Checking clearances on the secondary shaft assembly (Honda CR-V 2)

Note: The synchronizer sleeve and hub must be replaced as a set.

1. Insert the bearing inner race into a cartridge (A) of the appropriate size and press the race onto the secondary shaft (B).

2. Measure the clearance between the 2nd (C) and 3rd (D) gears using a feeler gauge (E).

If the gap exceeds the specified limit, proceed to step. 3.
If the gap is within the specified limit, proceed to step. 4.

Standard	0.06-0.16 mm
Limit	0.25 mm

3. Measure the thickness of the 3rd gear.

If the thickness of the 3rd gear is less than the specified limit, replace the 3rd gear with a new one.
If the thickness of the 3rd gear is within the specified limit, replace the 3rd/4th gear synchronizer hub with a new one.

Standard	23.92-23.97 mm
Limit	23.80 mm

4. Measure the clearance between the 4th gear (A) and the spacer sleeve (B) using a dial indicator (C). If the clearance exceeds the specified limit, proceed to step. 5.

Standard	0.06-0.16 mm
Limit	0.25 mm

5. Measure the distance [a] on the spacer sleeve.

If the distance [a] is different from the standard, replace the spacer sleeve with a new one.
If the distance [a] is within the normal range, proceed to step. 6.

Standard: 24.03-24.08 mm

6. Measure the thickness of the 4th gear.

If the thickness of the 4th gear is less than the specified limit, replace the 4th gear with a new one.
If the 4th gear thickness is within the specified limit, replace the 3rd/4th gear synchronizer hub with a new one.

Standard	23.92-23.97 mm
Limit	23.80 mm

7. Measure the clearance between the spacer sleeve (A) and the 5th gear (B) using a dial indicator (C). If the clearance exceeds the specified limit, proceed to step 1. 8.

Standard	0.06-0.16 mm
Limit	0.25 mm

8. Measure the distance [b] on the spacer sleeve.

If the distance [B] differs from the norm, replace the spacer sleeve with a new one.
If the distance [B] is within the normal range, go to p. 9.

Standard: 24.03-24.08 mm

9. Measure the thickness of the 5th gear.

If the thickness of the 5th gear is less than the specified limit, replace the 5th gear with a new one.
If the 5th gear thickness is within the specified limit, replace the 5th gear synchronizer hub with a new one.