Honda and Acura Technical Forums

Jeff C · 10-10-2003, 08:47 PM

Well I had a mishap with my newly installed clutch. The splines on the clutch disc completely stripped out and took a little of the splines off the mainshaft in my tranny. Not cool. I did not want to install the new disc with the manishaft partially stripped so I bought a new mainshaft from Acura, $230. I figured that while I was in the tranny I would do a little how-to. A lot of people are afraid to go inside a tranny for fear all the parts inside, I guess. This is my attempt at show-and-tell. Btw, this is on a Â‘92 GSR YS1 cable transmission.

First thing first, disconnect the battery and put Nikki in the house

Here are the tools that I used.

A shot of the patient and its new inard part

The first thing that I did was remove the clutch lever and release bearing by removing this bolt right herrr

then I removed the back up light switch

remove clutch cable bracket

then remove a few other misc bolts around the case

then this sealing bolt

which reveals the dreaded snap ring

lastly remove all the bolts that hold the transmission housing to the clutch housing

this is a good point for a drink of water

ok, now crack the two halfs apart

using the reverse snap ring tool (a must) spread the snap ring and the countershaft should clunk as it drops off the snap ring

closer look

and pull the trans housing up, you may have to wiggle it a little, and there you have it…the inards are exposed

then start removing the pieces around the counter and mainshafts,

first the reverse changer holder

then the reverse idler gear

then the shift piece/shift arm holder/select arm……stuff

now remove the countershaft w/ gears and synchros, mainshaft w/ gears and synchros and shifter forks all at once

and there sits the whole clump

another good point for a drink of water

here is the new and old mainshafts together. Also I have removed all the gears and synchros off the old shaft and have placed them upside down, in order, off to the side

here is the old mainshaft, you can see the shininess, that is where is has a little wear from the clutch disc strpping out

now, grease the new mainshaft up with assembly lube and start putting the gears and synchros on

here is the final assembled mainshaft

clean the hondabond off, wipe some old grease off, and lube up the sockets where the counter and mainshafts and shifter fork go into the tranny

now put in the countershaft w/ gears and synchros, mainshaft w/ gears and synchros and shifter forks all at once

here is the tranny with all the inards in and lubed up ready for the tranny case to go back on

now, if you get something out of order the helms manual, which I know you bought before you attempted this, has a nice exploded view with descriptions for everything inside and out of the tranny

Just put it back together in reverse order and don’t forget Hondabond and to torque all the bolts down correctly. If something is hard to put back together, then that probably means something is not right so double check. I hope now that you realize that working on the transmission is not all that bad. I may have forgot something so take your time.

Overall, it took me about an hour, and I was farting around. Level of difficulty would be about 2.5 on a scale of 10, at least I think so.

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Roger · 10-10-2003, 09:29 PM

good job. I like the portion when you had a drink of water. we did one of these last week and it took us about an hour with afew drinks from the hostess.

PhatOptimo · 10-10-2003, 09:33 PM

Snap ring pliars are not needed. Needle nose pliars will get the job done.
That white grease is not needed, MTF is.
Screw the water wheres the

Trannys are childsplay

.
Good pics except the H2O.

bartek_b · 10-10-2003, 10:00 PM

very nice writeup

Chiovnidca · 10-10-2003, 10:21 PM

Quote:

Originally Posted by Jeff C

Overall, it took me about an hour, and I was farting around. Level of difficulty would be about 2.5 on a scale of 10, at least I think so.

Yea, five speeds are easy. Did you clean, inspect and check the clearances before you put it back together? Usually when I see a mainshaft torn up like that there are usually syncros getting on the loose side and/or bent shift forks.

7PSI CRX · 10-11-2003, 01:33 AM

Excellent job.

Good clear pics!

Ive got a question or two if you don't mind.

1 - Think you can point out for me the bearings that give the dreadful "whine" on my old '91 Si tranny?
(I want to attempt the rebuild, but don't want the tranny sitting apart while I wait on the bearings. I want the parts on hand so I can get it back together the same day so I don't forget how things go. Letting it sit on a bench for a few days can only lead to possible problems)

2 - And I assume those bearings on the shafts slip off, no press needed?

3 - And the bearings that remain in the case, are they easily replaceable, or a press is necessary?

