Honda HR-V: Countershaft Disassembly, Reassembly, and Inspection (M/T)
Special Tools Required
Driver, 58 x 62 mm 070AD-PYZA100
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Driver Handle, 40 mm I.D. 07746-0030100
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Bearing Driver Attachment, 30 mm I.D. 07746-0030300
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Disassembly
NOTE: Refer to the Exploded View as needed during this procedure.
1. Countershaft - Disassemble
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- Securely clamp the countershaft assembly in a bench vise with wood
blocks
- Remove the special bolt (left-hand threads).
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- Support 6th gear (A) on steel blocks, and press the countershaft (B) out
of the ball
bearing and 6th gear using an attachment (C) and a press (D)
- Remove the 35 mm shim.
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- Support 4th gear (A) on steel blocks, and press the countershaft (B) out
of 4th gear
and 5th gear using an attachment (C) and a press (D).
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- Support 2nd gear (A) on steel blocks, and press the countershaft (B) out
of 2nd gear
and 3rd gear using an attachment (C) and a press (D).
Inspection
1. Countershaft - Inspect
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- Inspect the oil passage, gear, and bearing contact areas for wear and
damage, then
measure the countershaft at points A, B, C, and D. If any part of the
countershaft is
less than the service limit, replace it.
Standard:
- Ball Bearing Contact Area (Transmission Housing Side):
30.002-30.015 mm (1.18118-1.18169 in)
- 2nd Gear Distance Collar Contact Area:
40.2-40.6 mm (1.583-1.598 in)
- Countershaft Reverse Gear Contact Area:
42.975-42.991 mm (1.69193-1.69256 in)
- Needle Bearing Contact Area (Clutch Housing Side):
35.000-35.015 mm (1.37795-1.37854 in)
Service Limit:
- 30.002 mm (1.18118 in)
- 40.2 mm (1.583 in)
- 42.975 mm (1.69193 in)
- 35.000 mm (1.37795 in)
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- Inspect the runout by supporting both ends of the countershaft. Then
rotate the
countershaft two complete turns while measuring with a dial gauge. If the
runout
exceeds the standard, replace the countershaft.
Standard: 0.02 mm (0.0008 in) max.
Exploded View
1. Countershaft - Exploded View
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Fig. 26: Exploded View Of Countershaft With Torque Specifications
Reassembly
NOTE: Refer to the Exploded View as needed during this procedure.
1. Countershaft - Reassemble
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- Clean all parts in solvent, dry them, and apply MTF to all contact
surfaces
- Install the countershaft reverse gear (A)
- Install the needle bearing (B)
- Install 1st gear (C).
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- Install the triple cone synchro assembly (A) with the synchro spring (B)
by aligning
the synchro cone fingers (C) with the holes (D) in 1st gear.
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- Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers
(B) with the
grooves (C) in the 1st/2nd synchro hub.
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- Install the 1st/2nd synchro sleeve (A) by aligning the slots of the
1st/2nd synchro
sleeve and the 1st/2nd synchro hub (B).
NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.
- Check the operation of the 1st/2nd synchro hub set.
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- Install the triple cone synchro assembly (A) with the synchro spring (B)
by aligning
the synchro ring fingers (C) with the grooves (D) in the 1st/2nd synchro
hub.
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- Install the 2nd gear distance collar (A) with the needle bearing (B).
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- Install 2nd gear (A) by aligning the synchro cone fingers (B) with the
holes in 2nd
gear (C).
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- Support the countershaft (A) on steel blocks, then press on 3rd gear (B)
using the
58 x 62 mm driver and a press (C).
NOTE: Do not exceed the maximum pressure.
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- Press on 4th gear (A) using the 58 x 62 mm driver and a press (B).
NOTE: Do not exceed the maximum pressure.
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- Press on 5th gear (A) using the 40 mm I.D. driver handle and a press
(B).
NOTE: Do not exceed the maximum pressure.
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- Press on 6th gear (A) using the 40 mm I.D. driver handle and a press
(B).
NOTE: Do not exceed the maximum pressure.
