Author Topic: Manual gearbox rebuild. PDF available?? (Read 787 times)

cliveS · « **on:** December 19, 2022, 07:47:13 AM »

New to this forum, so forgive me if I have missed something.
We own an 05 Jazz which is a great little car. We got it from my MIL when she stopped driving, her having owned it since it was 3 years old. Apart from a few paint scuffs(!) the only issue with it is the dreaded input shaft bearing.
I plan to pull the box out, and with the aid of a friend who is an experienced gearbox chap (but not honda or anything very modern) change the bearing. But a workshop manual or similar would be useful so I can understand what I need to do.

I did find a link to a RAR file but I finding it impossible to open anything despite downloading winzip. Are there any other PDFs etc available?
Ta

Jocko · « **Reply #1 on:** December 19, 2022, 09:13:28 AM »

Welcome.
Try this@ http://www.hondafitjazz.com/transmission_manual.html

I had mine done by a local transmission specialist who replaced all the seals and bearings without taking the transmission out of the car. Cost me just over £300. Been brilliant. 5 years and 50,000 miles later it is still as sweet as a nut.

cliveS · « **Reply #2 on:** December 19, 2022, 11:51:18 AM »

Thank you!
That should do the trick.

I was going to use one of the "specialists" who do the £400 to supply/fit a "recon" gearbox. But I am cynical/paranoid about the quality of the bearings they use. Add to that it will take a day out of my week to get it done.
I should be able to pull the box in a morning, build the box (under supervision) in the afternoon, and refit the following morning.

Years ago I had a Zafira box "fixed" by a chappie for a fraction of the usual cost. He managed to change the bearings (using Timkin) without taking the box out. A 400 mile round trip, noisy on the way there, silent on the way home. There are some ingenious people about, sadly none on the south coast!

CRC · « **Reply #3 on:** December 19, 2022, 07:23:05 PM »

I've never seen a video showing how it's done on a Jazz, but there is a YouTube video showing a gearbox from a Civic having the similar bearings changed.
Seems pretty straightforward with no special tools, just a lot of care and attention regarding lifting out and replacing the gear / shaft cluster and getting things set correctly before snapping it back together.
A decent torque impact driver looks like it would be very useful to get the nut undone.
Can't imagine how it could be done with gearbox in place as the input shaft being in place would make drifting the bearing out problematic......

Jocko · « **Reply #4 on:** December 19, 2022, 09:15:12 PM »

Quote from: CRC on December 19, 2022, 07:23:05 PM

Can't imagine how it could be done with gearbox in place as the input shaft being in place would make drifting the bearing out problematic......

That is what I thought, but the transmission specialists who did mine said they did at least one a week and that is how they did mine. Perhaps they have a special tool. I have seen bearings pushed out of blind holes with hydraulics.

Lord Voltermore · « **Reply #5 on:** December 21, 2022, 03:58:05 PM »

I think there are various tricks of the trade where things can be levered out of the way contrary to the official workshop manual practice. The earliest example I can remember is using a heavy bar to lever the front suspension torsion bar out of the way to remove bolts on the Morris Minor brake master cylinder. Saved hours of work compared to the official method.
Maybe things can potentially go horribly wrong, but at their own risk, not Hondas.