I'm trying to swap the 5th gear on my D-series transmission. I have the trans opened up, do I have to remove both main and counter shaft completely? If so, how to I remove the top hex nut on the counter shaft? This write up doesn't really explain how to disassemble the shafts, just the removal. https://honda-tech.com/zerothread?id=596873


Modified by SiRay13 at 2:29 PM 1/6/2008

 

you'll want to remove the shafts for disassembly.

warning- a two jaw puller isn't the best tool to use but it gets the job done. you could damage or break some parts if you're not careful.

countershaft-you'll need a 5"-6" vise to set the the countershaft in. insert a 2x4 between the cs and vise and clamp the **** out of it. Don't waste time unstaking the nut. just remove the bolt because you have a new one to replace it with. next you'll have to get the bearing off. helms says you need a special tool so i made a special tool.

it's just a modified two jaw puller with material taken off the jaw for better grip. flip the jaws around and it will pull the cs needle bearing out of the housing w/o damaging the oil plate.
mainshaft is pictured but this tool also works for getting 5th off the cs.


i'm replacing my cs bearing so i had no problem grabbing the outer race and pulling it off.
once the bearing is removed you can pull 5th gear off the cs using the same puller.

mainshaft-set ms in vise. you might be able to pull the bearing off by hand. remove the sleeve and use the puller to remove the 5th gear synchro hub. in my case i was able to spin the nut on the puller by hand to remove the synchro hub. you can now pull 5th off the ms.

reassembly- i used pvc couplings and a rubber mallet to press the parts onto the shafts.





Modified by eda6 at 8:24 PM 1/6/2008

 

that's the information I was looking for, Thanks!