SHOP MANUAL 131 (4WD) MANUAL (AWD) «on MAINTENANCE AND REPAIR CRD ele kee teINTRODUCTION [— How to Use This Manual This manual contains information regarding repair procedures for the L3 (AWD) type of Manual Transmission. For information regard: ing installation and removal of the transmission, and the shift ‘mechanism, please consult the Chassis maintenance and repair ‘manual for the vehicle concerned, This manual is divided into 3 sections. The first page of each sec: tion is numbered with a black tab that lines up with one of the thumb index tabs on this page. You can quickly find the first page of each section without looking through a full table of contents. Each section includes: 1. A table of contents, or an exploded view index showing © Parts disassembly sequence. © Bolt torques and thread sizes @ Page references to descriptions in text. 2, Disassembly/assembly procedures and tools. 3. Inspection, 4, Repair. 5. Adjustments. -— Special Information Indicates a strong possibilty of severe personal injury (F 1088 of life if instructions are not followed, CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE: Gives helpful infarmation. CAUTION: Detailed descriptions of standard workshop proce: dures, safety principles and service operations ate not included Please note that this manual does contain warnings and cautions against some specific service methods which could cause PER- SONAL INJURY. or could damage a vehicle or make it unsafe. Please understand that these warnings cannat cover all conceivable ways in which service, whether or not recommended by Honda Motor, might be done, or of the possible hazardous consequences ach conceivable way, nor could Honda Motor investigate all such ways. Anyone using service procedutes or tools, whether or hot recommended by Honda Motor, must satisfy himself thorough Jy that neither personal safety nor vehicle safety willbe jeopardized. Ail information contained in this manual is based on the latest pro: duct information available at the time of printing. We reserve the rigtht to make changes at any time without notice. No part of this, Publication may be reproduced, stored in retrieval system, or trans. mitted, in any form by any means, electronic, mechanical, photoco. ying. recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. HONDA MOTOR CO., LTD. Service Publication Office First Edition 2/88 100 pages All Rights Reserved | General Information L Seereetias a I —— | Transmission overhaul [fF DifferentialGeneral Information Preparation of Work . Symbol Marks ...General Information Preparation of Work Work safely and give your work your undivided at- tention. Exchange signals as frequently as possible when 2 work involves two or more workers. Prior to removing or disassembling parts, they must, be inspected carefully to isolate the cause for which the service is called for. Observe all safety notes and precautions ang follow the proper pro- cedures as described in this manual. + Mark of place sll removed parts in order in a parts rack so they can be placed back to their Criginal places or parts from which they were removed or with which they were mated. + Check each part for distortion, cracks, scraches, fr other damages whenever it is removed. EP Use special tool when use of such tool is specified, or you may damage the parts or get injured. SPECIAL TOOL Parts must be assembled with the proper looseness or tightness according to the maintenance stan- dards established When tightening bolts or nuts, begin on center or large diameter bolts and tighten them in crisscross pattern in two or more steps if necessary, Use new Oxings and cotter pins whenever reassembling NOTE: This transmission uses no gaskets between the major housings: use Honda Genuine Liquid Sealant [Three Bond® 1216}. Assemble the housings within 20 minutes after applying the sealant and allow into cure for at least 30 minutes after assembly before filing it with oil Use genuine HONDA parts and lubricants or those equivalent, When parts are to be reused, they must, be inspected caretully to make sure they are not damaged or deteriorated and in good usable condition Coat of fil parts with specified grease. Clean all removed parts ino with salvent upon disassembly. 1-2Symbol Marks The following symbols stand for: TR: rot enn ot SEE = Aonly orease 1-3Transmission Overhaul Service Specifications. Special Tools 22 25 Mlustrated Index. 26 Shift Arm Cover Replacement. 240 Disassembl Reassembly Transfer Inspection Driven Gear Backlash... Gear Tooth Contact Transfer Drive Gear/Driven Gear Assembly Removal... [Link] Cover Race Replacement Transfer Driven Gear Disassembl Driven Gear Pre-load Adjustment. Thrust Shim Selection . Driven Gear Reassembly DriveniDrive Gear Reassembl Transmission Housing Removal Reverse Shift Fork/5th—Reverse Shift Piece Clearance Inspection..... Reverse Idler GeariReverse Shift Fork Clearance Inspection Mainshaft/Countershaft Removal Transfer Shaft Replacement Differential Oil Seal Removal Transfer Shaft Needle Bearing Replacement ‘Transfer Shaft Taper Bearing Replacement... Mainshaft Bearing/Oil Seal Replacement... Countershaft Bearing Replacement... Super-low 2 Shaft Bearing Replacement... Mainshatt Disassembly .. Countershaft Disassembly .... Synchro Ring and Gear Inspection Mainshatt/Countershatt Inspection Countershaft Clearance Inspection Mainshaft Clearance Inspection .. Mainshaft Thrust Shim Adjustment. Super-low 2 Shaft Thrust Shim Adjustment .. Transmission Reassembly ..Service Specifications Units mm {in.) PART MEASUREMENT SERVICE LIMIT ‘Transmission oil Capacity €(US. qt., Imp. at) STANDARD (NEW) 2.4 (25, 2.1) at assembly 2.3 (24, 2.0) at oll change End play Mainshaft (0,080.16 (0.003—-0.006) ‘Aajust with a shim Diameter of needle bearing | ‘contact area 27,987 — 28.000 (1.1018 ~ 1.1024) | 27.99 (1.100) Diameter of 3rd gear contact | area 34.984 — 36,000 (1.73 ~ 1.3780) | 34.89 11.375) Diameter of 63/28C ball bearing contact area 27.977 -27.990 (1.1018 1.1020) | 27.82 (1.098) Diameter of 6306/25 ball bearing contact area 24,987 ~ 25,000 (0.9837 —0.9843) | 24.99 (0.981 Runout 0.02 (0.001) max. 0.08 (0.002) Mainshatt 3rd gear | 1. “40,009 — 40.026 (1.6752 — 1.6758) | 40.07 (1.578) End play (0,060.21 (0.002 0.008) | 0.3 (0.00 | Thickness 32.42-32.47 (1.276~1.278) __| 32.3 (1.271 Mainshaft 4th gear | 1.0. | 40,009 — 40,025 (1.8762 — 1.5788) | 40.07 (1.578) End play 0.08-0.21 (0.002-0.008) 03 (0.011 Thickness 30,92~30.97 (1.217- 1.219) 30.8 (1.21), Mainshatt 6th gear | 1D. ‘40,009 — 40.025 (1.6752 1.8758) | 40.07 (1.578) End play 0.06- 0.21 (0.002 0.008) 0.3 0.01) Thickness 30.42~30.47 [1.198 ~ 1.200) 30.3 (1.19) ‘Countershaft End play (0,080.30 (0.002 0.012) 0.5 (0.02) ] Diameter of needle bearing ‘contact area | 29.000 -29.016 (1.1417 - 1.1423) | 28.94 (7.139) Diameter of ball bearing | ‘contact area 24,987 ~ 25.000 (0.9837 ~0.9843) | 24.98 (0.981) Diameter of super-ow 3 gear contact area 20,464 30,480 (1.1984— 1.2000) | 90.41 (1.197 Runout 0.02 (0.001) max. 0.08 (0.002) Countershatt 10. {50,009 ~ 60,026 (1.9689 1.96961 | 60.07 (1.971) low gear End play 0.03 0.08 (0.001 - 0.008) (0.18 (0,007) Adjust with a shim) Thickness 32.95 ~ 33.00 (1.297 ~ 1.299) 32.83 (1.293) [ Countershafe 1D. $50,009 60.026 (1.989- 1.9696) | 50.07 (1.971) 2nd gear | End play (0,080.10 (0.001 - 0.004) 0.18 (0.007)(Adjust with collar) Thickness 32,92—32.97 (1.296 ~ 1.298) 32.8 (1.291 Mainshaft 4th gear | 1.D. 28.002 28,012 (1.1024~ 1.1028) | 28.06 (1.105) & 6th gear distance | 0.D, $34,989 — 35,000 (1.3775 ~ 1.3780) | 34.98 (1.375) collar Length | 26.03 - 26.08 {1.025 - 1.027) 26.01 (1.024), Countershaft 2nd | 1.0. 