DCStreetHtch · 10-11-2003, 02:29 AM

bump so this is in my topics!!

-Bryan-

tinkerbell · 10-11-2003, 06:24 AM

bloody excellent mate!

real good work,

i assume it would be that easy to change a syncro too?

vtec_r · 10-11-2003, 06:49 AM

Very nice job

Hybridize · 10-11-2003, 07:52 AM

Excellent post!

Mista Bone · 10-11-2003, 10:48 AM

nice craftsman #45492 snap ring pliers..........

PHiZ · 10-11-2003, 11:25 AM

Thanks for the helpful post!

-PHiZ

I still ain't touching that scary bastard!

Jeff C · 10-11-2003, 12:55 PM

PhatOptimo, you can use your pliers and drink your

, but i wouldn't trade these snap ring pliers for anything.

Chiovnidca, about 75% of the gears and synchros in there were replace 25k mi ago. There is no play. The problem was the splines on the outside end got a little beat up. The inside are ok.

7PSI CRX, I personally am not familiar with the whining that you are talking about so I cant help you there. Correct, you do not need a press. However, there is a nut on the end of the countershaft, like the axle nut, that is a little PITA. The bearing in the case can easily be tapped out with a mallet.

tinkerbell, yes it easy to replace the synchros. you just need to make sure that you get them back in the correct place cause they are not all exactly the same.

Mista, I am glad you told me about those things awhile back. They are awesome!!

Thanks for the props. I hope that it helps somebody. Now I have to go install the tranny back into the car.

baphomet · 10-11-2003, 01:35 PM

great work - I have a new found confidence

Propulsion · 10-11-2003, 01:55 PM

ok, not as hard as its cracked up to be...

is putting in a LS 5th gear just as easy?

Jeff C · 10-11-2003, 05:43 PM

I am not sure what all is involved in putting a different gear in, ie having to use a different synchro too, but replacing gears is yes, just as easy.

Mista Bone · 10-11-2003, 06:28 PM

once you get the gear shafts out, swapping fifth gear only takes about 5-10 minutes. Getting to 30mm nut off is the hardest part.

baphomet · 10-11-2003, 06:40 PM

Now I need a Quaife how-to and I'm set

PhatOptimo · 10-11-2003, 08:21 PM

Thats got to be a TEG tranny. Bone told me abot thoes pliars a while back. I havent been to Sears to get them yet

. Time to install

.
Hers a few form my last encounter with my Y1.

All glued up and ready to install

Modified by PhatOptimo at 11:18 PM 10/11/2003

Audi RS4 · 10-11-2003, 08:36 PM

it looks scary

Jeff C · 10-12-2003, 11:16 AM

Mista, thanks for the input. I know how to replace a stock gear with a stock gear, but i was not for sure what would be involved in replacing a stock gear from one tranny with a stock gear from another.

slashDEVslashNULL, i have done a couple to those too. You would take the tranny apart the same way (obviously) and remove the gear sets the same way (obviously). The diff just pulls right out. The biggest PITA about a Quaiffe install is getting the correct shim. How I did it was put the put the Quaiffe in, reassemble the whole tranny and check for shim clearences just like the manual said. If it was good, then remove the case and apply the HOndabond. If it is not, keep trying different shims till you find the correct one with the proper clearences.

PhatOptimo, yes its a teg tranny, YS1. And yes the tool comes in very handy. Thanks for adding the pics too.

advanracing62 · 10-12-2003, 11:25 AM

good write up! I agree that Trannies aren't anything hard to work on.. just gotta remeber where shit goes!

Burke · 10-12-2003, 11:28 AM

those winey gears could be on either side of the diff - mine were, but you will need a puller to get them off. the whine could also be the bearing on the shaft or the ones pressed into the casing. the ones in the casing you can just pop out too.

Wes V · 10-12-2003, 12:31 PM

Jeff;

That's a great write-up!! I totally agree with the "water" aspect of it! (no preaching, just a little fun)

Maybe I'm in the wrong generation, but what's a "Nikki"?

About that snap ring;

Can the snap ring be removed / or installed through the access hole? The access hole doesn't look large enough to get it in and out.

