2004-2008 models:

Fig 1: Exploded View Of Countershaft (2004-2008 Models) With Torque Specifications

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

• Driver handle 07746-0030100
• Attachment, 30 mm I.D. 07746-0030300
• Attachment, 35 mm I.D. 07746-0030400

1. Install the 44 x 50 x 28 mm needle bearing and 2nd gear.
2. Install the friction damper (A), the double cone synchro (B), and the synchro spring (C) as shown.
   Fig 2: Installing Friction Damper, Double Cone Synchro And Synchro Spring

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3. Install the 1st/2nd synchro hub (A) and the sleeve (B) as shown.
   Fig 3: Installing 1st/2nd Synchro Hub And Sleeve

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4. Install the synchro spring (A) and the double cone synchro (B) as shown.
   Fig 4: Installing Synchro Spring And Double Cone Synchro

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5. Install the friction damper (2000-2003 models) on 1st gear, then install 1st gear by aligning the grooves as shown.
   Fig 5: Installing 1st Gear (2000-2003 Models)

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6. Install the 51 x 57 x 23 mm needle bearing, distance collar, and 38 x 43 x 26 mm needle bearing.
7. Install the reverse gear.
   Fig 6: Installing Reverse Gear

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8. Install the synchro ring and synchro spring.
9. Install the reverse synchro hub (A) and the sleeve (B).
   Fig 7: Installing Reverse Synchro Hub And Sleeve

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10. Install the ball bearing (A) using the special tools and a press as shown.
    Fig 8: Installing Ball Bearing

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11. Securely clamp 4th and 5th gears in a bench vise with wood blocks (A).
    Fig 9: Installing Spring Washer And New 27 mm Locknut

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12. Install the spring washer (B) and the new 27 mm locknut (C).
13. Tighten the 27 mm locknut to the specified value.

    Torque: 162 --> 0 --> 162 N.m (16.5 --> 0 --> 16.5 kgf.m, 119 --> 0 --> 119 lbf.ft) 

14. Stake the locknut tab into the groove.
    Fig 10: Staking Locknut Tab Into Groove

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15. Install the needle bearing inner race (A) using the special tools and a press as shown.
    Fig 11: Installing Needle Bearing Inner Race

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16. Install the needle bearing.
    Fig 12: Installing Needle Bearing

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