36.48 ~ 36.49 (1.436 — 1.437) 36.54 (1.439) ‘gear distance 00. 443.989 ~ 44,000 (1.7318 1.7323) | 43.98 (1.7301 collar Length 28.96 ~ 29.40 (1.140~ 1.1871 Saleot with 6 type collar Reverse idle gear | LD. 20,016 20.043 (0.7680 0.7890) | 20.08 (0.781) Gear to shaft clearance 0,036 - 0.084 (0.0014 ~0,0033) _| 0.14 (0.006), ‘Superlow 1 shaft | Distance of needle bearing | contact area | 23,994 ~23.993 (0.9443.-0.9446) | 23.99 (0.942), ‘Superlow 1 gear | 1.0. 20.000 30.013 (7.1811 ~ 1.1816) | 29.98 (7.179) Thickness 62.95~63.00 (2.478- 2.480) | 62.883 (2.474) ‘Superlow 2 shatt | Diameter of needle bearing contact area 22.987 ~ 23.000 (0.9050 0.9055) | 22.93 (0.903) | End play 0,070.20 (0.003 -0.008) ‘Adjust with a shim, Diameter of ball bearing | contact area 62/28 | 27.987 28.000 (1.1018-1.1024) | 27.99 (1.100) 620aU | 18.987 -20.000 (0.7a69-0.7874) | 19.99 (0.785) Runout 0.02 (0.001) max. 0.08 (9.002) 2-2Unit: mm (in) PART MEASUREMENT ‘STANDARD (NEW) SERVICE LIMIT Superlow 2 gear | 1.0, {37.009 -37.025 (1.4570 — 1.4877) | 37.07 (1.458) End pley 0.03 0.16 (0.001 ~ 0.006) 0.24 (0.008) Thickness 34.42~34.47 (1,355~ 1.357) 34.3 (1.35) Superlow 3 gear | Diemeter of needle bearing contact area 43.984 — 44.000 (1.7318 ~ 1.7323) | 49.99 (1.730) Width of needie bearing contact area 31,08—31.08 (1.222~1.224) 31.01 (1.221) Super-low 2 gear | 1.D. 23.000 23.013 (0.9085 0.9060) | 23.06 (0.908) distance collar o.. 31.989 ~32.000 (1.2694 - 1.2598) | 31.98 (1.257) Width 31,00 ~31.03 (1,220- 1.222) 30.98 (1.220), ‘Transfer shaft Diameter of needle bearing | contact area 27.987 ~28.000 (1.1018 1.1024) | 27.93 (1.100) Diameter of taper bearing contact area 16.989 ~ 17,000 (0.6689 0.6693) | 16.98 (0.667) Width of transfer driven bevel gear contact area 48.01 ~ 45.05 (1.721.774) 48.17 (1.778) Diameter of drive bevel gear contact area 36.002-36.018 (1.3760- 1.3787) | 34.96 (1.376) Punout 0.02 (0.001) max. | 0.05 (0.002) Transfer driven | 1.0. ‘34,008 - 34.025 (1.3389.~ 1.3396) | 34.07 (1.341) gear Diameter of needle bearing contact area 54,000 — 54,015 (2.1260~2.1266) | 53.94 (2.124) End play 0.04~ 0.13 (0.002 ~ 0.006) 0.21 (0.008) Thickness 44.92 ~ 44.97 (1.690~ 1.770) 44.8 (1.76) Transfor drive 1D. '25,000— 25,021 (0.9843 — 0.9851) | 25.06 (0.987) bevel gear Diameter of taper bearing | contact area 35.002 -36.018 (1,3780~1.3787)_| 34.96 (1.376) Transfer driven Backlash 0.10-0.45 (0.040.006) ‘Adjust with a shim, bevel gear Diameter of taper bearing contact area 32007 | 36.002 -35.018 (1.3780 ~ 1.9787) | 34.95 (1.376) 320/28__| 27.987 28.000 (1.1018 1.1024) | 27.99 (1.100) Blocking ring Ring-to-gear clearance (0.85 — 1.10 (0.083 — 0,043) 0.4 (0.02) ‘Ist/2nd shit fork & | Synchronizer sleeve groove ‘3rd/4th shift fork width 7.95 -8.05 (0.313 -0.317) - Shift fork-to-synchronizer sleeve clearance —Thrust_—_| 0.45—0.65 (0.018 -0,026) 1.0 (0.08) Radiat —_| 0,050.48 (0.002 0.018), 0.8 (0.08) Fork shattto-shift fork clearance | 0,040-0.138 (0,0016 0.0054) | — ‘th shift fork ‘Synchronizer sleeve groove width | §.78~6.85 (0,226—0.230) = Shift fork-to-synchronizer sleeve clearance Thrust | 0,250.45 (0.010-0.018) 0.8 (0.03) Radial —_ | 0.05~0.45 (0.002 ~0.018) 0.8 (0.03) Fork shaft-to-shift fork clearance Sth/Reverse shift fork shaft | 0.005—-0.070 10.0002~0.0028) | — ‘st/2nd shift fork shaft 0.440 ~0.670 (0.0173-0,0264) | — Reverse shift fork | Claw thickness 13.0- 133 (0.51 —0.62) = Shift fork-to-revorse idle gear clearance 0.5~ 1.1 (0.02—-0.04) 1.8 10.07) Loroove width 7.05~ 7.25 (0.278 -0.285) - Shift fork-to-5th/ Reverse shift piece clearance 0.05 ~ 0.25 (0.002—-0.014) 0.5 (0.02) | Shift arm & Diameter of shift piece contact | area 128-130 (0.508~0.512) = Shift arm-to-shift plece clearance 0.2-0.5 (0.01-0,02) 0.7 (0.03) Lo. 16,000 ~ 16.068 (0.6299 0.6926) | — L | Shift arm-to-shatt clearance 0.011 ~ 0.082 (0,0004~ 0.0036)Service Specifications Units mm (ind PART MEASUREMENT STANDARD (NEW) SERVICE LIMIT ‘Shift arm Diameter of shift arm A contact, area 11,9 12.0 (0.489-0.472) a Shift arm-to-shift arm A clearance 0.05 ~ 0.25 {0.002~-0.010) 0.5 (0.02), Select arm Diameter of shift arm A contact, area 7.95 ~8.00 (0.313-0.315) - Select arm-to-shift arm A clearance 0.10-0.25 (0.004—-0.0101 0.5 (0.02) Superlow shift | Synchronizer sleeve groove fork wicth 8,756.85 (0.226 -0.230) - Shift fork-to-synchronizer sleeve clearance Thrust | 0.25-0.45 (0.010.018) 0.8 (0.03), Radial —_| 0.05~0.45 (0.020.018) 0.8 (0.03), a Superlow shift | Shift plece-to-fork shaft piece A clearance 0.040 0.138 (0.0016 --0.0054) Diameter of super-low shift lever contact area 10.1 10.2 (0.398 -0.402) - Shift piece-to-super-low shift lever clearance 0.1-0.3 (0.004 ~0.012) - ‘Superlow shift | Diameter of super-iow shift lover piece 8 contact area 79-80 (0311-0318) - Shift piece-to-super-tow shift lever clearance 0.05 0.25 (0.002 0.010) 0.5 (0.02) Disengagement | Sleeve groove width 8.45 8.55 (0.383 0.537) = fork Fork-to-sleeve clearance Thrust | 0.45~0.65 (0.018—-0.0261 1.0 (0.08) Redial | 0.21.1 (0.01-0.04) 1.5 (0.06)Special Tools eee Gee O7JAC—PHEOT00 o7JAc—PHE0200 o7741—0010201 Bearing Remover Attachment Remover Handle Remover Weight No. Tool Number | Description Remarks oO 07746—0010500 Attachment, 62x68mm @ 077490010000 Driver (073496110000 may also be used. ® 97926—-SD30000 ‘Companion Flange Holder ® 079076010300 Socket Wrench Handle © 07746—0010400 Attachment, 52x55mm_ ® (07JAJ—PH80200 Driven Gear Dummy Shaft @ 07JAJ—PH80100 Drive Gear Gauge ® 07746—0030100 Driver C © 07746—0030400 Attachment, 36mm, @ 07948—sc20200 il Seal Driver © 07860—1870100 Spring Compressor Attachment ® 07746—0010200 Attachment, 37%40mm, @ 07746—0010600 Attachment, 72x75mm 8 07836—8890101 Bearing Remover Set ® 07746—0010300 Attachment, 42x47mm @ 079476110500 Oil Seal Driver Attachment ® 07947—SD90100 il Seal Driver Attachment ®@ 07979—PJ40000 Magnet Base Stand ® 07GAJ—PG20101 Mainshaft Clearance Inspection Tool ® 07JAC—PH80000 Adjustable Bearing Remover SetIllustrated Index (ore: ‘Clean all parts thoroughly in solvent and dry with compressed air. © Lubricate all parts with oll before reassert bly. & Replece Replace @ Replace Replace. 