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Transaxle Disassembly

NOTE: On B18C1 and B18C5 VTEC engines, when replacing either transaxle housing, bearing preload must be reset.
NOTE: Place clutch housing on supports high enough to keep mainshaft from hitting workbench.
  1. Remove back-up light switch. Remove transaxle hanger. Remove bolts, washers springs and steel balls from transaxle cover. Remove all housing bolts in crisscross pattern. Remove 32-mm sealing bolt (32-mm bolt has square hole). See Fig 1 and Fig 2 .
  2. Remove snap ring on countershaft ball bearing. Separate transmission housing and clutch housing. Remove thrust shim and oil guide plate and oil gutter plate from housing. Remove 16-mm sealing bolt (bolt has hex hole). Remove oil gutter plate.
  3. Measure clearance between reverse shift fork and 5th-reverse shift piece pin. Clearance for reverse side (top of "L" groove) should be .002"-.018" (.05-.45 mm). Clearance for 5th gear side should be .016-.035" (.40-.90 mm). See Fig 3 . If clearance exceeds specification, measure width of groove in reverse shift fork. Width for reverse side should be .278-.285" (7.05-7.25 mm). Width for 5th gear side should be .291-.303" (7.40-7.70 mm). If width of groove exceeds specification, replace reverse shift fork. If width of groove is within specification, replace 5th-reverse shift piece.
  4. Measure clearance between reverse idler gear and reverse shift fork. See Fig 4 . Clearance should be .020-.043" (.50-1.10 mm). Service limit is .071" (1.80 mm). If clearance exceeds service limit, measure width of reverse shift fork pawl groove. Opening should be .512-.524" (13.0-13.3 mm). If width exceeds specification, replace reverse shift holder. If width is within specification, replace reverse idler gear.
    Fig 1: Exploded View Of S80 Transaxle Assembly (1 Of 2)
    G95D20902Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 2: Exploded View Of S80 Transaxle Assembly (2 Of 2)
    G96E29904Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 3: Measuring Reverse Shift Fork Pin Groove
    G93I22747Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 4: Measuring Reverse Shift Fork
    G93A22749Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Remove reverse shift holder. Remove reverse idler gear shaft and reverse idler gear. Measure clearance between shift piece and shift arm. Clearance should be .004-.012" (.10-.30 mm). Service limit is .024" (.60 mm). If clearance exceeds service limit, measure width of groove in shift piece. See Fig 5 . Width should be .319-.323" (8.10-8.20 mm). If width of groove exceeds specification, replace shift piece. If width of groove is within specification, replace shift arm.
  6. Measure clearance between select arm and interlock. Clearance should be .002-.010" (.05-.25 mm). Service limit is .020" (.50 mm). If clearance exceeds service limit, measure width of interlock. See Fig 6 . Width should be .390-.394" (9.90-10.00 mm). If width exceeds specification, replace select arm. If width is within specification, replace interlock.
  7. Measure clearance between select arm and shim. Clearance should be .0004-.008" (.01-.20 mm). See Fig 7 . If clearance exceeds specification, select appropriate thrust shim for correct clearance. See THRUST SHIM SPECIFICATIONS  table.
    Fig 5: Measuring Shift Piece
    G93F22751Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 6: Measuring Interlock Clearance
    G93H22753Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 7: Measuring Select Arm Clearance
    G93J22755Courtesy of AMERICAN HONDA MOTOR CO., INC.
    THRUST SHIM SPECIFICATIONS

    Part Number Thickness - In. (mm)
    24435-689-000 .031 (.80)
    24436-689-000 .039 (1.00)
    24437-689-000 .047 (1.20)
    24438-689-000 .055 (1.40)
    24439-689-000 .063 (1.60)
  8. Measure clearance between shift arm holder and change piece. Clearance should be .002-.014" (.05-.35 mm). Service limit is .031" (.80 mm). See Fig 8 . Width should be .474-.478" (12.05-12.15 mm). If clearance exceeds service limit, measure groove of change piece. If groove exceeds specification, replace change piece. If groove is within specification, replace change piece.
  9. Measure clearance between select arm and change piece. Clearance should be .002-.014" (.05-.35 mm). Service limit is .020" (.50 mm). See Fig 8 . If clearance exceeds service limit, measure width of select arm. Width should be .474-.478" (12.05-12.15 mm). If width exceeds specification, replace select arm. If width is within specification, replace change piece.
  10. Remove shift piece shaft, then remove shift piece and interlock. Remove change holder assembly. Tape mainshaft spline for protection. Remove mainshaft and countershaft assemblies with shift fork from clutch housing. Remove differential assembly. Remove chamber plate. Remove shift rod change piece bolt and spring washer. Remove set bolt, spring and steel ball. Remove shift rod, then remove change piece. Remove oil seal.
  11. Measure clearance between synchro sleeve and shift fork. Clearance should be .014-.026" (.35-.65 mm). Service limit is .039" (1.00 mm). If clearance exceeds service limit, measure width of shift fork fingers. On 3rd and 4th gear shift fork fingers, thickness should be .291-.299" (7.4-7.6 mm). If width of shift fork fingers exceeds specification, replace shift fork. If width of shift fork fingers is within specification, replace synchro sleeve. Synchro sleeve and synchro hub should ALWAYS be replaced together.
  12. Measure clearance between shift piece or shift fork and shift arm. Clearance should be .008-.020" (.20-.50 mm). Service limit is .031" (.80 mm). See Fig 9 . If clearance exceeds service limit, measure width of shift piece. Clearance should be .469-.472" (11.9-12.0 mm). If width of shift piece or shift fork exceeds specification, replace shift piece or shift fork. If width is within specification, replace shift arm.
Fig 8: Measuring Shift Arm Holder & Change Piece
G93A22756Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 9: Measuring Shift Piece & Shift Fork Shaft
G93G22760Courtesy of AMERICAN HONDA MOTOR CO., INC.
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