Transmission fluid 1. Park the vehicle on level ground and turn off the engine. 2. Unscrew the filler plug, remove the washer, check the fluid condition and make sure that the fluid level is normal. 3. If the transmission fluid is dirty,...
Reversing light switch 1. Disconnect the 2-pin reversing light switch connector. 1. WASHER, Replace 2. REVERSE LIGHT SWITCH, 25 Nm (2.5 kgf/m) 2. Check the continuity between the terminals. Conductivity should be when switching the lever to...
Transfer case — check on the car Warning! Make sure jacks and safety stands are securely installed ( see ch. 1 ). 1. Raise the front of the car and securely fasten it to the safety stands ( see ch. 1 ). 2. Apply the parking brake and block both rear...
Transfer case — removal Warning! Make sure jacks and safety stands are securely installed ( see ch. 1 ). 1. Raise the front of the car and securely fasten it to the safety stands ( see ch. 1 ). 2. Apply the parking brake and block both rear...
Transfer case — installation 1. Install a new O-ring on the transfer case assembly. 2. Wipe the areas where the transfer case assembly and transmission meet with solvent or carburetor cleaner and dry with compressed air. Then apply MTF transmission...
Gear shift mechanism — repair Note: When disassembling, check the rubber parts for wear and damage. Make sure the new cotter pin is tight. Be careful not to damage the guide tube when removing the cables. 1. GEAR LEVER HANDLE, 8 Nm (0.8 kgf/m) 2....
Removing the gearbox Warning! Make sure jacks and safety stands are securely installed ( see ch. 1 ). Apply the parking brake and block the rear wheels so that the vehicle does not roll off the bed and fall on you while you are working...
Gearbox — design description When disassembling / assembling the gearbox, be guided by the following figures. Thoroughly clean all parts in solvent and dry with compressed air. Lubricate all parts with MTF before assembly. Note: In the gearbox of...
Transmission housing — disassembly 1. Remove the transfer case assembly or left cover. 2. Remove the gearshift cover assembly and clean it of sealant. 3. Loosen the locking bolt. 4. Turn the gear selector counterclockwise, then remove the shifter pin A...
Cover and axis of the gearshift leash — disassembly and assembly Cover of a leash of switching assy 1. Unscrew the breather cap and ball set screw, remove the washer, spring and steel ball. 2. Unscrew the special bolt and remove the conical spring washers. 3. Remove the shift lever,...
Reverse shift fork holder Clearance check 1. Measure the gap between the reverse shift fork holder and the 5th/reverse shift pin. 2. If the gaps exceed the specified limit, measure the width of the grooves in the reverse shift fork holder....
Shift Forks Assemblies — Disassembly, Assembly and Inspection Disassembly/Assembly Before assembly, wipe all parts with solvent, dry them and apply lubricant to the contact areas. 1. 3rd/4th gear fork 2. 1ST/2nd GEAR SHIFT FORK 3. DRINK, 5 mm, 07GAD-PG20100 4. SPRING PIN 5x22 mm....
Output shaft — design description Note: The 3rd/4th and 5th gear synchronizer hubs and ball bearing are installed using a press. Before assembly, wipe all parts with solvent, dry them and apply lubricant to the contact areas. However, the 3rd/4th and...
Output Shaft — Clearance Check Note: Synchronizer cage and hub must be replaced as an assembly. 1. Using a chuck to hold the bearing inner race, press the race onto the output shaft. 2. Measure the clearance between the 2nd and 3rd gears. Standard:...
Output shaft — disassembly, inspection and assembly Disassembly Warning! Remove the synchronizer hubs using a press and steel bars, as shown in the figure. If you use a puller with grips, you can break the gear teeth. 1. Mount the 5th gear on steel blocks and press the...
Intermediate shaft — design description Before assembly, wipe all parts in solvent, dry them and apply lubricant to the contact areas. 1. reverse gear; 2. 1st/2nd gear synchronizer hub; 3. friction damper; 4. synchronizer spring; 5. two-cone synchronizer; 6....
Intermediate Shaft — Clearance Check Note: Synchronizer cage and hub must be replaced as an assembly. 1. Measure the clearance between the 1st gear and thrust washer. Standard: 0.06-0.18mm Limit: 0.23mm 2. If the clearance is greater than the specified...
Intermediate shaft — disassembly 1. Clamp the layshaft assembly securely in a vise with blocks of wood in place. 2. Bend the tongue of the locknut out of the groove on the intermediate shaft, then unscrew the locknut and remove the spring washer. 3....
Intermediate shaft — wear check 1. Check the surface of the gears and bearings for wear and damage, then take measurements on the countershaft at points A, B and C. Standard Limit A: 36.000-36.015 mm 35.95 mm IN: 36.984-37.000 mm 36.93 mm WITH:...
Intermediate Shaft — Assembly Warning! Press the 3rd, 4th and 5th gears onto the countershaft without lubrication. When pressing the gears of the 3rd, 4th and 5th gears, install the shaft on steel bars and use a press. Press the 3rd, 4th and 5th...
Clip and hub of the synchronizer Examination 1. Check all hubs and synchronizer cages for rounded gear teeth, indicating wear. 2. Insert the hubs into their respective synchronizer sleeves and check if they rotate freely. Note: Synchronizer cage and...