9 Replace.12 Nem (12g, OT TORQUE VALUES Free — Gov Bol PAZ Nem B: Gm Special Bolt 18 Nem (1.8 kg-m, 11 loo] c: 8mm Bolt 0:10mm Bok ‘TRANSMISSION HOUSING Removal, page 229 Installation, page 262 © 18 mm SEALING BOLT 35 Nem (8.6 kg-m, 25 lb-ft} @ 32 mm SEALING BOLT 70 Nem (7.0 kg-m, 51 Ib) © 14 mm DRAIN PLUG 40 Nom (4.0 kg-rs, 29 t-t) © SEALING WASHER @ DIFFERENTIAL OIL SEAL Removal, page 224 Installation, page 269, © OW FitLeR BOLT 45 Nem (4.5 kg-m, 23 bt) DETENT BALL. @ SPRING @ SEALING WASHER DETENT SCREW 22 Nem (2.2 kg-m, 16 tb-t) (@ SEALING WASHER 26 Nem (2.6 kg-m, 19 Ib-f) 45 Nem (4.8 ka-m, 32 bt) | (@ SUPER-LOW SHIFT LEVER BOLT 440 Nem (4.0 kg-m, 29 BH) ® vowel PIN ( REVERSE IDLER SHAFT BOLT 155 Nem (5.5 kg-m, 40 I-A) @ sour 40 Nem (4.0 kg-m, 29 Ib-t) ® Washer @ TRANSMISSION HANGER ® CLUTCH CABLE BRACKET @ OWL COLLECT PLATE 4) OIL GUTTER PLATE @® INTERLOCK @ SHIFT ARM A, @ SUPER-LOW SELECT RETAINER, @® SUPER-LOW RETURN SPRING @ SELECT RETURN PIN @ SELECT RETURN SPRIND @® SPRING PIN 6.0mm, dp SELECT ARM @ REVERSE LOCK CAM ® SHIFT ARM ® 18 mmPLus @ SHIFT ARM SHAFT @ BACK-UP LIGHT SwiTcH 25 Nem (2.6 kg-m, 18 bf) SEALING WASHER @ DETENT SCREW 22 Nem (2.2 kg-m, 16 bf) @ SEALING WASHER @ SPRING @ DETENT BALLS @ SHIFT ARM CoveR @ INTERLOCK BOLT 40 Nem (4.0 kgm, 29 tot) @ DETENT screw 22 Nem (2.2 kg-m, 16 lost) © SEALING WASHER @ BLEATHAR TUBE @ SHIFT LEVER @ SELECT LEVER © OW SEALsIllustrated Index 2-8NOTE: Remove and clean the magnet (i whenever the transmission is disassembled (ror vars IC: Bmm Bot 26 Nem [Ar 6mm Bok 12 Nem (1.2 kgm, BA B: Gmm Special bolt A | 15 Nem (1.5 kg-m, 11 lb-ft) (2.6 ko-m. 19 b-f}) (4.8 kom, 33 tot) 1D: 10mm Bott 45 Nem E: 6mm Special bolt 8 | 17 Nem (1.7 kg-m, 12 lb-ft) SPRING PIN (@ te/2nd SHIFT FORK SHAFT @ SUPER-LOW SHIFT PIECE (© tee/and SHIFT FORK. Remove, page 29 instalation. page 25% @ SNAP RING Selection, pape 38 (Flom ovrFenemit assewaLy G SNAP RING 8 LOcKNUT 110» 0+ 140N-m (11.0 +0 =11.0 kgm, 80-0 BOIb-) > SPRING WASHER BALL BEARING 5m GEAR 2 4m GEAR 5a GEAR © 2nd GEAR, @ FRICTION DampEn @ DISTANCE CoLLAR Selection, nage 2-41 NEEDLE BEARING @ SYNCHRO RING SYNCHRO SPRING 1 REVERSE GEAR 4 SYNCHRO HUE O ietceaR @ THRUST WASHER Selection, page 24° [Link] ard GEAR (® COUNTERSHAFT 1 NEEDLE BEARING (8 O1L cuiDe Pare (8 BEARING OUTER RACE (8 TAPER ROLLER BEARING iwneR NEEDLE BEARING @ TRANSFER SHAFT fh TRANSFER ORIVEN GEAR 3 NEEDLE BEARING Replacement, page 234 (© SUPER-LOW Sit LEVER 8 [Link] SHIFT © SPRING PIN (8 SUPER-LOW SHIFT FORK SHAFT @ Lock wasHeR 4 SUPER-LOW SHIFT FoRK 4 THRUST SHIM Selection, pege 248 @ BALL BEARING 4 DISTANCE COLLAR, NEEDLE BEARING 4 FRICTION DAMPER © SUPER-LOW 2 GEAR © SYNCHRO RING | SYNCHRO SPRING { SYNCHRO SLEEVE SYNCHRO HUB © SUPER-LOW 2 SHAFT f BALL BEARING f THRUST WASHER (@ THRUST NEEOLE BEARING © SUPER-LOW 1 GEAR ( NEEDLE BEARING {DISTANCE COLLAR, THRUST WASHER @ SPRING WASHER 4 DISTANCE COLLAR SPRING PIN @ suPeR-tow 1sHart 1G SeVREVERSE SHIFT FORK SHAFT © bh SHIFT FORK © 2rd-ath SHIFT FORK it BOVREVERSE SHIFT PIECE @ LOCK WasHER © Ol GUIDE PLATE fo THRUST SHIM Selection, page 245 @ BALL SEARING (© SYNCHRO SLEEVE © SYNCHRO HUB SYNCHRO SPRING @ SYNCHRO RING @ sm Gear © NEEDLE BEARING © SPACER COLLAR 9 aun GEAR SYNCHRO RING (@ SYNCHRO SPRING © SYNCHRO SLEEVE © SYNCHRO HUB 3 GEAR 6 MAINSHAFT Inspection, page 240, 18 SPRING WasHeR 19 BALL BEARING OWL seaL © MAGNET (@ REVERSE IDLER SHAFT ©) REVERSE IDLER GEAR © SPRING PIN @ Lock cous Gr REVERSE SHIFT HOLDER (@ SUPER-LOW SHIFT PIECE © DeTENT BALL (@ BALL SPRING { SPRING COLLAR & REVERSE SHIFT FORK. S DOWEL FIN, @ Dowel PIN @ DISENGAGEMENT LEVER (@ STOPPER BOLT (@ Lock PLATE 6 O-RING (G SPEEDOMETER GEAR G CLUTCH HOUSING 8 THAUST SH Selection, page 220 (@ TRANSFER ORIVE GEAR (@ TAPER ROLLER BERING @ BEARING OUTER RACE © O-RING (@ TRANSFER THRUST SHiM ‘lection, page 29 \ TRANSFER L SIDE Coven G@ DISENGAGEMENT SLEEVE © TRANSFER DISTANCE COLLAR @ vowel pin a (@ TRANSFER case @ SPRING, @ DeTeNT sau @ DISENGAGEMENT FORK © Dowel PIN 8 @ OW SEAL ( TRANSFER DRIVEN GEAR TAPER ROLLER BEARING INNER © BEARING OUTER RACE © TRANSFER SPACER © O-RING 6) DRIVEN GEAR THRUST SHIM Selection, page 216 (TRANSFER REAR COVER © THRUST WASHER [f BEARING OUTER RACE 1 TAPER ROLLER BEARING Inner @ OW SEAL © COMPANION FLANGE @ TRANSFER DUST COVER @ SPRING WASHER. @ LocknuT 120 Nim (12 kgm, 87 A)Shift Arm Cover -- Replacement 1. Remove the mounting bolts and shift arm cover 12 Nem (1.2 kgm, 9 of) SHIFT ARM COVER DOWEL PINS 2. Apply sealant to the shift arm cover mating sur- face of the transmission case. NOTE: This transmission uses no gaskets between “the shift arm cover and transmission case: use Honda, Genuine Liquid Sealant (Three Bond® 1216). Assem- ble the housing within 20 minutes after applying the sealent and allow it to cure at least 30 minutes after assembly before filing it with oil 2-10Disassembly. Remove the breather tube and back-up light switch, Remove the reverse lock cam, detent screws, washers, springs and detent ball from tho shift arm cover Remove the interlock bolt Remove the 18 mm plug, shift arm, shift atm shaft, interlock, shift arm A, retainer and super-ow retuin spring Remove the spring pin, select arm, select return spring and select lover Remove the shift lever bott and shift lever. Remove the stopper bolt, washer and shift arm. Remove the oil seals. Remove the select return pin, SELECT Lever SELECT ARM ow seat Repace SPRING PIN Replace, NN, SELECT RETURN. SS SPRING NS SELECT RETURN pIN-———— supentow RETURN SPRING SHIFT ARM RETAINER P SHIFT ARM A werendock SHIFT ARM SHAFT REVERSE Lock CaM 2-11Shift Arm Cover r~ Reassembly NoTE *Lubrisat all parts with ot before reassembly “Lubricate al! moving and alising surfaces with grease 4. Installnew oll seals in the shift arm cover. SHIFT ARM COVER Ol. seats Feplace. Sam 2. Fit the select lever through the shift arm cover, then install the select arm and the 5 x 25 mm spring pin. NOTE: Rest the end of the lever on a hard surface {as shown when driving in the spring pin. 3 Install the shift arm with the 6 x 16 mm stopper bolt. 8X25 mm SPRING PIN Foplace ‘SeLecT = SHIFT ARM ‘HARD SURFACE 6 mm STOPPER BOLT A ‘SELECT LEVER. 4, Assemble the interlock unit with the shift arm A, re tainer and spring, then install them in the shift arm cover. 5, Install the shift arm shaft through the cover into shift arm A, 6, Fit the interlock bolt through the shift arm cover; align the bolt with the groove in the interlock unit, ‘then install the 18 mm plug. NOTE: Seal the throads of the interlock bolt and ‘8mm plug with Honda Genuine Liquid Sealant (Three Bond® 126, RETURN SPRING RETAINER WreRLOCK SHIFT ARM A iwTeRLock Bou 40 N-m (4.0 kgm, 30 I-A 18 mm PLUG 40 N-m (4.0 kg-m, 30 B.A) 7. Install the reverse lock cam on the shift arm cover. Install the detent scrows and backup light switen (on the cover. 6 mm SPECIAL BOLT 15 Nem (1.5 kgem. 11 tbe) REVERSE LOCK Peplace com Replace BACK-UP LIGHT SWITCH 25 Nem (2.5 kgm, 18 lot) DETENT SCREWS 22. Nom (2.2 kg-m, 16 lb-ft) 2-12re eer eee 8. Install the shift fever onto the shift arm A, NOTE: Align the punch mark on the shift lever with the one on shift arm A, (mee ruse punci some XS 15 Nem (1.5 ko-m, 11 of) 10. Install the breather tube on the shift arm A, 3 Transfer Inspection r Driven Gear Backlash: 1. Set the disengagement lever in 2WO. DISENGAGEMENT LEVER Using a dial indicator, measure the backlash twice: Conce at the top of the companion frange, then rotate. the companion flange 180° and measure it in the same way, Standard: 0:10-0:15 mm (0.004 ~0.006 in) DIAL INDICATOR ‘COMPANION FLANGE {f the backlash is outside the specifications, adjust as per instructions described on page 216. 2-13Transfer Inspection ,-Gear Tooth Contact 1. Place the disengagement lever in 2WD. 2. Remove the transfer driven gear assembly from the clutch housing. A\ Q\ 2 ; Replace, DRIVEN GEAR ‘THRUST SHIM DRIVEN GEAR, ASSEMBLY 3. Apply Prussian Blue to the driven gear teeth evenly, ‘and reinstall it 4. Torque the gear holder mounting bolts. 