Secondary Shaft Inspection — 1990-91 Accord, 1988-91 Prelude (Honda Accord 3)

1. Inspect the needle bearings for wear and damage.

2. Inspect the inner surface of the synchronizer locking rings for wear.

3. Insert the hub into the appropriate 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 chatter.

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 oil passages in the secondary shaft for blockage.

9. Measure the outer diameter of the contact surface of the needle bearing. The tolerance is 32.95-33.02 mm.

10. Measure the outside diameter of the contact surface of the low gear behind the splines. The tolerance is 39.93-40.00 mm.

11. Measure the outside diameter of the ball bearing surface near the threaded end of the shaft. The tolerance is 24.94-25.00 mm.

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