Ring, synchronizer gear Examination 1. Check the synchronizer ring and gear. A. Check the synchronizer ring for wear on the inside. B. Check the teeth of the synchronizer cage and the corresponding teeth on the synchronizer ring for wear...
Differential — design description Note: When replacing parts marked with an asterisk (*), the tapered roller bearing preload needs to be adjusted. 1. 'THRESHOLD GASKET'. Adjustment ( see below ) 2. 'OUTER RING OF BEARING'. Replacement ( see below )....
Differential — check and replace 1. Fix differential in gathering on prisms and establish both semiaxes. 2. Measure the clearance between both side gears and satellites. If the clearance is greater than the specified range, replace the differential...
Differential — Replacing the outer race of the bearing Note: Bearing outer race and tapered roller bearing must be replaced together. When replacing a tapered roller bearing, check and adjust its preload. 1. Press the oil seals out of the gearbox housing and clutch housing....
Differential — Tapered Roller Bearing Preload Adjustment Note: When replacing any of the components listed below, the tapered roller bearing preload must be adjusted. gearbox housing clutch housing differential cup Tapered roller bearing and bearing outer ring thrust washer...
Replacement of oil seals Gearbox housing 1. Remove the oil seal from the gearbox housing. 2. Using the special tool, press a new oil seal into the gearbox housing as shown in the illustration. Note: The oil seal must be pressed in with a...
Transfer case — design description 1. TRANSFER BOX CASE 2. O-ring, replace 3. DAMPING HUB 4. NEEDLE BEARING 5. DRIVE GEAR OF THE TRANSFER BOX 6. TRANSFER BOX SHAFT 7. OUTER RING OF TAPERED ROLLER BEARING 8. TAPERED ROLLER BEARING 9. TRANSFER BOX SHAFT...
Transfer case — checking the elements Note: To prevent damage to the transfer case housing, always secure it in a soft jaw vise or insert gasket material between the vise and transfer case. Measuring the clearance in the transfer case gear (hypoid gear) 1....
Transfer case — disassembly 1. Remove covers A and B of the transfer case. 1. COVER A OF TRANSFER BOX 2. TRANSFER BOX CASE 3. COVER IN TRANSFER BOX 4. O-ring. Replace 5. O-ring. Replace 2. Cut off the retaining tabs of the locknut with a chisel....
Transfer case drive gear bearing replacement Note: Apply oil to all parts when assembling. 1. Using the special tool, press the tapered roller bearing out of the transfer case drive gear. 1. DRIVE HANDLE, 07749-0010000 2. PRESS 3. DRIVER, 37x40 mm, 07746-0010200...
Replacing the bearing of the driven gear of the transfer case Note: Apply oil to all parts when assembling. 1. Using the special tool, press the tapered roller bearing off the transfer case driven gear shaft. 1. TRANSFER GEAR DRIVE SHAFT 2. PRESS 3. WASHER 4. TAPERED ROLLER...
Disassembly and assembly of the transfer case shaft 1. Install the transfer case driven gear on steel bars, then press the transfer case shaft out of the damper hub as shown. 1. DAMPER HUB 2. PRESS 3. TRANSFER BOX SHAFT 4. DRIVE GEAR OF THE TRANSFER BOX 2. Align the...
Replacing the outer ring of the bearing cover A of the transfer case Note: Apply oil to all parts when assembling. 1. Press the tapered roller bearing outer race out of the transfer case cover A by heating the cover to about 100"With a fan heater. Do not heat the lid above 100°C. 1. FAN...
Replacing the outer ring of the transfer case housing bearing Note: Apply oil to all parts when assembling. 1. Knock out the tapered roller bearing outer race from the transfer case housing. 1. TRANSFER BOX CASE 2. BEARING OUTER RING 2. Using the special tool, press in a new...
Transfer case — assembly Note: When assembling the transfer case assembly: Check and adjust the shape of the contact patch of the gear teeth of the transfer case. Measure and adjust the clearance in the transfer case gears. Check and adjust the...
Front bearing and oil seal — replacement 1. Using the special tool, press out the ball bearing as shown in the illustration. 1. ADJUSTABLE BEARING PULLER, 07JAC-PH80000 2. CLUTCH CASE 2. Remove the oil seal from the clutch housing (figure in the right column...
Countershaft bearing — replacement 1. Remove the mounting plate from the clutch housing. 1. CLUTCH CASE 2. Replace 3. MOUNTING PLATE 2. Using the special tool, press out the needle bearing, then remove the oil dispensing plate. 1. ADJUSTABLE BEARING...
Output shaft thrust clearance — adjustment 1. Remove the 78mm shim and oil dispensing plate from the transaxle case. 2. Install the 3rd/4th synchro hub, spacer, 5th synchro hub, bush, and ball bearing onto the output shaft, then install these assemblies into the...
Gearbox — assembly 1. Install the differential assembly into the clutch housing. 2. Install the spring washer and washer at an angle to the clutch housing as shown. 3. Insert the secondary and intermediate shafts into the shift forks and...
Gearbox — installation 1. Make sure the two dowel pins are installed in the clutch housing. 2. Apply HONDA Genuine Urea Grease UM264 (P/N 41211-PY-305) on the release fork, release fork bolt, release bearing and release bearing guide. 3....