You made a comment that you will hear a "clunk" when the countershaft falls free. Am I correct that this is due to already having the cases spread apart? If you just pulled the cases apart, I'm assuming that the gears would fall all over the place as they came off the counter shaft.

When putting it back together, do you have to worry about the countershaft being in the correct position to get the snap ring on? Does the snap ring just flop around free, after bolting the transmission halfs together and before it's snapped into place?

Thanks!!

Wes Vann

MrTodd · 10-12-2003, 01:29 PM

I also have the same question as listed above...

In addition to that, I'm also wondering about the 'whine' that my '90 Si (CRX) tranny makes. Someone said that it could be the bearings in the differential??? And you need a puller to get to those? What's a puller?

10-10-2003, 09:33 PM	#3
PhatOptimo Junior Member Join Date: Nov 2001 Location: OuT tHERE, TN, USA Posts: 758	Re: Here's a little tranny how-to for j00!! (Jeff C) Snap ring pliars are not needed. Needle nose pliars will get the job done. That white grease is not needed, MTF is. Screw the water wheres the Trannys are childsplay . Good pics except the H2O. __________________ Whip list: '08 S2000 '90 CRX '94 240SX Coupe.

10-11-2003, 01:33 AM	#6
7PSI CRX Junior Member Join Date: May 2000 Location: Lower Hudson Valley, NY Posts: 381	Re: Here's a little tranny how-to for j00!! (Jeff C) Excellent job. Good clear pics! Ive got a question or two if you don't mind. 1 - Think you can point out for me the bearings that give the dreadful "whine" on my old '91 Si tranny? (I want to attempt the rebuild, but don't want the tranny sitting apart while I wait on the bearings. I want the parts on hand so I can get it back together the same day so I don't forget how things go. Letting it sit on a bench for a few days can only lead to possible problems) 2 - And I assume those bearings on the shafts slip off, no press needed? 3 - And the bearings that remain in the case, are they easily replaceable, or a press is necessary? __________________ 7PSI CRX has driven one of two CRXs for over 269,000 miles His ass was hurtin', so he got rid of the *CRX, and now drives an '05 Legacy GT LTD*

10-11-2003, 02:29 AM	#7
DCStreetHtch Member Join Date: May 2002 Location: SouthCounty, CA Posts: 6,352	Re: Here's a little tranny how-to for j00!! (Jeff C) bump so this is in my topics!! -Bryan- __________________ *Dunk SB "HUNTERS" Reese Forbes II's size 10.5, Serious HEATTTT here!!!* Liars and Thieves, all of you!

10-11-2003, 06:24 AM	#8
tinkerbell Member Join Date: Jan 2002 Location: Sydney, Australia Posts: 2,229	Re: Here's a little tranny how-to for j00!! (EGStreetHtch) bloody excellent mate! real good work, i assume it would be that easy to change a syncro too? __________________ www.jscc.asn.au Japanese Sports Car Club "ban low performance drivers - not high performance cars"

10-11-2003, 06:49 AM	#9
vtec_r Join Date: Jul 2003 Location: Richmond Hill, GA, us Posts: 67	Re: Here's a little tranny how-to for j00!! (tinkerbell) Very nice job __________________ Everone should learn how to install there own sh*t

10-10-2003, 09:29 PM	#2
Roger Join Date: May 2002 Location: Fremont, Ca Posts: 265	good job. I like the portion when you had a drink of water. we did one of these last week and it took us about an hour with afew drinks from the hostess.

10-10-2003, 10:00 PM	#4
bartek_b Join Date: Sep 2002 Location: London, ont, canada Posts: 2,309	Re: (Roger) very nice writeup

10-11-2003, 07:52 AM	#10
Hybridize Join Date: Sep 2003 Location: Washington, USA Posts: 301	Excellent post! __________________ '90 CRX Si - B20B - S1/LS5th Best MPG to date. 42.24, route driven.http://images.honda-tech.com/set1/smile/embeer.gif My vouch thread.

