Go Back   Honda-Tech > Honda and Acura Technical Forums > Transmission & Drivetrain
Sign in using an external account
Register Forgot Password?
Search


Welcome to Honda-Tech!
Welcome to Honda-Tech.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the Honda-Tech community today!


Reply
 
 
 
submit to reddit
 
LinkBack Thread Tools Search this Thread
Old 08-21-2011, 10:03 AM   #1
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default rebuilding S40. d16y8 transmission

so this all started due to my 2nd gear popping out, which people said was because of this particular bearing "walking" or coming out.

figured if im going to rebuild this tranny, might as well replace the clutch/flywheel too..

competition oem clutch
fidanza flywheel
rebuild kit from Synchrotech.

having never gone inside a transmission before.. i feel it has been a lot easier than expected, im using a service manual as my guide.. and calling a buddy too.. but honestly looking at the gears and trying to figure everything out, has been a little nerve racking...

so here goes..

Click the image to open in full size.
Click the image to open in full size.


i held this ends apart with some flat heads, then had roomie tap the casing with a rubber mallet, then the bearings dropped right out.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


dirty magnet, MUST CLEAN this whenever opening the tranny.
Click the image to open in full size.
Click the image to open in full size.

rebuild kit from Synchrotech!!
Click the image to open in full size.


reverse selector removed.. think thats what it was called.
Click the image to open in full size.


main & counter shaft
Click the image to open in full size.


hows the best way to remove these 2 bearings on the left???? i dont have a bearing puller. is there a neat trick to it or something????
Click the image to open in full size.


THE CAUSE OF THE PROBLEM, just like the guys said.
you can see the bearing is scratched up on the side there....
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


Click the image to open in full size.
Click the image to open in full size.


Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.



ok.. so for now im still trying to figure out how to remove those 2 bearings without buying the tool... any tips guys??
hondaZvic is offline   Reply With Quote
Old 08-21-2011, 10:30 AM   #2
Honda-Tech Member
 
SR20S13's Avatar
 
Join Date: Jan 2007
Location: NWCCT
Posts: 947
iTrader Rating: (0)
Send a message via AIM to SR20S13
Default Re: rebuilding S40. d16y8 transmission

rent one?
SR20S13 is offline   Reply With Quote
Old 08-21-2011, 10:50 AM   #3
Honda-Tech gave me this lousy title
 
94EG8's Avatar
 
Join Date: Jun 2008
Location: Miramichi, NB, Canada
Posts: 14,200
iTrader Rating: (0)
Default Re: rebuilding S40. d16y8 transmission

You can do the ISB easy enough, use a fairly small prybar, stick it through from the engine side of the bell housing and hit the handle from the backside to drive out the bearing, Move the pry bar around after each hit or two so you don't drive the bearing out all crooked. The other one, you can try setting the countershaft back in it and pull the top side ways and while holding it that way pull up, it may come out.
__________________
"Bacon tendercrisp chicken, the most powerful sandwich in its class."

Per ardua ad astra


My F/S thread -> http://hondamarketplace.com/showthread.php?t=2900962

Quote:
Originally Posted by Knightsport View Post
Hello,

This is Knightsport, from the internet. I will be out of the internet from June 2 and returning on June 11th. In my absence I suggest you pray as there can be only one Knightsport from the internet.

Thank you and God Bless,

-Knightsport
94EG8 is offline   Reply With Quote
Old 08-21-2011, 12:14 PM   #4
D Tranny Guru
 
Mista Bone's Avatar
 
Join Date: Oct 2001
Location: Cincity, OH, USA
Posts: 8,723
iTrader Rating: (0)
Send a message via AIM to Mista Bone
Default Re: rebuilding S40. d16y8 transmission

OP, what ever fluid you are using in the tranny, stop using it!!!!

Switch to 10w30 motor oil. The blackening is a bad sign of wrong fluid.

Also strip both shafts down and flush them out as there is debris in there.

