL3-B00 .06229" (1.6 mm) 41448-PL3-B00 .06693" (1.7 mm) 41449-PL3-B00 .06693" (1.8 mm) 41450-PL3-B00 .04134" (1.05 mm) 41451-PL3-B00 .04528" (1.15 mm) 41452-PL3-B00 .04921" (1.25 mm) 41453-PL3-B00 .05315" (1.35 mm) 41454-PL3-B00 .05709" (1.45 mm) 41455-PL3-B00 .06102" (1.55 mm) 41456-PL3-B00 .06496" (1.65 mm) 41457-PL3-B00 .06890" (1.75 mm) - Disassemble case once correct shim is installed. Insert spring washer and thrust washer with angle against clutch housing. Tape mainshaft splines before installation, then insert mainshaft and countershaft into shift forks and install them as an assembly.
- Install change holder assembly in clutch housing. Tighten bottom right side 6-mm bolt to 11 ft. lbs. (15 N.m). Tighten 2 remaining 6-mm bolts to 106 INCH lbs. (12 N.m). Assemble shift piece and interlock and insert shift guide shaft.
- Measure distance from top of shift piece shaft to top of interlock after mounting shift guide shaft. Clearance should be .468-.484" (11.90-12.30 mm). If clearance is not correct, check installation. Install reverse idler gear and idler gear shaft in clutch housing. Install reverse shift fork in clutch housing. Install oil guide plate and 72- mm thrust shim into housing.
- Install oil gutter plate and 16-mm sealing bolt. Install mainshaft thrust shim into transmission housing. Use mainshaft thrust shim selected during mainshaft reassembly.NOTE: This transmission uses no gaskets between major housings; use Honda Genuine Liquid Gasket (08178-550000-OE). Assemble housing within 20 minutes after applying liquid gasket. Allow 30 minutes curing time before filling with oil.
- Apply liquid gasket to transmission mating surface of clutch housing. Install dowel pins on clutch housing; place transmission housing over clutch housing, ensuring shafts are aligned.
- Lower transmission housing with snap ring expanded and set snap ring in groove of countershaft bearing. Ensure snap ring is securely seated in groove of countershaft bearing. Snap ring opening clearance should be .180-.327" (4.57-8.30 mm).
- Place transmission hanger between bolts No. 11 and 15. Tighten transmission housing bolts to 21 ft. lbs. (28 N.m) in sequence. See Fig 1 .
- Apply liquid gasket to 32-mm bolt threads. Tighten sealing bolt to 18 ft. lbs. (25 N.m). Install and tighten reverse idler gear shaft bolt. Install clutch cable bracket and tighten bolt to 16 ft. lbs. (22 N.m). Install back-up light switch and tighten bolt to 18 ft. lbs. (25 N.m). Install harness and harness clamp; tighten bolt to 106 INCH lbs. (12 N.m).