Honda Jazz/Fit 2004 · Service Manual

M/T Countershaft Reassembly (5MT)

M/T Countershaft Reassembly

Exploded View

 

SAA2E01E34150200000LDAD0122 mm LOCKNUT
Replace.108 N·m
(11.0 kgf·m,
79.6 lbf·ft)22 mm SPRING WASHERBALL BEARING
Check for wear
and operation.
Note the direction
of installation.BALL BEARING
Check for wear
and operation.5TH GEAR4TH GEAR3RD GEARNEEDLE BEARING
Check for wear
and operation.DISTANCE COLLAR2ND GEARSYNCHRO RINGREVERSE GEAR1ST/2ND
SYNCHRO HUBSYNCHRO SPRING1ST GEARNEEDLE BEARING
Check for wear
and operation.COUNTERSHAFTFRICTION DAMPER
Check for wear
and operation.SYNCHRO SPRINGFRICTION DAMPER
Check for wear
and operation.SYNCHRO RING

Special Tools Required
Driver, 40 mm I.D. (  07746-0030100)
 

S80WA00S746003T0100000D01
Attachment, 25 mm I.D. (  07746-0030200)
 
S3YYE00S746003T0200000D01
Attachment, 30 mm I.D. (  07746-0030300)
 
S3YYE00S746003T0300000D01
Attachment, 35 mm I.D. (  07746-0030400)
 
S3YYE00S746003T0400000D01



NOTE: Refer to the Exploded View, as needed during this procedure.

1.Clean all the parts in solvent, dry them, and apply lubricant all contact surfaces.

2.Install the needle bearing (A), 1st gear (B), and friction damper (C) on the shaft.

3.Install the 1st gear synchro ring (D) and synchro spring (E) on the shaft.

 

SAA2E01E34150200000LDAD02EDCBA

4.Align the fingers (A) on the friction damper with the grooves (B) on the 1st/2nd synchro hub (C), then install the 1st/2nd synchro hub onto the shaft.

 

SAA2E01E34150200000LDAD03ABC

5.Install the reverse gear (A), synchro spring (B), and synchro ring (C) on the shaft.

 

SAA2E01E34150200000LDAD04CBA

6.Install the distance collar (A) and friction damper (B), then align the fingers (C) on the friction damper and grooves (D) in the 1st/2nd synchro hub.

 

SAA2E01E34150200000LDAD05BACD

7.Install the needle bearing (A) and 2nd gear (B).

 

SAA2E01E34150200000LDAD06BA

8.Install the 3rd gear (A) using the special tools and a press (B).

 

SAA2E01E34150200000LDAD0707746-003010007746-0030400AB

9.Install the 4th gear (A) using the special tools and a press (B).

 

SAA2E01E34150200000LDAD0807746-003010007746-0030300AB

10.Install the 5th gear (A) using the special tools and a press (B).

 

SAA2E01E34150200000LDAD0907746-003010007746-0030300AB

11.Install the ball bearing (A) using the special tools and a press (B).

 

SAA2E01E34150200000LDAD1007746-003010007746-0030200AB

12.Install the ball bearing (A) using the special tools and a press (B).

 

SAA2E01E34150200000LDAD1107746-003010007746-0030200AB

13.Install the 22 mm spring washer (A) and 22 mm locknut (left-hand threads) (B).

 

SAA2E01E34150200000LDAD12BA

14.Securely clamp the countershaft assembly in a bench vise with wood blocks.

15.Torque the new locknut to 108 N·m (11.0 kgf·m, 79.6 lbf·ft), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.