Don't forget to stake the CSB in place so it doesn't walk out again.
__________________
"D" Tranny Guru
Mista Bone is online now   Reply With Quote
Old 08-21-2011, 02:02 PM   #5
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

94eg8, thats exactly how i got them out.. lol i just had to go stare at them for a while and i figured it out.. they werent in there that hard.

mista bone, i have actually been using penzoil 10w30 synthetic... so i dont know why it was that dark.. but there was a lot of shavings and debris in there..
but anyways, i picked up some honda MTF.

some more pix:


cleaned magnet
Click the image to open in full size.

1st bearing out..
Click the image to open in full size.

both out now..
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

new bearing in..
Click the image to open in full size.

harbor freight
Click the image to open in full size.

staked.
Click the image to open in full size.

Click the image to open in full size.
Click the image to open in full size.


now i have the main shaft done, with the new synchros and bearings on it.. and all i have left is this counter shaft... but having a hard time getting this lock nut off....
hondaZvic is offline   Reply With Quote
Old 08-21-2011, 03:09 PM   #6
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

got the counter shaft apart.... home made vice.. hahahha

Click the image to open in full size.
Click the image to open in full size.


why are these synchros different?? old one on left / new one on right

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
hondaZvic is offline   Reply With Quote
Old 08-21-2011, 09:52 PM   #7
Go Tigers!
 
Bense's Avatar
 
Join Date: Mar 2003
Location: Clemson, SCarolina!
Posts: 9,477
iTrader Rating: (0)
Default Re: rebuilding S40. d16y8 transmission

wat
Bense is offline   Reply With Quote
Old 08-22-2011, 01:09 AM   #8
D Tranny Guru
 
Mista Bone's Avatar
 
Join Date: Oct 2001
Location: Cincity, OH, USA
Posts: 8,723
iTrader Rating: (0)
Send a message via AIM to Mista Bone
Default Re: rebuilding S40. d16y8 transmission

while 1-2 synchros are interchangeable, Honda decided to leave 6 teeth off the second gear OEM synchro.

That extra notch, looks like a syncho from Aceomatic/Recon that I dealt with a decade ago.
__________________
"D" Tranny Guru
Mista Bone is online now   Reply With Quote
Old 08-22-2011, 03:54 AM   #9
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

ok.. yeah its kinda weird that it would change like that... Dave said it was ok, so tonight i will finish putting that tranny back together...

i have to spend all day at work.. bummer.
hondaZvic is offline   Reply With Quote
Old 08-22-2011, 04:50 AM   #10
Go Tigers!
 
Bense's Avatar
 
Join Date: Mar 2003
Location: Clemson, SCarolina!
Posts: 9,477
iTrader Rating: (0)
Default Re: rebuilding S40. d16y8 transmission

how about a shot of the 2nd gear synchro sleeve?
Bense is offline   Reply With Quote
Old 08-22-2011, 05:56 AM   #11
Honda-Tech gave me this lousy title
 
94EG8's Avatar
 
Join Date: Jun 2008
Location: Miramichi, NB, Canada
Posts: 14,200
iTrader Rating: (0)
Default Re: rebuilding S40. d16y8 transmission

Btw, make sure you lube up the gear cone and synchro with some oil or MTF when you're putting this together.
__________________
"Bacon tendercrisp chicken, the most powerful sandwich in its class."

Per ardua ad astra


My F/S thread -> http://hondamarketplace.com/showthread.php?t=2900962

Quote:
Originally Posted by Knightsport View Post
Hello,

This is Knightsport, from the internet. I will be out of the internet from June 2 and returning on June 11th. In my absence I suggest you pray as there can be only one Knightsport from the internet.

Thank you and God Bless,

-Knightsport
94EG8 is offline   Reply With Quote
Old 08-22-2011, 08:43 PM   #12
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

bear with me or correct me if my terminology is wrong, please.

im not sure which gears they were, but these are the larger synchros on the counter shaft. (i think thats right)

Bense, those ones that i pictured, each had an identical twin. the smaller synchros all matched up perfectly.

old synchros still on.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


old synchro on, / new synchro off
Click the image to open in full size.


old / new
Click the image to open in full size.
Click the image to open in full size.



new synchros on.
Click the image to open in full size.
Click the image to open in full size.

now heres where i got irritated, before i disassembled it. the gear selector moved back and forth over the synchros just fine.
i took off the old ones and put on the new ones.
the gear selector moved back and forth just fine again.

sooo, then i took them off one by one cleaning / lubing them and making sure to put them back the same way they came off.. but once i had it all lubed and put back together, the gear selector will not move back and forth over the synchros. ??? whats going on??

is there something that i AM NOT supposed to lube??

