2. Inspect the inner surface of the synchronizer locking rings for wear.
3. Insert each hub into its original coupling and check for play. If replacement is required, they should be replaced together as a single unit.
4. Inspect the teeth of the synchronizer locking rings and the mating teeth on the gears for wear and tear.
5. Inspect the pinion hub thrust and cone surfaces for wear.
6. Inspect all gear teeth for uneven wear, scoring, burrs and cracks.
7. Install the synchronizer locking ring into the cone of the corresponding gear and rotate it until it stops. The clearance between the ring and the gear has a tolerance of 0.40-1.10 mm. Remove the ring from the gear.
8. Inspect the splines and gear teeth on the input shaft for damage and excessive wear.
9. Inspect the oil passages for blockages.
10. If the clearance between the 2nd and 3rd gears does not meet the tolerance, measure the thickness of the 3rd gear from the flat end to the top of the conical end. The tolerance is 32.30-32.47 mm. If the width tolerance is not met, replace the gear. If the tolerance is met, replace the synchronizer hub.
11. If the clearance between the 4th gear pinion and the seal does not meet the tolerance, measure the length of the half of the seal that faces the 4th gear pinion. The tolerance is 26.01-26.08 mm. If the tolerance is not met, replace the seal. If this tolerance is met, measure the thickness of the 4th gear pinion from the flat end to the top of the conical end. The width tolerance is 30.80-30.97 mm. If the width does not meet the tolerance, replace the pinion; if it does, replace the synchronizer hub.
12. If the clearance between the 5th gear pinion and the seal does not meet the tolerance, measure the length of the half of the seal that faces the 5th gear pinion. The tolerance is 26.01-26.08 mm. If the tolerance is not met, replace the seal. If this tolerance is met, measure the thickness of the 5th gear pinion from the flat end to the top of the conical end. The width tolerance is 30.30-30.47 mm. If the width does not meet the tolerance, replace the pinion; if it does, replace the synchronizer hub.
13. Measure the outer diameter of the contact surface of the ball bearing in front of the 1st gear. The tolerance is 27.94-27.99 mm.
14. Measure the outer diameter of the contact surface of the 3rd gear. The tolerance is 37.93-38.0 mm.
15. Measure the outside diameter of the contact surface of the needle bearing behind the splines of the 5th gear synchronizer hub. The tolerance is 27.94-27.99 mm.
16. Check the wear of the primary shaft. The maximum permissible wear is 0.05 mm. If any of the tolerances are not met, the primary shaft should be replaced.
Material obtained from the website hondabook