5. Turn the companion flange, then note tooth impres sion on the drive gear at more than three teeth. Go00 contact 6, If the pattern is too high or too low, correct as per instructions described on page 2-26. 7. Ifthe tooth contact is correct, reassemble the drive gear assembly using new Oring. Transfer Drive Gear/Driven Gear Assembly — Removal 4. Set the disengagement lever in 200. 2. Remove the five Lside cover mounting bolts 8, Remove the [Link] cover, transfer thrust shim and Oring. 4, Remove the drive gear and drive gear thrust shim. 5. Remove the six bolts and transfer dust cover. 6. Remove the driven gear assembly, driven gear thrust shim and O-ring, DRIVE GEAR, DRIVE GEAR o-rinG Replace ‘TRANSFER THRUST SHIM 45 Nm (6.5 kg-m. 33 tb, DRIVEN GEAR ASSEMBLY S TRANSFER. bust cover O-Ring Replace DRIVEN GEAR THRUST SHIM 26 Nem (2.6 kg-m, 20 bt) 2-14j-L. Side Cover Race Replacement. NOTE The outer race should be replaced with the bearing as a set 1. Remove the drive gear bearing race with a bearing puller as shown, ‘TAPER BEARING OUTER RACE 2. Install the new race with the special tools shown, Driver 97748-00100 ATTACHMENT 82 * 68 mm 07748—-0010500 TRANSFER Drive Gear L SIDE cover BEARING RACE - Transfer Driven Gear Disassembly ——, 1. Slide the driven gear assembly into the clutch hous: ing and secure with the six bolts DRIVEN Gear ASSEMBLY 2, Hold the companion flange with the flange holder ‘and remove the lock nut with a 32 mm socket COMPANION FLANGE HOLDER (078255030000 32 mm SOCKET SOCKET WRENCH HANDLE ‘79076010300 3. Remove the companion flange holder. 4. Remove the driven gear holder assembly. {cont'd} 2-15Transfer 5. Remove the companion flange from the driven gear shaft 6. Remove the ctiven gear from the transfer rear ‘cover by tapping the driven gear shaft. ‘TRANSFER REAR cover DRIVEN GEAR, 7. Remove the inner driven gear bearing from the driven gear shatt. DRIVEN GEAR, SHAFT INNER DRIVEN GEAR BEARING [Transfer Driven Gear Disassembly (cont'd) 8, Pry the oil seal off the transfer rear cover, “TRANSFER REAR COVER 8. Remove the washer and outer driven gear bearing race from the transfer rear cover. WASHER ‘OUTER DRIVEN GEAR BEARING RACE 10. Remove the inner driven gear bearing race from the transfer rear cover. nM INNER DRIVEN GEAR BEARING RACE 2-1652 3 r— Driven Gear Pre-load Adjustment ATTACHMENT 62x68 mm 07746-0010500 2 ATTACHMENT. 077460010400 NOTE: Clean all tools and parts thoroughly in sol- vent and dry with compressed ir. Press the inner driven gear beating race into the transfer rear cover with the tools shown. Driver 97743-00100 INNER DRIVEN GEAR BEARING RACE Install the washer in the transfer rear cover. Press the outer driven gear beating race into the transfer rear cover with the tools shown river 07749.0010000 x55 mm im) ‘OUTER DRIVEN GEAR BEARING Race waster Coat the races with clean oil 4. Slide the inner driven gear bearing onto the Dummy Driven Gear Shaft then install the Dummy Shaft in the rear cover DUMMY DRIVEN GEAR SHAFT (07JAJ-PH80200 INNER DRIVEN. GEAR BEARING washer | REAR COVER ouTER DRIVEN coe eae COMPANION FLANGE = — Lock washer TA 5. Slide the outer driven gear besring on the Dummy Driven Gear Shaft. "22 mm LOCK NUT 6. Install the companion flange, lock washar and 22 mm lock nut on the dummy shaft. Nore: © Use a new 22 mm lock nut. © Do not install the oil seal © Install the lock washer with the dished side toward the rear cover. (conta) 2-17Transfer r Driven Gear Pre-load Adjustment —| (cont'd) 7. Hold the dummy shaft by inserting the end of a screwdriver into the hole in the shaft, then torque ‘the 22 mm lock nut to about 10 Nem (1.0 kgem, 7 Ib) ‘SCREWDRIVER WASHER Ss "32 mm LOCK NUT 10 Nem(1.0kg-m, 7 bt) 8 Turn the companion flange several times to assure normal bearing contact. 8. Measure preload using @ torque wrench. Standard: 0.5-0.8 N-m (6.0- Ib-in) Okg-em, 4.3-6.9 10. If the preload is outside the above limits, re-adjust by turning the lock nut NOTE: Do not overtighten the lock nut. [- Thrust Shim Selection 1. Insert the dummy shaft/driven gear assembly into the transfer housing. 2. Remove the drive gear bearing puller. @ bearing ‘SPRING COMPRESSOR ATT 07960-1870100 DRIVEN GEAR, BEARING 3. Lubricate the drive gear bearing with clean oil, then install it on the Drive Gear Gauge. Slide the bearing and gauge onto the transfer shaft. Nore: © Do not install the drive gear thrust washer. © Pull the dummy shaft/drivan gear assembly out slightly to allow the drive gear gauge to seat ‘TRANSFER REAR “\ coven’ DRIVE'GEAR GAUGE (074A4-PH80100 INNER TAPER BEARING (2007) DRIVE GEAR GAUGE (079738090500 “DRIVEN GEAR DUMMY SHAR. O7sAJ—PHET2OO Pie omen [LEE see 2-184. Install L. side cover without the bolts. 5. To determine driven gear thrust shim thickness, rotate the companion flange several times to seat the bearings, measure the clearance between the trans- ‘fer rear cover and transfer case at several locations with a fesler gauge, then record the average, NOTE: The clearance should be taken while pressing the dummy shaft all the way in [Link] CovER \ eas FEELER GAUGE 6. The correct shim thickness is determined by recording the average clearance between the transfer rear cover and the transfer case, then ‘adding to subtracting the machining tolerance, which is etched in to the driven gear NOTE: The plus (+) or minus (—) number given as Machining tolerance represements hundredths of ‘milimeter. Example: # Clearance measured in Step 5: 1.08 mm ‘© Machining tolerance etched in the driven gear (42) Corrected shim thickness: 1.08 + 0.02 mm = 1.10 mm Example: # Clearance measured in Step 5: 1.08 mm ‘© Machining tolerance etched in the driven gear: (3) Corrected driven gear thrust shim thickness 1.08-0.03 mm=1.05 mm TOLERANCE THICKNESS MARK Part No Thickness | 0.5 mm (0,020 in.) 0.85 mm (0.033 in.) 0.90 mm (0.038 in.} 0.95 mm (0.037 in.) 1.00 mm (0,039 in.) 1.05 mm (0.041 in.) 1.10 mm (0.043 in.) 1.18 mm (0.045 in.) 1.20 mm (0.047 in.) 1.25 mm (0.049 in.) 1.30 mm (0.081 in.) 29481—PH8—000 29482—PH8—000 29483—PH8—000 29484—PH8—000 29485—PHB—000 29486~PH8—000 29487—PH8—000 29488—PH8—000 29489—PHE—000 29491 —PH8—000 29492—PH8—000 To determine the L. side cover thrust shim thickness, measure the clearance between the transfer L. side cover and transfer case at several locations with a fesler gauge, and record the average, NOTE: The clearance should be measured while Pressing the L. side cover all the way against the transfer case. FEELER GAUGE ‘The correct shim thickness is determined by record ing the clearance between the transfer case and the LL Side cover, then adding or subtracting the machin- ing tolerance, which is etched into the drive gear. Example: # Clearance measured in Step 7: 1.04 mm © Machining tolerance etched on drive gear: (+2) Corrected shim thickness: 1,04+0.02 mm=1.08 mm Example: © Clearance measured in Step 7: 1,04 mm © Machining tolerance etched on drive gear: (—1) Corrected shim thickness: 0.01 mm=1.03 mm aa 10 (cont’s} 2-19Transfer TOLERANCE THICKNESS MARK DRIVE GEAR, Part No. Thickness 0.30 mm (0.012 in.) (00 mm {0.039 in.) (03 mm (0.041 in.) (06 mm (0.042 in.) (09 mm (0.043 in.) 12 mm (0.044 in.) 15 mm (0.045 in.) 18 mm (0.046 in.) 21 mm (0.048 in.) 24 mm (0.049 in.) 27 mmm (0.060 in.) 30 mm {0.051 in.) | 33 mm {0.082 in.) 29461—PH8—000 29462~PH8—000 29453—PH8—000 | 29484—PHS—000 29465—PHB—000 29486—PH8—000 29487~PH8—000 29458 —PH8—000 29489—PH8—000 29471—PH8—000 29472—PHB—000 29473~PH8-000 29474~PH-000 ;—Thrust Shim Selection (cont!) ——£ ———H————— 9. Install two 1.75 mm “dummy” shims (P/N 28415 — PH8—000) on the transfer shaft ‘TRANSFER SHAFT 10. Press the drive gear bearing on the drive gear. DRIVER C (07746-0030100 INNER TAPER BEARING (2007) ATTACHMENT. 