mrgadfly

I was in the process of replacing the 5th gear assembly (23626-PLW-305) on a 2002 Honda Civic DX Coupe (kept slipping out of 5th gear while driving). As I was disassembling the main shaft, I noticed that out of the 23 gear teeth on the 2nd gear (see photos), 5 of the teeth were slightly chipped right at the bottom—not big chips, but enough to catch my eye.

What do you guys think? Should I replace the main shaft ($215+)? Or are the chips small enough where maybe I could just file/sand the rough edges a little bit and still use the main shaft?

I guess, from what I’ve read, there might be some slight humming, but do you guys think it will be that noticeable? More importantly, do you think the chipped teeth will cause excessive wear on the countershaft 2nd gear teeth and cause a catastrophic transmission failure?

I have also ordered a new 5th gear shift fork since the old one, according to the shop manual, is beyond limits (i.e., too thin).

I appreciate any input!