10-11-2003, 10:48 AM	#11
Mista Bone Member Join Date: Oct 2001 Location: Cincity, OH, USA Posts: 7,942	Re: Here's a little tranny how-to for j00!! (Jeff C) nice craftsman #45492 snap ring pliers.......... __________________ "D" Tranny Guru

10-11-2003, 11:25 AM	#12
PHiZ Member Join Date: Apr 2003 Location: NL, CT, cuba Posts: 3,346	Thanks for the helpful post! -PHiZ I still ain't touching that scary bastard! __________________ More go fast, less look fast. Wideband tuning, ECUs, Conversion Harnesses, and ECU chipping available!!

10-11-2003, 12:55 PM	#13
Jeff C Member Join Date: Feb 2002 Location: Dandridge, TN, USA Posts: 2,027	Re: Here's a little tranny how-to for j00!! (Chiovnidca) PhatOptimo, you can use your pliers and drink your , but i wouldn't trade these snap ring pliers for anything. Chiovnidca, about 75% of the gears and synchros in there were replace 25k mi ago. There is no play. The problem was the splines on the outside end got a little beat up. The inside are ok. 7PSI CRX, I personally am not familiar with the whining that you are talking about so I cant help you there. Correct, you do not need a press. However, there is a nut on the end of the countershaft, like the axle nut, that is a little PITA. The bearing in the case can easily be tapped out with a mallet. tinkerbell, yes it easy to replace the synchros. you just need to make sure that you get them back in the correct place cause they are not all exactly the same. Mista, I am glad you told me about those things awhile back. They are awesome!! Thanks for the props. I hope that it helps somebody. Now I have to go install the tranny back into the car. __________________ 1998 Accord Sedan EX 5 spd, will always be stock 1981 Silverado bagged, shaved and 20s...maybe Duramax

10-11-2003, 01:35 PM	#14
baphomet Join Date: Jan 2003 Posts: 1,964	Re: Here's a little tranny how-to for j00!! (Jeff C) great work - I have a new found confidence

10-11-2003, 01:55 PM	#15
Propulsion Member Join Date: Jan 2002 Location: Norcal / NYC, usa Posts: 3,457	Re: Here's a little tranny how-to for j00!! (slashDEVslashNULL) ok, not as hard as its cracked up to be... is putting in a LS 5th gear just as easy? __________________ <U>Vouches</U>: I8ayellowcrayon, Lang, 137, pravo2, 94white-si, Aberkrombie, HmgLauj69, gotGSR, 3Tdt, thermal, EBP-Si, SRCivic97, Navin, terrible one, speed94, Ek-CoolGuy, dIveR$E[323], EF8 JUNKIE9, ernald711, CIVICMIKE, siblue_gzer, pdiggitydogg, Pearl Crx, IntegraDA ITR EG, Quick 99, JDM INSPIRED, fishnfst, EKHB, UCLAcivic, Acura_I-RS, jetpilot, Riceball777, TEAM562racing, RyanR

10-11-2003, 05:43 PM	#16
Jeff C Member Join Date: Feb 2002 Location: Dandridge, TN, USA Posts: 2,027	Re: Here's a little tranny how-to for j00!! (SilverCIVIC96) I am not sure what all is involved in putting a different gear in, ie having to use a different synchro too, but replacing gears is yes, just as easy. __________________ 1998 Accord Sedan EX 5 spd, will always be stock 1981 Silverado bagged, shaved and 20s...maybe Duramax

10-11-2003, 06:28 PM	#17
Mista Bone Member Join Date: Oct 2001 Location: Cincity, OH, USA Posts: 7,942	Re: Here's a little tranny how-to for j00!! (SilverCIVIC96) once you get the gear shafts out, swapping fifth gear only takes about 5-10 minutes. Getting to 30mm nut off is the hardest part. __________________ "D" Tranny Guru

10-11-2003, 06:40 PM	#18
baphomet Join Date: Jan 2003 Posts: 1,964	Re: Here's a little tranny how-to for j00!! (Mista Bone) Now I need a Quaife how-to and I'm set

10-11-2003, 08:21 PM	#19
PhatOptimo Junior Member Join Date: Nov 2001 Location: OuT tHERE, TN, USA Posts: 758	Re: Here's a little tranny how-to for j00!! (slashDEVslashNULL) Thats got to be a TEG tranny. Bone told me abot thoes pliars a while back. I havent been to Sears to get them yet . Time to install . Hers a few form my last encounter with my Y1. All glued up and ready to install Modified by PhatOptimo at 11:18 PM 10/11/2003 __________________ Whip list: '08 S2000 '90 CRX '94 240SX Coupe.