35 mm (07746-0030800 DRIVE GEAR, 2-2011, Slide the drive gear onto the transfer shaft. TRANSFER THRUST SHIM L. SIDE coveR 12, Place the shim selected in Step 7 on the L, side Cover, and install the cover on the transfer case 13. Rotate the companion fisnge several times to seat the bearings, measure the clearance between the L. side cover and transfer case at several locations while pushing against the left side cover, and record the average. FEELER GAUGE 14, Subtract the clearance measured in step 13 from 3.6 mm to obtain the correct shim thickness. Example: © Clearance measured in Step 13: 1.87 mm 1 Thickness of dummy shims 3.5 mm Cortected drive gear thrust shim: 3.5-1.87 mm Thickness: 1.93 mm Pato, [Thickness 28811~PH6-000 | 0.48 mm 0019 m) 29412 PHE—000 | 1.57 mm o.00s nh 29413-PH8—000 | 1.63 mm (0.964 In} 28414PH8—000 | 1.89 mm (0.067 In} 29418-P6 000 | 4.75 mm 0.089 me) 28416 -PH3000 | 1.81 mm (0.971 inh 29417—PH8—000 | 1.87 mm (Oor« nh 28418 -PH8—000 | 183mm o.o76 mn) 2-21Transfer [Driven Gear Reassmbly 1. Remove the driven gear dummy shaft from the transfer rear cover. DRIVEN GEAR DUMMY SHAFT O7JAS-~PHEn200 INNER DRIVEN GEAR BEARING Nt WASHER REAR COVER OUTER DRIVEN ee ‘COMPANION FLANGE === Lock washer TPA oe nm tock nur 2. Press the oll seal in to the transfer reer cover. RIVER (07749-0010000 ll SEAL Driver Ol SEAL (07948-8C20200 3. Coat the main and side sealing lips of the oil seal with grease YS 4, Press the inner driven gear bearing on the drive gear DRIVER c (07746-0030100 INNER TAPER BEARING ATTACHMENT, a5mm (07746-0030800 DRIVEN GEAR 5, Install the following parts in the transfer rear cover: Drive gear. 1 Transfer spacer (new spacer! © Companion flange ‘© Spring washer © 22 mm lock nut NOTE: Install the spring washer with the dished side toward the companion flange. 2-226. Temporarily install the driven gear assembly and ‘mounting bolts in the transfer case. DRIVEN GEAR ASSEMBLY 7. Tighten the lock nut to the specified torque. ‘Torque: 120 Nem (12 kg-m, 87 Ib-ft) FLANGE HOLDER / 07826-s090000 SOCKET WRENCH HANDLE 79676010300 Remove the driven gear assembly from the transfer case, and measure the preload NOTE: Before measuring the preload, rotate the companion tlenge several times to assure normal bearing contact. Preload: 0.8—1.1 Nem (8.0-11.0 kg-em, 7.0-9.5 tb-in} NOTE: If the preload exceeds 1.1 Nem (11.0 kg ‘om, 8.8 bn), replace the tansfer spacer with a New one and readjust. Do not try to adjust the pre load by loosening the locknut. 1. If the preloed is less than 0.8 Nem (8 kg-em, 7.0 Ib in}, adjust by turning the lock aut ina little at a time, NOTE: Replace the transfer spacer with a new Cone if the preload is still outside the above limits when the lock nut is tightened to 230 Nem (23 kg rm, 166 Ib-ft) 2-23Transfer 1. Apply sealant to the clutch case mating surface of the transfer case. NOTE: This transmission uses no gaskets between the major housings; use Honda Genuine Liquid Sealant (Three Bond® 1216). Assemble the housings ‘within 20 minutes after applying the sealant and allow itto cure for at least 30 minutes after assembly before filing it with ol 2 49 N-rl4.5 kgm, 33 lo) — Driven/Drive Gear Reassembly —__— 3, Install the following parts in and on the transfer case and shaft: transfer thrust shim. drive gear (coat with clean cil. —drive gear thrust shim. =L side cover and boits. ‘TRANSFER THRUST SHIM, 45 N (4.5 kgm, 33 Ib L. SIDE cover 4, Install the following parts: driven gear thrust shim. driven gear assembly and bolts, i DRIVEN GEAR DRIVEN GEAR, ASSEMBLY 26 Nm (2.6 kg-m, 19 tbh) 2-245, Measure the total bearing preload: @ Rotate the companion flange several times to assure normal bearing contact. ‘© Sot the disengagement lever in 2WD. (© Measure the preload with a torque wrench. ‘The total bearing preload should be 0.7—1.0 N-m (7.0~10.0 kg-om, 6.1—8.75 tbsin) greater than ‘the preload on the driven gear assembly alone (see page 223, step 8), Example: If the preload of the driven gear assembly alone was 0.8.N-m (9.0 kg-om, 7.9 bin, the total bearing preload should be betwoon 1.6 Nem (16.0kg-cm,14 lb-in) and 1,9 Nem (19 kg-om, 16 Ib-in) DISENGAGEMENT LEVER 6. Ifthe preload is outside of the specifications, adjust it by replacing the transfar thrust shim © Ifthe total bearing preload is less than the speci- fication, reduce the size of the transfer thrust shim. © If the total bearing preload is more then the specification, increase the size of the transfer ‘thrust shim, 7 After the bearing preload has been adjusted proper- ly, measure the gear backlash © Place the disengagement lever in 2W0. DISENGAGEMENT LEVER © Using a dial indicator, measure the backlash ot the top of the companion fienge, then tate the companion flange 180° and measure again, Backlash: 0.10-0,18 mm (0.004-0.006 in.) COMPANION FLANGE (cont's) 2-25Transfer ;- Driven/Drive Gear Reassembly (cont’d) —£_—H————_ © If the backlash is outside the specifications, adjust by changing the driven goar and drive gear thrust shims. ‘TRANSFER THRUST Ne ORIVEN GEAR THRUST SHIM 8. Check for proper tooth contact after the backlash adjustment has been completed. @ Remove the driven gear assembly from the transfer case, and coat the driven gear teeth evenly with Prussian Blue. © Reinstall the driven gear assembly in the transfer ‘case and tighten the bolts to the specified torque © With the disengagement lever in 2WD, rotate the companion flange one full turn in both directions. @ Remove the driven gear assembly from the transfer case and note the tooth impression on the gear. NOTE: Compare the tooth impression of the gear ‘with the examples below and follow the appropriate adjustment instructions. Continue the check/adjustment procedure until the tooth contact is correct. 1 1 i { I I | t CORRECT TOOTH CONTACT IMPROPER TOOTH CONTACT TOE CONTACT FLANK CONTACT CA Adjust deve — | Acjust riven gear and driven ¢ Ly | gear only ear = HEEL CONTACT CD FACE CONTACT E® &, Adjust drive —- E Adjust driven ‘gear oniy TOE CONTACT If the pattern shows toe contact, use 2 thicker drive gear thrust shim and increase the thickness of the transfer thrust shim an equal amount. TOE CONTACT CXS. 2-26TRANSFER THRUST SHiN DRIVE GeaR ae i= SONS An t DRIVEN GEAR, ) THRUST SHIN - HEEL CONTACT If the pattern shows heel contact, it indicates too much backlash. To correct, reduce the thickness of the drive ‘gear thrust shim, The thickness of the transfer thrust shim must also be reduced by the amount by which the rive gear thrust shim thickness is reduced. NOTE: The driven gear thrust shim will have to be changed also to compensate for the change in back: lash, HEEL Contact CD TRANSFER THRUST SHIM DRIVE GEAR THRUST SHIN DRIVEN GEAR THRUST SHIM FACE CONTACT To correct face contact, use a thicker driven gear thrust shim to move the driven gear away from the drive gear ‘The backlash should remain within the limits If the backlash cannot be held within the limits (page 12.25), make correction in the same manner as for HEEL, ‘CONTACT. FACE CONTACT EX TRANSFER ‘THRUST SHIM DRIVE GEAR THRUST SHIM DRIVEN GEAR f THRUST SHIM g FLANK CONTACT If the pattem shows flank contact, move the driven {gear in toward the drive gear by using a thinner shim tor the driven gear. The backlash must remain within the limits If the backlash exceeds the limits (225), make correc: tion in the same manner as for TOE CONTACT. FLANK CONTACT ECD (cont 2-27Transfer [- Driven/Drive Gear Reassembly (cont'd) 11. Install the thrust shim and a new O-ing on the driven gear assembly, then install the assembly in ‘TRANSFER THRUST SHIM eee 4. DRIVE GEAR tx at SE ‘THRUST SHIM } DRIVEN GEAR 1 THRUST SHIM 8. After the correct gear tooth contact has been acom- O-RING plished, remove the transfer drive and driven gears, Fepiace. 