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- Install the 35 mm shim (A), and temporarily press on the used ball
bearing (B)
using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver
attachment, and a
press (C).
NOTE:
- Use any size of 35 mm shim, and note size you used. Measurements
taken in the
following steps will determine the correct shim to use for final
assembly.
- Make sure the ball bearing is installed in the correct direction.
- Measure the clearance between the ball bearing (A) and the 35 mm shim
(B) with a feeler gauge (C).
Standard: 0.04-0.10 mm (0.0016-0.0039 in)
- If the measured clearance in step 17 is not within the standard, select
another suitable 35 mm shim from the table, then go to next step to replace
the 35 mm shim and the ball bearing with new
ones. If the measured clearance in step 17 is within the standard, go to the
next step to replace only the ball bearing with a new one.
35 mm Shim
A 0.87 mm (0.0343 in)
AA 0.91 mm (0.0358 in)
B 0.95 mm (0.0374 in)
AB 0.99 mm (0.0390 in)
C 1.03 mm (0.0406 in)
AC 1.07 mm (0.0421 in)
D 1.11 mm (0.0437 in)
AD 1.15 mm (0.0453 in)
E 1.19 mm (0.0469 in)
AE 1.23 mm (0.0484 in)
F 1.27 mm (0.0500 in)
AF 1.31 mm (0.0516 in)
G 1.35 mm (0.0532 in)
AG 1.39 mm (0.0547 in)
H 1.43 mm (0.0563 in)
AH 1.47 mm (0.0579 in)
J 1.51 mm (0.0594 in)
AJ 1.55 mm (0.0610 in)
K 1.59 mm (0.0626 in)
AK 1.63 mm (0.0642 in)
L 1.67 mm (0.0657 in)
AL 1.71 mm (0.0673 in)
M 1.75 mm (0.0689 in)
AM 1.79 mm (0.0705 in)
N 1.83 mm (0.0720 in)
AN 1.87 mm (0.0736 in)
P 1.91 mm (0.0752 in)
AP 1.95 mm (0.0768 in)
Q 1.99 mm (0.0783 in)
- Remove 6th gear with the ball bearing and the 35 mm shim using a press.
- Repeat step 15 to install 6th gear.
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- Install the correct 35 mm shim (A) and a new ball bearing (B) using the
40 mm
I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press
(C).
NOTE:
- If necessary, replace the 35 mm shim with the correct one selected
in step 18.
- Make sure the ball bearing is installed in the correct direction.
- Recheck the clearance between the ball bearing and the 35 mm shim with a
feeler
gauge.
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Fig. 27: Countershaft Assembly Special Bolt With Torque Specifications
- Securely clamp the countershaft assembly in a bench vise with wood
blocks (A)
- Tighten a new special bolt (B) (left-hand threads).
NOTE: Apply new MTF to the bolt threads and flange.
READ NEXT:
Special Tools Required
Driver Handle, 40 mm I.D. 07746-0030100
Driver, 30 mm I.D. 07946-MB00000
Disassembly
NOTE: Refer to the Exploded View as needed during this procedure.
1. Mainshaft - Disassemb
Inspection
1. Synchro Sleeve and Hub - Inspect
Inspect the gear teeth on all synchro hubs and synchro sleeves for wear
(rounded off
corners)
Install each synchro hub (A) in its mating synchro s
SEE MORE:
NOTE: Before you troubleshoot, review the how to troubleshoot the
electric parking brake system.
1. Problem verification:
Turn the vehicle to the ON mode.
Clear the DTC with the HDS.
Turn the vehicle to the OFF (LOCK) mode, then to the ON mode.
Pull the electric parking brake switch to apply
REMOVAL & INSTALLATION
ENGINE START/STOP SWITCH REMOVAL AND INSTALLATION
Removal and Installation
1. Dashboard switch Panel - Remove
2. Engine Start/Stop Switch - Remove
3. All Removed Parts - Install
Install the parts in the reverse order of removal.
STARTER REMOVAL, INSTALLATION, AND PERFO