Reassembly

1. Clean all liquid gasket residue from the mating surfaces of transmission and clutch housings.




2. Install the shift rod, selector arm, new lock plate and bolt. Bend the lock tab on lock plate over against bolt head.




3. Install the 72 mm snap ring in the clutch housing, then install the differential.




4. Align the shift arm with selector arm and install the shift arm holder. Install the bolts, using the correct bolt in each hole, and torque as shown.




5. Install the mainshaft and countershaft as an assembly.




6. Lift the countershaft 1st and 2nd synchro sleeve to shift into 2nd gear.




7. Install the 1st/2nd gear shift fork on synchro sleeve, then rotate into place so that lugs on back of fork fit over shift arm.




8. Insert the 3rd/4th shift fork shaft into 3rd/4th shift guide, and install the 5 mm spring pin as shown.




9. Insert the 3rd/4th shift fork shaft into 3rd/4th shift fork, then install the shift fork and hook shift guide to shift arm.




10. Install the 1st/2nd shift shaft.




11. Hook the 5th/reverse shift guide to shift arm, then install the shift shaft.




12. Install the spring and detent ball in hole in clutch housing.




13. Install the reverse shift fork with special washer and nut.






NOTE: Make sure that reverse shift fork is aligned with detent ball.




14. Install the reverse idler gear and shaft.




15. Install the three special boils and lock plates on shift shafts then bend tab on each lock plate against boll head.

NOTE: To ease reassembly, lightly oil the shift shafts, transmission shafts, and differential bearings.




16. Apply liquid gasket to the clutch housing as shown.

NOTE: This transmission uses no gasket between the major housings; use Honda P/N 08740-99986 sealant. Assemble the housings within 20 minutes after applying the sealant and allow it to cure at least 30 minutes after assembly before filling it with oil.

17. Install the dowel pins on the clutch housing.




18. Install the transmission housing being careful to line up shafts. Expand countershaft bearing snap ring so that transmission housing can fall into place.




19. Torque bolts (8 x 1.25 mm) in sequence shown, 27 N.m (2.7 kg-m, 20 lb.ft).




20. Install the three detent balls, washers, springs, and retaining screws.




21. Install the thrust washer and the needle bearing.
22. Install the synchro ring and the synchro spring.




23. Install the synchro hub and the synchro sleeve onto the shift fork. Install them onto the mainshaft.

NOTE: Install the synchro hub with its raised inner shoulder facing down.

24. Install the bearing.




25. Drive the spring pin into the shift fork.




26. Apply sealant on the sealing surface of the transmission housing as shown.

NOTE: This transmission uses no gaskets between the major housings; use Honda sealant, P/N 08740-99986. Assemble the housings within 20 minutes after applying the sealant and allow it to cure for at least 30 minutes after assembly before filling it with oil.




27. Install the 5th gear housing, and torque its bolts to 12 N.m (1.2 kg-m, 9 lb-ft).