10-11-2003, 08:36 PM	#20
Audi RS4 Lover Join Date: Feb 2002 Location: Jacksonville, FL, United States Posts: 1,776	Re: Here's a little tranny how-to for j00!! (Jeff C) it looks scary __________________ Glock 9X19..... http://images.honda-tech.com/set1/smile/emwink.gif 06' CBR600RR 03' Audi A4 1.8T Quattro (BEAST) Jack "YACK" Harris & P1 Auto http://images.honda-tech.com/set1/smile/emthup.gif PLEASE HELP ME! Taking $1 to $5 donations. Paypal 03Audi@comcast.net Any help is appreciated.

10-12-2003, 11:16 AM	#21
Jeff C Member Join Date: Feb 2002 Location: Dandridge, TN, USA Posts: 2,027	Re: Here's a little tranny how-to for j00!! (Mista Bone) Mista, thanks for the input. I know how to replace a stock gear with a stock gear, but i was not for sure what would be involved in replacing a stock gear from one tranny with a stock gear from another. slashDEVslashNULL, i have done a couple to those too. You would take the tranny apart the same way (obviously) and remove the gear sets the same way (obviously). The diff just pulls right out. The biggest PITA about a Quaiffe install is getting the correct shim. How I did it was put the put the Quaiffe in, reassemble the whole tranny and check for shim clearences just like the manual said. If it was good, then remove the case and apply the HOndabond. If it is not, keep trying different shims till you find the correct one with the proper clearences. PhatOptimo, yes its a teg tranny, YS1. And yes the tool comes in very handy. Thanks for adding the pics too. __________________ 1998 Accord Sedan EX 5 spd, will always be stock 1981 Silverado bagged, shaved and 20s...maybe Duramax

10-12-2003, 11:25 AM	#22
advanracing62 New User Join Date: May 2001 Location: Boise, ID Posts: 2,243	Re: Here's a little tranny how-to for j00!! (Jeff C) good write up! I agree that Trannies aren't anything hard to work on.. just gotta remeber where shit goes! __________________ It's so quiet this high up, the feeling you get is that you're one of those space monkeys. You do the little job you're trained to do. Pull a lever. Push a button. You don't understand any of it, and then you just die.

10-12-2003, 11:28 AM	#23
Burke Banned Join Date: Jun 2001 Location: Youngstown, OH Posts: 1,991	Re: Here's a little tranny how-to for j00!! (Jeff C) those winey gears could be on either side of the diff - mine were, but you will need a puller to get them off. the whine could also be the bearing on the shaft or the ones pressed into the casing. the ones in the casing you can just pop out too.

10-12-2003, 12:31 PM	#24
Wes V Member Join Date: Oct 2002 Location: Winnetka, Calif, USA Posts: 2,351	Re: Here's a little tranny how-to for j00!! (Burke) Jeff; That's a great write-up!! I totally agree with the "water" aspect of it! (no preaching, just a little fun) Maybe I'm in the wrong generation, but what's a "Nikki"? About that snap ring; Can the snap ring be removed / or installed through the access hole? The access hole doesn't look large enough to get it in and out. You made a comment that you will hear a "clunk" when the countershaft falls free. Am I correct that this is due to already having the cases spread apart? If you just pulled the cases apart, I'm assuming that the gears would fall all over the place as they came off the counter shaft. When putting it back together, do you have to worry about the countershaft being in the correct position to get the snap ring on? Does the snap ring just flop around free, after bolting the transmission halfs together and before it's snapped into place? Thanks!! Wes Vann

10-12-2003, 01:29 PM	#25
MrTodd Member Join Date: May 2002 Location: Hell, frozen over. USA Posts: 1,843	Re: Here's a little tranny how-to for j00!! (Wes V) I also have the same question as listed above... In addition to that, I'm also wondering about the 'whine' that my '90 Si (CRX) tranny makes. Someone said that it could be the bearings in the differential??? And you need a puller to get to those? What's a puller? __________________ "It is better to destroy than to create what is meaningless, so the picture will not be finished."

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