10. Apply sealant to the clutch housing and transfer case ‘THRUST SHIM mating points on the driven gear mating surface. NOTE: This transmission uses no gaskets between the major housings; use Honda Genuine Liquid ‘Sealant (Three Bond 1216). Assemble the housings Within 20 minutes after applying the sealant and allow it to cure for atleast 30 minutes after assembly before filling it with ol 26 N-rw (2.6 kgm, 19 Ib.) NOTE: Coat a new O-ring with oil Aoply sealant. 2-28Transmission Housing 12, Slide the drive gear thrust shim and drive gear onto ‘the transfer shaft. DRIVE GEAR ‘TRANSFER THRUST SHIM |. SIDE coveR \ DRIVE Gear THRUST SHIM (4.5 kgm, 33 tb) 13. Place the transfer thrust shim and O-ring (74.52.58 mm} on the L. side cover and install them on the transfer case. NOTE: # Coat a new O-ring with oil © Apply sealant (Honda Genuine Liquid Sealant Three Bond® 1216) to the threads of L. side cover attaching bolts. 14, Measure the total bearing preload after assembly r~ Removal NOTE: Place the clutch housing on two 70 x 70 x 450 mm (2.786 x 2.756 x 17.717 in) pieces of lumber to hold the transmission housing 1, Remove the shift arm cover (page 2-10) 2. Remove the bolts shown from the transmission housing REVERSE IDLER SHAFT BOLT 55 Nem (6.6 kg-m, 40 Ib) WASHER WASHER Replace SUPER-LoW SHIFT LEVER BOLT SUPER LOW SHIFT SET BALL SCREW 440 Nem (40 kg-m, 30 Ib it aa reyes 16 io) 3. Remove the 8 mm bolts attaching the clutch case to the transmission housing, (cont’a) 2-29Transmission Housing - Removal (cont'd) 4, Remove the 32 mm sealing bolts. 5. Separate the transmission housing from the clutch housing by puling up the trensmission housing while ‘expanding the snap ring holding the countershaft ball bearing with 2 pair of snap ring pliers. ‘32 mm SEALING BOLT SNAP RING 6. Remove the transmission housing, Clean the mating surfaces thoroughly. 7. Remove the mainshaft thrust shim, oil quide plate and superow 2 shaft thrust shim from transmis: sion housing, ‘[Link] 2 SHAFT MAINSHAFT THRUST SHIM & Sf taust sam eZ ol auipe pute Reverse Shift Fork/ 5th-Reverse Shift Pice r Clearance Inspection 1. Measure the clearance between the reverse shift fork and &th—reverse shift piece pin ‘Standard: 0.08—0.35 mm (0.002—0.014 in.) Service Limit: 0.5 mm {0.020 in.) STH—REVERSE SHIFT PIECE REVERSE SHIFT FORK 2. I the clearance is outside the above limits, mea~ sure the width of the L-groove in the reverse shift fork. Standard; 7.05—7.25 mm (0.278—0.285 in.) STH—REVERSE SHIFT PIECE PIN LGROOvE REVERSE SHIFT FORK. 3. Replace the reverse shift fork with a new one if the width exceeds 7.25 mm. 2-30Reverse Idler Gear/ Reverse Shift Fork r Clearance Inspection 1. Measure the clearance between the reverse idler gear and reverse shift fork, Standard: 0.5—1.1 mm (0.020-0.043 in.) Service Limit: 1.8 mm (0,071 in.) REVERSE IDLER GEAR 2. If the clearance exceeds 1.8 mm (servece limit), ‘measure the width of the reverse shift fork paw! ‘groove. Standard: 13.0— 13.3 mm (0,612—0.524 in.) 3. If the width is outside the above limits, replace the shift fork with @ new ene. Mainshaft/Countershaft -- Removal 1. Remove the reverse idler shaft end reverse idler gear from the clutch housing, |a— REVERSE IDLER SHAFT REVERSE IDER GEAR \ 2. Remove the following parts, in the order shown, from the reverse shift holder assembly. ( Yst—2nd SHIFT FORK SHAFT @ SUPER-LOW SHIFT PIECE BAR @ SUPER-LOW SHIFT LEVER {@ SUPER-LOW SHIFT PIECE A 8. 1st—2nd SHIFT FORK REVERSE SHIFT HOLDER ASSEMBLY (cont'd) 2-31Mainshaft/Countershaft 3. Remove the following parts, in the order shown, from the clutch housing © 6 mm SPECIAL BOLT @ Lock PLATE @ Sth/REVERSE SHIFT FORK SHAFT © Sth SHIFT FORK © 3rd—4th SHIFT FORK @ REVERSE SHIFT FORK Qe? Sho % @ 4, Remove the reverse shift holder assembly from the clutch housing. ice ff nevegse srr [Link] in 5 -- Removal (cont'd) AAA i i _ _ e Remove the following parts from the clutch housing: © SUPER-LOW SHIFT FORK SHAFT ASSEMBLY @® BALL BEARING @ DISTANCE COLLAR @ NEEDLE BEARING © FRICTION DAMPER @ SUPER-LOW 2 GEAR ® SYNCHRO RING @® SYNCHRO SPRING © SYNCHRO SLEEVE @ SYNCHRO HUB © THRUST WASHER, @ THRUST NEEDLE BEARING © SUPER-LOW 1 GEAR @ NEEDLE BEARING @ DISTANCE COLLAR ( NEEDLE BEARING (D THRUST NEEDLE BEARING @ THRUST WASHER, @ SPRING WASHER @ DISTANCE COLLAR @) SUPER-LOW 1 SHAFT 2-32Transfer Shaft 6. Remove the mainshaft assembly, countershaft ‘assembly and superiow 2 shaft from the clutch housing. COUNTERSHAFT ASSEMBLY ‘SUPER-LOW 2 SHAFT mawsHart { ‘ASSEMBLY ay g spnine wagner © 7. Remove the bearing from the transfer shat. 8. Remove the differential assembly from the clutch housing DIFFERENTIAL ASSEMBLY BEARING - Replacement 1, Remove the disengagement lever fram the clutch housing. stoppen BOLT 12 Nem (1.2 kgm, 9 Itt) Lock washer Replace 6 mm SPECIAL BOLT 7 Nem (1.7 kam, 12 1) 2. Remove the disengagement fork, disengagement sleeve, and transfer distance calar from the clutch housing 3. Remove the transfer shaft, needie bearing, and transfer driven gear from the transmission side of the clutch housing TRANSFER DISTANCE COLLAR DISENGAGEMENT SLEEVE NEEDLE BEARING i DISENGAGEMENT FORK ‘TRANSFER SHAFT ‘TRANSFER DRIVEN GEAR 2-33Differential Oil Seal r- Removal 1. Remove the 80 mm snap ring from the transmission housing 80 mm SNAP RING Transfer Shaft Needle Bearing (Clutch Housing) r- Replacement 1. Remove the needle bearing from the clutch side of the clutch housing, 2. Drive a new needle bearing into hole of the clutch housing with the tools shown, baiver (077490010000 ATTACHMENT, 72x75 mm 07746-01060 NEEDLE BEARING 2-34Transfer Shaft Taper Bearing (Transmission Housing) Replacement 1. Remove the bearing outer race with the tool shown, BEARING REMOVER SET . 07936-2890101 Drive a new bearing outer race into the transmis: sion housing, DRIVER 077490010000 ATTACHMENT, 37. 