Honda Element. Manual — part 632

Fig. 97: Identifying Length Of Distance Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Measure the thickness of 2nd gear.



If the thickness is less than the service limit, replace 2nd gear.



If the thickness is within the service limit, replace the 1st/2nd synchro hub and reverse gear as a set.

Standard: 27.92-27.97 mm (1.099-1.101 in.)

Service Limit: 27.87 mm (1.097 in.)

Fig. 98: Identifying Thickness Of 2nd Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.

COUNTERSHAFT DISASSEMBLY

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

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element

Fig. 99: Removing Countershaft Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Remove the special bolt (left-hand threads).

3. Support the ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the

countershaft out of the ball bearing.

Fig. 100: Pressing Countershaft Ball Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the 35 mm shim and distance collar.

5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the

countershaft (E) out of 5th gear (F).

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element

Fig. 101: Pressing Countershaft Of 5th Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the

countershaft (E) out of 3rd gear (F).

Fig. 102: Pressing Countershaft Out Of 3rd Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.

COUNTERSHAFT INSPECTION

1. Inspect the gear and bearing contact areas for wear and damage, then measure the countershaft at points

A, B, and C. If any part of the countershaft is less than the service limit, replace it.

Standard:

A Ball Bearing Contact Area (Transmission Housing Side): 30.020-30.033 mm (1.1819-1.1824 in.)

B Distance Collar Contact Area: 39.937-39.950 mm (1.5723-1.5728 in.)

C Needle Bearing Contact Area (Clutch Housing Side): 35.000-35.015 mm (1.3780-1.3785 in.)

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element

Fig. 103: Identifying Gear And Bearing Contact Areas For Wear And Damage With Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. 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 is more than the service limit, replace the
countershaft.

Standard: 0.02 mm (0.001 in.) max.

Service Limit: 0.05 mm (0.002 in.)

Fig. 104: Inspecting Runout With Supporting Both Ends Of Countershaft
Courtesy of AMERICAN HONDA MOTOR CO., INC.

COUNTERSHAFT REASSEMBLY

EXPLODED VIEW

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element