Honda Element. Manual — part 628

Fig. 67: Identifying Shift Fork Parts
Courtesy of AMERICAN HONDA MOTOR CO., INC.

MAINSHAFT ASSEMBLY CLEARANCE INSPECTION

NOTE:

If replacement is required, always replace the synchro sleeve and synchro hub

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element

1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).

Fig. 68: Measuring Clearance Between 2nd Gear And 3rd Gear With Feeler Gauge
Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).



If the clearance is more than the service limit, go to step 3.



If the clearance is within the service limit, go to step 4.

Standard: 0.06-0.16 mm (0.002-0.006 in.)

Service Limit: 0.25 mm (0.010 in.)

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 3rd/4th synchro
sleeve as a set.

Standard: 23.92-23.97 mm (0.941-0.944 in.)

Service Limit: 23.80 mm (0.937 in.)

Fig. 69: Identifying Thickness Of 3rd Gear

as a set.

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element

Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C).



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: 0.06-0.16 mm (0.002-0.006 in.)

Service Limit: 0.25 mm (0.010 in.)

Fig. 70: Measuring Clearance Between 4th Gear And Distance Collar With Dial Indicator
Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Measure the length (1) of the distance collar as shown.



If the length (1) is not within the standard, replace the distance collar.



If the length (1) is within the standard, go to step 6.

Standard: 24.03-24.08 mm (0.946-0.948 in.)

Fig. 71: Identifying Length Of Distance Collar
Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Measure the thickness of 4th gear.



If the thickness is less than the service limit, replace 4th gear.

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element



If the thickness is within the service limit, replace the 3rd/4th synchro hub and 3rd/4th synchro
sleeve as a set.

Standard: 23.92-23.97 mm (0.941-0.944 in.)

Service Limit: 23.80 mm (0.937 in.)

Fig. 72: Identifying Thickness Of 4Th Gear
Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the

clearance is more than the service limit, go to step 8.

Standard: 0.06-0.16 mm (0.002-0.006 in.)

Service Limit: 0.25 mm (0.010 in.)

Fig. 73: Measuring Clearance Between Distance Collar And 5th Gear With Dial Indicator
Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Measure the length (2) of the distance collar as a set.



If the length (2) is not within the standard, replace the distance collar.



If the length (2) is within the standard, go to step 9.

2007 Honda Element EX

2007-2008 TRANSMISSION Manual Transmission - Element