Transmission Reassembly

NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and lubricate all contact surfaces.

Install the magnet (A), magnet set plate (B), differential assembly (C), and reverse lock cam (D).

Fig 1: Installing Magnet, Magnet Set Plate, Differential Assembly, And Reverse Lock Cam
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 36 mm spring washer (A) and 26 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer (A).

Fig 2: Installing Spring Washer And Washer Over Ball Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply tape to the mainshaft splines (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install them as an assembly.
Install the reverse idler gear (A) and reverse gear shaft (B).

Fig 3: Installing Reverse Idler Gear And Reverse Gear Shaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the reverse shift fork (A) and MBS cam holder (B).

Fig 4: Installing Reverse Shift Fork And MBS Cam Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see MANUAL TRANSMISSION ). Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).

Fig 5: Installing Oil Gutter Plate, Oil Guide Plate, And Shim Into Transmission Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove any dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent leakage.
NOTE: Do not install the components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.

Fig 6: Applying Liquid Gasket To Sealing Surface
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 14x20 mm dowel pins (A).

Fig 7: Installing Dowel Pins
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Lower the transmission housing the rest of the way as you expand the 52 mm snap ring (B). Release the snap ring so it seats in the groove of the countershaft bearing.
Make sure the 52 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 4.6 - 8.3 mm
1. (0.18-0.33 in.)
Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the 32 mm sealing cap (C), and install it on the transmission housing.
NOTE: Do not install the components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.
Install the transmission hanger (A) and the 8 mm flange bolts, finger-tight.

Fig 8: Installing Transmission Hanger And Flange Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
8 x 1.25 mm

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

Fig 9: Identifying Tightening Sequence Of Transmission Flange Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove any dirt and oil from the change lever assembly sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface.
NOTE: Do not install the components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.

Fig 10: Applying Liquid Gasket To Change Lever Assembly Sealing Surface
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 8x10 mm dowel pins (A) and change lever assembly (B).

Fig 11: Identifying Tightening Torque Of Change Lever Assembly Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the set screws, then install the set screws (A), springs, and steel balls.
NOTE: Do not install the components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.

Fig 12: Identifying Tightening Torque Of Set Screws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the back-up light switch (B) and neutral position switch (C). Install the switches.
NOTE: Do not install the components if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.
Install the drain plug (A), filler plug (B), O-ring (C), and vehicle speed sensor (VSS) (D).

Fig 13: Identifying Tightening Torque Of Drain Plug
Courtesy of AMERICAN HONDA MOTOR CO., INC.