Warning!
- Press the 3rd, 4th and 5th gears onto the intermediate shaft without lubrication.
- When pressing in the 3rd, 4th and 5th gears, place the shaft on steel blocks and use a press.
- Press the 3rd, 4th and 5th gears onto the intermediate shaft with a seating force of 9800 N (1000 kgf).
- For final landing the force must be 925480 N (2600 kgf).
Note: When assembling, refer to the figure of the intermediate shaft assembly (see above).
1. Install the thrust washer, needle bearing, 1st gear and friction damper.
Note: Install the friction damper on the 1st gear before installation.
2. Install the double-cone synchronizer.
3. Install the 1st/2nd gear synchronizer hub by aligning the tabs on the friction damper with the grooves on the synchronizer hub.
4. Using a special tool, install the friction damper on the bushing and press it in as shown in the figure.
5. Install the 2nd gear gear by aligning the projections of the synchronizer cone with the grooves of the 2nd gear gear.
6. Install the intermediate shaft on steel blocks as shown in the figure, use a special tool to install the 3rd gear pinion and press it in as shown in the figure.
7. Using the special tool, install the 4th gear and press it in as shown in the figure.
8. Using the special tool, install the 5th gear pinion and press it in as shown in the figure.
9. Using a special tool, install the needle bearing and press it in as shown in the figure, install the outer ring of the bearing.
10. Using the special tool, install the ball bearing and press it in as shown in the figure.
11. Securely clamp the intermediate shaft assembly in a vice using wooden blocks.
12. Install the spring washer.
13. Install the new locknut, tightening it to the required torque, then tap the locknut tongue into the groove.
Tightening torque: 127-0-127 Nm (13-0-13 kgf/m)
(You will find the original on the portal: Hondabook.ru)