Last edited by hondaZvic; 08-22-2011 at 09:40 PM.
hondaZvic is offline   Reply With Quote
Old 08-22-2011, 08:50 PM   #13
Honda-Tech gave me this lousy title
 
94EG8's Avatar
 
Join Date: Jun 2008
Location: Miramichi, NB, Canada
Posts: 14,200
iTrader Rating: (0)
Default Re: rebuilding S40. d16y8 transmission

Did you try turning the synchro slightly with your finger? Remember when the gears aren't moving chances are everything isn't lined up. This is also why you'll sometimes have difficulty getting into first from a dead stop. Btw what you're calling a gear selector is a sleeve/slider depending on who you talk to.
__________________
"Bacon tendercrisp chicken, the most powerful sandwich in its class."

Per ardua ad astra


My F/S thread -> http://hondamarketplace.com/showthread.php?t=2900962

Quote:
Originally Posted by Knightsport View Post
Hello,

This is Knightsport, from the internet. I will be out of the internet from June 2 and returning on June 11th. In my absence I suggest you pray as there can be only one Knightsport from the internet.

Thank you and God Bless,

-Knightsport
94EG8 is offline   Reply With Quote
Old 08-22-2011, 08:53 PM   #14
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

yeah, i was moving it all around quite a bit thinking it might catch.. maybe ill just take them off and try again..
hondaZvic is offline   Reply With Quote
Old 08-22-2011, 09:38 PM   #15
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

ok.. i figured it out.. its the small spring ring on the synchros. the gear selector has to slide hard enough over it and catch for it to go all the way to whichever side... and the new ones are obviously stronger than the old ones.

Last edited by hondaZvic; 08-22-2011 at 09:55 PM.
hondaZvic is offline   Reply With Quote
Old 08-25-2011, 09:07 PM   #16
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

ok now i have everything put back together and the casing on with just 4 bolts.
i still cannot get this to go into 1st or 2nd. 345R all work fine. any ideas??

i've compared this with my service manual multiple times and everything seems to be on as it should be.
the only thing i can think of is that the slider is not sliding over the spring rings on the synchros, but i cant figure out why..?

heres how it looked before i put the casing on.

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
hondaZvic is offline   Reply With Quote
Old 08-26-2011, 01:13 PM   #17
Honda-Tech Member
 
Gearspeed-Performance's Avatar
 
Join Date: Feb 2004
Location: Rancho Cucamonga, CA
Posts: 5,860
iTrader Rating: (1)
gear.speed.1
Default Re: rebuilding S40. d16y8 transmission

In the last picture it looks like the forks are lined up for the neutral position at the shaft pin..but the 5th is selected on the shaft. Take a pic of the shift change if you you can.
__________________
Gearspeed Honda/Acura Tranmission Parts and Performance - www.gearspeedwholesale.com - 909-476-7252
*Rebuild Kits*LSD*Carbon Synchros*Gears*Final Drives*Trans building*
Gearspeed-Performance is offline   Reply With Quote
Old 08-26-2011, 05:13 PM   #18
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

ok, getting some pix.

i didnt have the shift fork installed on the other side.. but the problem still remains that the sleeve on 1 & 2 is not sliding, it seems to be stuck between the rings on the synchros
hondaZvic is offline   Reply With Quote
Old 08-26-2011, 05:46 PM   #19
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

neutral..

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

3rd

Click the image to open in full size.
Click the image to open in full size.

4th

Click the image to open in full size.
Click the image to open in full size.

