Honda Pilot: Secondary Shaft 2nd Gear and 5th Gear Axial Clearance Inspection

Inspection

1. Secondary Shaft - Assemble

1. Place the idler gear (A) in the direction shown.

2. Place the idler gear (A) on press bases (B).
3. Place a spacer (C) between the secondary shaft (D) and a press to prevent damaging the secondary shaft.
4. Install the idler gear using the press.

5. Install these parts in the following order:
   1. 49 x 66 x 3 mm thrust needle bearing (A)
   2. 45 x 50 x 25 mm needle bearing (B)
   3. 5th gear (C)
   4. 49 x 66 x 3 mm thrust needle bearing (D)
   5. 5th gear collar (E)

6. Press the 5th gear collar into place using the 40 mm I.D. driver handle and the press.

7. Install these parts in the following order:

   1. 2nd/5th clutch (A)
   2. 2nd gear collar (B)

   NOTE: Do not install the O-rings during inspection.

8. Install the ball bearing (A).
9. Press the ball bearing into place using the 40 mm I.D. driver handle and the press.

10. Secure the idler gear (A) in a bench vise with wood blocks.
11. Install the old lock bolt (B) to 78 N-m (8.0 kgf-m, 58 lbf-ft).

    NOTE: After this procedure, remove wood chips that may be stuck to the gear.

2. Secondary Shaft 2nd Gear and 5th Gear Axial Clearance - Inspect

1. Measure the clearance between the 2nd gear collar (A) and the ball bearing (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.

Standard: 0.05－0.12 mm (0.002－0.004 in)

2. If the clearance is out of the standard, remove the 2nd gear collar and measure its height.
3. Select and install a new 2nd gear collar, then recheck the clearance.

2nd Gear Collar

1. 32.89 mm (1.2949 in)
2. 32.94 mm (1.2968 in)
3. 32.99 mm (1.2988 in)
4. 33.04 mm (1.3008 in)
5. 33.09 mm (1.3028 in)
6. 33.14 mm (1.3047 in)
7. 33.19 mm (1.3067 in)
8. 33.24 mm (1.3087 in)

3. Secondary Shaft - Disassemble

Special Tool Required

• Driver Handle, 40 mm I.D. 07746-0030100

Seat Belt InspectionSecondary Shaft Installation Height Inspection and Adjustment