DennisWaller

Recently I rebuild the 5 sp manual transmission on a 1991 Honda Civic DX 1.5L. All the bearings and oil seals were replaced with Honda parts but the differential carrier was not disassembled. After the engine and transmission were reinstalled in the car I discovered the left drive shaft will not seat in the transmission: it strikes something hard and stops about 1" short leaving a gap between the inner shoulder of the CV joint and the oil seal in the side of the transmission. The right drive shaft seats normally. Lubricating the splined shaft with transmission oil and removing the split ring made no difference. The L & R inner CV joints are different: the splined shaft on the L inner CV joint is about 1 " longer. The diagram in the shop manual and in Honda dealer on-line parts diagrams shows the splined shafts of the inner CV joints enter the back of the drive pinion gear (#41221-PL3-A03) until the split ring expands on the inner side of the dp gear locking the drive shaft in place. Since I did not disassemble the differential carrier or ring gear I do not understand how I could have misassembled the transmission parts and caused this problem. Before I remove the transmission and engine from the car again I want to explore all other alternatives. Can any Honda tech suggest a solution to this problem?

Note: the transmission in this car differs slightly from the diagrams in the shop manual and the Dealer parts manual. In the latter one large ball bearing is located on each side of the differential carrier. However in this differential, both ball bearings are located on the speedometer drive side of the carrier and there is no ball bearing on the back of the carrier. I assume this was a manufacturing change and is unrelated to the problem I am experiencing.
Dennis Waller
Foreign Auto Service

Mista Bone

Carriers must have a bearing on both sides, this is NOT a manufacter change.

Do you have any pics of this carrier????

This is how the speedo drive side of a DX diff should look.



THe other side