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Home >> Honda >> 2009 >> S2000 Base >> Repair and Diagnosis >> Transmission >> Manual Transmission Overhaul >> Mainshaft Assembly Clearance Inspection
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Mainshaft Assembly Clearance Inspection

NOTE:
  • If replacement is required, always replace the synchro sleeve and hub as a set.
  • Support the bearing inner race, and push down on the mainshaft as shown.
    Fig 1: Measuring Clearance Between 3rd Gear And Ball Bearing With Feeler Gauge
    G03693453Courtesy of AMERICAN HONDA MOTOR CO., INC.
  1. Measure the clearance between 3rd gear (A) and the ball bearing (B) with a feeler gauge.
    • If the clearance is more than the service limit, go to step 2.
    • If the clearance is within the service limit, go to step  4.

    Standard: 0.06-0.19 mm (0.002-0.007 in.) 

    Service Limit: 0.3 mm (0.012 in.) 

    Fig 2: Measuring Clearance Between 3rd Gear And Ball Bearing With Feeler Gauge
    G03693454Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Measure the distance of the distance collar.
    • If distance is not within the standard, replace the distance collar.
    • If distance is within the standard, go to step 3.

    Standard: 35.23-35.28 mm (1.387-1.389 in.} 

    Fig 3: Measuring Distance Of Distance Collar
    G03693455Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Measure the thickness of 3rd gear.
    • If the thickness is less than the service limit, replace 3rd gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub and sleeve.

    Standard: 35.09-35.17 mm (1.381-1.385 in.) 

    Service Limit: 34.97 mm (1.377 in.) 

    2000-2003 models: 

    Fig 4: Measuring Thickness Of 3rd Gear (2000-2003 Models)
    G03693456Courtesy of AMERICAN HONDA MOTOR CO., INC.

    2004-2008 models: 

    Fig 5: Measuring Thickness Of 3rd Gear (2004-2008 Models)
    G03693457Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Measure the clearance between 4th gear (A) and the distance collar (B) with a feeler gauge.
    • If the clearance is more than the service limit, go to step 5.
    • If the clearance is within the service limit, go to step  7.

    Standard: 0.06-0.19 mm (0.002-0.007 in.) 

    Service Limit: 0.3 mm (0.012 in.) 

    Fig 6: Measuring Clearance Between 4th Gear And Distance Collar
    G03693458Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Measure distance (1) on the distance collar.
    • If distance (1) is not within the standard, replace the distance collar.
    • If distance (1) is within the standard, go to step 6.

    Standard: 32.03-32.08 mm (1.261-1.263 in.) 

    Fig 7: Measuring Distance On Distance Collar
    G03693459Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Measure the thickness of 4th gear.
    • If the thickness is less than service limit, replace 4th gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub and sleeve.

    Standard: 31.89-31.97 mm (1.256-1.259 in.) 

    Service Limit: 31.77 mm (1.251 in.) 

    2000-2003 models: 

    Fig 8: Measure Thickness Of 4th Gear (2000-2003 Models)
    G03693460Courtesy of AMERICAN HONDA MOTOR CO., INC.

    2004-2008 models: 

    Fig 9: Measure Thickness Of 4th Gear (2004-2008 Models)
    G03693461Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Measure the clearance between 5th gear (A) and the distance collar (B) with a dial indicator.
    • If the clearance is more than the service limit, go to step 8.
    • If the clearance is within the service limit, go to step  10.

    Standard: 0.06-0.19 mm (0.002-0.007 in.) 

    Service Limit: 0.3 mm (0.012 in.) 

    Fig 10: Measuring Clearance Between 5th Gear And Distance Collar
    G03693462Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Measure distance (2) on the distance collar.
    • If distance (2) is not within the standard, replace the distance collar.
    • If distance (2) is within the standard, go to step 9.

    Standard: 32.03-32.08 mm (1.261-1.263 in.) 

    Fig 11: Measuring Distance On Distance Collar
    G03693463Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Measure the thickness of 5th gear.
    • If the thickness is less than the service limit, replace 5th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and sleeve.

    Standard: 31.89-31.97 mm (1.256-1.259 in.) 

    Service Limit: 31.77 mm (1.251 in.) 

    Fig 12: Measuring Thickness Of 5th Gear
    G03693464Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Measure the clearance between 6th gear (A) and the mainshaft (B) with a dial indicator. If the clearance is more than the service limit, go to step 11.

    Standard: 0.06-0.19 mm (0.002-0.007 in.) 

    Service Limit: 0.3 mm (0.012 in.) 

    Fig 13: Measuring Clearance Between 6th Gear And Mainshaft
    G03693465Courtesy of AMERICAN HONDA MOTOR CO., INC.
  11. Measure the thickness of 6th gear.
    • If the thickness is less than the service limit, replace 6th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub and sleeve.

    Standard: 28.89-28.97 mm (1.137-1.141 in.) 

    Service Limit: 28.77 mm (1.133 in.) 

    Fig 14: Measuring Thickness Of 6th Gear
    G03693466Courtesy of AMERICAN HONDA MOTOR CO., INC.
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