Secondary Shaft Inspection — 1984-89 Accord, 1984-87 Prelude (Honda Accord 3)

1. Inspect the needle bearing for wear or damage.

2. Check the clearance between each shift fork and its corresponding synchronizer sleeve. The tolerance is 0.35-1.00 mm. If the clearance exceeds the tolerance, measure the groove width on the sleeve. The width tolerance is 6.75-6.85 mm.

3. Inspect the gear teeth on all hubs and synchronizer couplings for worn edges, which indicates wear.

4. Insert each hub into its respective coupling and check for play. If necessary, replace them together as a single unit.

5. Inspect the inner surface of the synchronizer ring, its teeth and the corresponding teeth on the gear for worn edges.

6. Inspect the thrust and conical surfaces of the gear hub for wear.

7. Inspect all gear teeth for uneven wear, scoring, burrs and cracks.

8. Install the synchronizer 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 0.40-1.18 mm. Remove the ring from the gear.

9. Inspect the oil passages for clogging. Inspect the secondary shaft splines for damage.

10. Measure the diameter of the outer surface of the bearing from the end opposite the thread. The tolerance is 32.95-33.02 mm.

11. Measure the outer surface diameter of the bearing located in front of the secondary shaft gear. The tolerance is 33.93-34.00 mm.

12. Measure the diameter of the outer surface of the bearing closest to the threaded end. The tolerance is 24.93-25.00 mm.

13. Check the secondary shaft for wear. The maximum allowable wear is 0.05 mm. If any of the tolerances are not met, the secondary shaft should be replaced.