40 mm (07746-0010200 CAUTION: Support the transmission housing with @ wood block to avoid damaging the transmission housing, Mainshaft Bearing/Oil Seal (Clutch Housing) , Replacement 1. Remove the mainshaft bearing and oll seal from the ‘clutch side. 2 Driver (07749-00100 ATTACHMENT, 42 47 mm (07748-0010300 Using the tools as shown, drive in @ new bearing from the transmission side, RIVER 077490010000, crass 2-35Countershaft Bearing (Clutch Housing) Replacement 1. Remove the needle bearing with the bearing puller HE ES ADJUSTABLE BEARING REM ‘Grsac—PH000 2. Position the oil guide plate and new needle bearing in the bore of the clutch housing NOTE: Position the needle bearing with the oil hole facing up, ow HOLE Po on cue mare 3. Drive the neadie bearing in using the tools shown, river (077480010000 ATTACHMENT, NEEDLE BEARING Super-low 2 Shaft Bearing (Clutch Housing) -— Replacement 1. Remove the superlow 2 shaft bearing ADJUSTABLE BEARING REMOVER SET Grsac-PHsoc00 2. Drive the superlow 2 shaft bearing in the clutch housing DrIVER (07749-0010000 ATTACHMENT, 52 * 55 mm (07746-0010800 2-36Mainshaft Overhaul. NOTE: The needle bearings are of the same size. 7Bj 8etore assembling, clean ol parts in solvent, dry them with compressed ar, then coat them with clean of SYNCHRO HUB é Ls ame ( 6 J sth GEAR \ Clearance inspacton, page 2-88 BALL BEARING SPACER COLLAR, Chock wear and operation, SYNCHRO SLEEVE SYNCHRO RING Inspection, page 259 NEEDLE BEARING Check wear and operation NEEDLE BEARING Check wear and operation ‘SYNCHRO HUB 4th GEAR Clearance inepection, page 244 ‘SYNCHRO SPRING ‘SYNCHRO SLEEVE [SYNCHRO SPRING Sear Inspection, page 239 rd GEAR Inspection, page 243 NEEDLE BEARING Check wear and operation. MAINSHAFT Inspection, page 240 2-37Countershaft Overhaul: NoTE ‘©The nosdle bearings ae ofthe some siz. '* Remove the Sth gear and 4th gear with a bearing pall. Before assembling, clean alt parts in solvent, blow dry, and coat with clean oi SPRING WASHER 23 mm eam @ é i isocnut L © &e (11,0--0-11.0kg:m, 80-080 lb-t} Replace, nee NEEDLE BEARING Check wear and operation DISTANCE COLLAR, Selection, page 241 SYNCHRO RING 3rd GEAR, FRICTION DAMPER iopcten gn 899 ~ Y atioe, { Iscecton,pge 20 2nd GEAR [SYNCHRO SPRING 7 REVERSE GEAR NEEDLE BEARING SUPER-LOW 3 GEAR Check wear and operation, lnspecton, page 242 SYNCHRO SPRING FRICTION DAMPER te GEAR ‘THRUST WASHER Selection, page 241 ‘COUNTERSHAFT Inspection, page 240 2-38Synchro Ring and Gear r- Inspection SYNCHRO SPRING 1. Inspect the inside of synchro ring for wear SYNCHRO RING. 2. Inspect the synchro ring teeth and matching teeth on ‘ear for wear (rounded off) ay 2. Inspect the gear hub thrust surface for wear. 4. Inspect the cone surface for wear or roughness 5. Inspect the teeth on all gears for uneven wear, scoring, galling or cracks. ©. Coat the cone surface of the gear with oil and place ‘the synchro ring en the matching gesr. Rotate the ring, making sure that it does not slip. Measure the clearance between the ring and gear all the way around, NOTE: Hold the ring against the gear evenly while measuring the clearance Ring-to-Gear Clearance Standard: 0.85—1.10 mm (0,038—0.089 in.) Service Limit: 0.4 mm (0.02 in.) 7. Separate the synchro ring and gear, and coat them wath 0 8. Install the synchro spring on the eynchra ring, then set it aside for later reassembly. SYNCHRO SPRING 2-39Mainshaft/Countershaft [— Mainshaft Inspection 1. Measure the mainshatt 0.0. at points A, B and C Standards: A: 27,977—27.980 mm (14014~11020 in) B: 34.984—35,000 mm (1.8773-1.3780 in) ©: 24.987~25.000 mm '9837—0.9843 in) Service Limits: A: 27.92 mm (4100 in.) B: 34.93 mm (1.375 in.) ©: 2493 mm (0:81 in.) Inspect the ol passages for clogging Inspect for weer or damage Inepect tor wear or damage 2. Replace the mainshatt if any readings are out of tol: erance, Inspect for runout, Stand: 0.02 mm (0.0008 in.) Max. Service Limit: 0.05 mm (0.001 in.) Support with lathe type tool or V-biocks, Rotate two complete revolutions 4. Replace the mainshaft if the reading is out of toler - Countershaft Inspection 1. Measure the countershaft 0.D. at points A, B and C| Standards: A: 29.000—29.015 mm. (14417-11428 in.) B: 90.464—30.480 mm, (41994—1.2000 in) : 24.987—25.000 mm (0.9837—0.9843 in) Service Limits: A: 28.94 mm ©: 24.83 mm (0.981 in) Inspect the oll passages for logging Inspeet for wear ar damage A 2. Replace the countershatt if any readings are out of tolerance, 3. Inspect for runout Standard: 0.02 mm (0.0008 in.) Max. ‘Service Limit: 0.05 mm (0,001 in.) ‘Suppor with lathe type too! or V-blocks. Rotate two complete 4, Replace the countershatt if the reading is out of tol 2-40Countershaft ;-Clearance Inspection. 1 ssemble the gear, distance collar, thrust washer, synchro hub, needla Bearings and bal bearings as per the instruc: tion shown below. NOTE: 4th gear and 5th gear are press fit. Lock nut Gr MO ON sm (11.0 0 11.0 kg-m, 80-+ 0 80 Ib-f) G+— tock waster 23 mm I &- DISTANCE COLLAR ee Ve © ——rnicrion oameen (Selective) Distance collar Part Number Length 23911—PK5—000 | 29.03 29.05 mm (@, |< an ean / (1.1429 1.1497 in.) 23912—PK5—000 | 29.01 28.03 mm (11421 = 1.1428 in) 23913—~PK5—000 | 28.93-29.01 mm (1.4413 1.1421 in} 23814—PK5—000 | 28.97-28.99 mm (1.4405 — 1.1431 in) %, 22915—PKs-00 | 28.95- 28.87 mm (CD)}-— tw cean (1.1398 ~ 1.1406 int al (cont'd) Thrust wash [Part Number Thickness -23921—PHB—900 | 1.95 mm 10.0768 in) 23922—PH8—900 | 1.96 mm (0.0772 in} = 23923—PH8—900 | 1.97 mm (0.0776 in) Oy-— tunusr wastien | donot pre_soo | | £98 mm (0.0780 in) i rd 23925—PH8—300 | 1.89 mm (0.0784 in) J<— sureriow saean | 23926—PH8—900 | 2.00 mm (0.0787 in) 23827—PHB—200 | 2.01 mm (0.0791 in} 23928—PHE—900 | 2.02 mm (0.0795 in) 23929—PH8—900 | 2.03 mm (0.0799 in) 23830—PH8—900 | 2.04 mm (0.0803 in) 23931—PHE—900 | 2.05 mm (0.0807 in} |< countensarr 23932~PHB—900 | 2.06 mm (0.0811 in) 23833—PH8—900 | 2.07 mm (0.0815 ind 2394—PH8—900 | 2.08 mm (0.0819 in) 23835—PHB—200 | 2.09 mm (0.0823 in) 23036—PHE~800 | 2.10 mm (0.0827 in) | 2-41Countershatt (Clearance Inspection (cont'd) A} 2, Tighten the countershatt lock nut to the correct 5. Measure the clearance between the 2nd gear and torque. 3:d gear. NOTE: Place the shaft in a vice with soft jaws. 2nd and 3rd Gear Clearance: Standard: 0.03-0.08 mm 110-+0-> 110 N-m 11.0-+0-+ 11.0 ka-m, 800 80 Ib-tt (0.001—0.003 in.) Service Limit: 0.18 mm (0.007 in.) 3rd GEAR, SOFT JAWS or wooo tock 3. Measure and record the clearance between the su per-low gear and thrust washer. Super-low Gear Clearance: Standard: 0,03—0.08 mm {0.001—0.003 in.) 6. Ifthe clearance is out of tolerance, select the appro- ‘Service Limit: 0,18 mm (0.007 in.) priate distance collar for the correct clearance from the charts on page 2-81 SUPER-LOW 3 GEAR LOW GEAR THRUST WASHER 4, the clearance is out of tolerance, select the appro: priate thrust washer for the correct clearance from the charts on page 2-41 2-42Mainshaft 1 ‘Assemble the bearings, synchro hub, synchro sleove, gears and spacer coller on the mainshaft as in structed below. = oy ) «BALL Bearing <——svNchno sueeve 5th GEAR SPACER COLLAR 4th GEAR SYNCHRO SLEEVE i SYNCHRO HUB rd Uy rd GEAR NEEDLE BEARING 2. 4 5, p- Clearance Inspection Push down on the bearing inner race with about 30kg (66 Ib) using @ socket wrench and measure the clearance between 3rd and 2nd gears. 3rd and 2nd Gear Clearance: Standard: 0.06—0.21 mm (0.002—0.008 in.) Service Limit: 0.3 mm (0.012 in.) Std Gear If the reading is outside specifications, measure the thickness of 3rd gear. ‘3rd Gear Thickness: Standard: 32.42—32.47 mm (1.276—1.278 in.) Service Limit: 32.3 mm (1.272 in.) If the reading is within specifications, replace the synchro hub. If the service limit is exceeded, replace the 3rd gear. (cont’a) 2-43Mainshaft 6. Measure the clearances between 4th gear and the spacer collar Standard: 0,06—0.21 mm (0.002—0.008 in.) Service Limit: 0,3 mm (0.01 in.) 4 PRESS DOWN 4th GEAR ‘SPACER COLLAR 7. If the reading is out of specifications measure dis tance(A)on the spacer collar. Standard: 26.03~-26.08 mm (1.025 — 1.027 in.) Service Limit: 26.01 mm (1.02 in.) 7 al Lath GEAR SIDE st << 5th GEAR SIDE 8. If distance ‘A, is within specification, measure the thickness of 4th gear. Standard: 30.92~30.97 mm (1.217-1.220 in.) Service Limit: 30.8 mm (1.21 in.) 9. Replace 4th gear if its measurement is out of specification. Replace 4th gear synchro hub if 4th gear is within specification. ‘Clearance Inspection (cont?) ADADBPaA 10, Measure the clearance between Sth gear and the spacer collar Standard: —0.06—0.21 mm {0.002—0.008 in.) Service Limit: 0.3 mm (0.01 in.) 4 PRESS Down, f i SPACER COLLAR = a oe 11. If the reading is out of specifications, measure distance (B) on the spacer collar. 26.03-26.08 mm (1.025 —1.027 in.) Service Limit: 26.01 mm (1.026 in.) Standard: 5th GEAR SIDE 12. If eistance (8) is within specification, measure the thickness of 6th gear. Sth Gear Thickness: Standard: 30.42—30.47 mm (1,198—1.200 in.) Service Limit: 30.3 mm (1.193 in.) 18. Replace Sth goar if its measurement is out of specification, Replace 5th gear synchro hub if Sth gear is within specification. 2-44Mainshaft Thrust Shim Adjustment 1. Remove the thrust shim and oil guide plate from the transmission housing (page 2-90). 2. Install the 3rd/4th synchro hub, spacer collar, Sth synchro hub and transmission side ball bearing on the mainshaft. Install the assembly in the transmission housing. @ _ s:a/atm syncHro Hue SPACER COLLER { 5th SYNCHRO HUB. BALL BEARING 3. Measure the distance B between the end of the trans- mission housing and mainshaft Nore © Use a straight edge and feeler gauge © Measure at three locstione and average the read: ings 4. Measure the distance C between the surfaces of the cluteh housing and bearing inner race Note: © Use a straight edge and feoler gouge © Measure at three locations and average the read ings. END SURFACE OF CLUTCH HOUSING af ps | INNER RACE OF BALL BEARING | | 5. Select the correct thickness thrust shim as follows: 4, Add the measurement (C) of clutch housing ball bearing inner race surface and clutch housing soal Surface determined in step 4 to the measurement (8) of mainshaft and transmission housing end in step 3, », Subtract the distance 0.94 mm (0.0370 in.) from the dimension determined in step 5a). Example: B: 2.34 mm (0.0921 in.) ¢: + 0.04 mm (0.0016 in.) 2.38 mm (0.0997 in.) Max. 2.38 mm (0.0937 in.) 0.94 mm (0.0370 in.) 1.44 mm (0.0567 in.) ©, Select the 1.44 mm {0.0567 in.) thickness shim. NOTE: Do not use more than one shim. (conta) 2-45Mainshaft Thrust Shim (Adjustment (cont'd) Part No Thickness 20 mm (0.0472 in) 23 mm (0.0484 in) .26 mm (0.0496 in) .29 mm (0.0509 in) .32 mm (0.0520 in) 35 mm (0.0531 in) 38 mm (0.0543 in) 23948—PH8~900 41 mm (0.0555 in} 23949-PH8—900 44 mm (0.0567 in} 23941-PH8-900 | 1 1 1 1 1 1 1 1 1 23950—PH8—900 | 1.47 mm (0.0579 in} 1 1 1 1 1 1 1 1 1 1 23942—PH8-900 23943-PH8—900 23944—PH8~900 23945-PH8~900 23946—PH8-900 | 23947—PH8—900 23951-PH8—300 | 1.50 mm (0.0591 in) 23952~PHB—900 | 1.53 mm (0.0602 in) 23983-PHB—800 | 1.56 mm (0.0614 in) 23954-PH8-900 | 1.59 mm (0.0626 in) 23955-PH8—200 | 1.62 mm (0.0638 in} 23958-PH8—800 | 1.65 mm (0.0649 in} 23957-PHa-200 | 1.68 mm (0.0861 in) 23958-PHa—200 | 1.71 mm (0.0873 in) 23959-PHB—900 | 1.74 mm (0.0885 in) 23960-PH8—900 | 1.77 mm (0.0887 in) 23961-PH8—900 23962-PH8—B00 23963-PH8~900 23964~PH3~800 23965-PH8—900 23966-PH8—200 23967 —PH8—900 | 23968-PH8—900 | 2.01 mm (0.0791 in} 23969-PHa—800 | 2.04 mm (0.0803 in) 1.80 mm (0.0709 in) 1 1 1 1 1 1 2 2 23970—PH8~-900 | 2.07 mm (0.0815 in} 2 2, 2 2 2 2 {83 mm (0.0720 in) 86 mm (0.0732 in) {89 mm (0.0744 in) 92 mm (0.0756 in) 95 mm (0.0768 in} 98 mm (0.0780 in} 23971-PH8-900 10 mm (0.0827 in} 23972—PH8~—900 13 mm (0.0839 in) 23973-PH8~—900 16 mm (0.0850 in} 23974~—PH8—300 19 mm (0.0862 in} 23975~—PH8—900 22 mm (0.0874 in} 23976-PH8—900 25 mm (0.0886 in} 23977—PH8—900 28 mm (0.0898 in) 23978-PH8-900 | 2.31 mm {0.0909 in) 23979-PH8-300 | 2.34 mm {0.0921 in) 23980—PH8~900 | 2.37 mm {0.0933 in) Check the thrust clearance in the manner described below. 4. Install the oil guide plate shim selected in the transmission housing. sHIM bb Install the spring washer on the mainshatt, NOTE: Clean the spring washer and shim thoroughly before installation. Install the spring washer and shim properly c. Install the mainshaft in the clutch housing and in stall the 3rd/4th synchro hub, spacer collar, 5th synchro hub and ball bearing. d, Place the transmission housing over the main: shaft and onto the clutch housing, fe. Tighten the clutch and transmission housings with several 10 mm bolts. 1, Tap the mainshaft with a plastic hammer.9. Attach the collar and shaft holder of the special tool (Mainshatt Clearance Inspection Too)) to the ‘mainshatt. First turn bolt Ain just enough to keep ‘the tool away from the mainshatt splines; then, tum bolts B and C equally to secure the tool “off center” nearest to bolt A. out SHAFT HOLDER iit qe | couLAR MAINSHAFT CLEARANCE INSPECTION TOOL 07GAs—PG20107 CAUTION: Screw the three bolts into the area below the spline. Never screw into the splined area. h, Attach the special tool (magnet stand base) to the clutch housing and set the dial gauge on the top of the mainshaft i. Tum the bolt clockwise and measure the clearance, CAUTION: * Do not tum the bolt more than 60 degrees after the needle of the gauge stops moving. Be careful not to overtighten. * Measurement should be made at room temperature, i. Clearance is correct if the reading is between 0.08--0.15 mm (0.0031 —0,0069 in.) If not, readjust the shim thickness, MAGNET STAND BASE (07879 Ps40000 MAINSHAFT CLEARANCE INSPECTION TOOL 07GAJ-PG20101 2-47Super-low 2 Shaft Thrust Shim Install the synchro hub, synchro spring, synchro ring, super-iow 2 gear, distance collar and ball bearing fon the superiow 2 shaft; Install the assembly in the transmission housing. 3, Measure the distance (8) between the end of the transmission housing and superiow 2 shaft Note: ‘© Use a etiaight edge and fester gauge. {© Measure at three locations and average the readings. SYSCHRO HUB \ Tomei RING = NY WA Jl a DISTANCE COLLAR, 4, Measure the distance © between the surfaces of the cluteh housing and bearing inner race Note ‘© Use a straight edge and feeler gauge. {© Measure at three locations and average the readings END OF CLUTCH HOUSHING \e = 1 / TIS BALL BEARING Adjustment 1. Remove the superiow 2 shaft thrust shim (page Select proper shim or shim pair) on the basis of the 2.30) following calculations: NOTE: Do not use more than one shim. 2. Add measurement B in step 3 to the measurement Cin step 4, b. Subtract the 0.07—0.20 mm (0.0027—0.0079 in.) from the distance in step 5-3 Example: 0.50 mm (0.0197 in.) 4 1.00 mm (0.0394 in.) 7.50 mm (0.059% in.) Max. 1.50 mm (0.0591 in.) 0.07 mm (0.0028 in.) 1.43 mm (0.0563 in.) Min, 1.60 mm (0.0591 in.) “= .0.20 mm (0.0079 in.) '30 mrn (0.0512 in.) c. The required thrust shim is 1.40 mm (0.0561 in.). PART NUMBER THICKNESS 237750-PHB-900 | 1.0 mm (0.0394 in) 237751-PH8-800 1mm (0.0433 in} | 237752-P18-200 237783-PH8-800 237754-PH8-00 2a77bs-Pie-900 237756-PH8-900 237757-PH8-800, [Link] (0.0472 in) 3. mm (0.0512 in) “4 mmm (0.0551 in) 5 mm (0.0881 in) 6 mm (0.0630 in} 7mm {0.0670 in 2-48