5th

Click the image to open in full size.
Click the image to open in full size.

rev

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
hondaZvic is offline   Reply With Quote
Old 08-26-2011, 08:17 PM   #20
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


i have come to the conclusion that i have put this thing back together properly & that the new parts are just making it tougher than normal....
this thing will be on its tires tomorrow.

Last edited by hondaZvic; 08-26-2011 at 09:00 PM.
hondaZvic is offline   Reply With Quote
Old 08-27-2011, 06:48 AM   #21
H-T Premium Sponsor
 
Synchrotech-Transmissions's Avatar
 
Join Date: Nov 2008
Location: San Dimas CA
Posts: 865
iTrader Rating: (1)
http://www.facebook.com/pages/Synchrotech-Transmissions-Inc/262408617830
Default Re: rebuilding S40. d16y8 transmission

It looks like you may have clocked the 1-2 sleeve in the wrong position but it is hard to tell from the picture. There are three sets of two sleeve teeth (6 total) that are longer than the others. These should go in the deeper hub grooves not in the opening for the synchro blocking section. The deeper grooves are located half way between each opening. I'm not sure if this is what is going on but it is definately worth rechecking.

Click the image to open in full size.
__________________
Synchrotech Transmissions / MFactory R&D
Carbon Synchros - LSDs - Torco MTF - Custom Builds - Gears - FD Sets - Rebuild Kits
Tech Support: David (909) 592-5900
www.synchrotech-transmissions.com
Synchrotech-Transmissions is offline   Reply With Quote
Old 08-27-2011, 06:54 AM   #22
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

yeah, if you see where i put the sharpie mark, that is between those 2 bigger teeth. and those i did line up with the opening.
hondaZvic is offline   Reply With Quote
Old 08-27-2011, 06:57 AM   #23
H-T Premium Sponsor
 
Synchrotech-Transmissions's Avatar
 
Join Date: Nov 2008
Location: San Dimas CA
Posts: 865
iTrader Rating: (1)
http://www.facebook.com/pages/Synchrotech-Transmissions-Inc/262408617830
Default Re: rebuilding S40. d16y8 transmission

You will need to reposition the sleeve to the correct spot and it will be fine
__________________
Synchrotech Transmissions / MFactory R&D
Carbon Synchros - LSDs - Torco MTF - Custom Builds - Gears - FD Sets - Rebuild Kits
Tech Support: David (909) 592-5900
www.synchrotech-transmissions.com
Synchrotech-Transmissions is offline   Reply With Quote
Old 08-27-2011, 07:17 AM   #24
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

Crap.... I see it now, thank you so much!!!!!
hondaZvic is offline   Reply With Quote
Old 08-29-2011, 05:00 AM   #25
Honda-Tech Member
 
hondaZvic's Avatar
 
Join Date: Jun 2002
Location: tx
Posts: 6,943
iTrader Rating: (0)
Send a message via AIM to hondaZvic
Default Re: rebuilding S40. d16y8 transmission

here you can see those deeper grooves.. cant believe i missed that... i actually went back and saw the pic in the service manual where it says to line those up. hahaha

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


putting the new snap ring in... used one of the old bearings to drive it all the way down.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


new parts..
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

new clutch would not fit over alignment pins on the flywheel so i had to dremel them out some...
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

then it fit like a glove.
Click the image to open in full size.

my flywheel lock.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.


and its done.


thanks for your help guys. (shout out to dave @synchrotech for the kit and last minute help!!)

the clutch is super soft / easy, and the tranny feels great, shifter is held in tight in each gear and it shifts smooth as butter, feels amazing.
hondaZvic is offline   Reply With Quote
 
 
 
submit to reddit
Reply

Similar Threads
Thread Thread Starter Forum Replies Last Post
Johnson_Racing's All Motor EG Build johnson_racing All Motor/ Naturally Aspirated 8 10-12-2012 07:21 PM
Hi!! ek4 ferio!! crazy26 Honda / Acura 27 09-13-2012 07:44 PM
My Edm CRX VTEC ee8 Build **TONS OF PICS** tonyjdm Appearance Build Threads 11 01-30-2012 11:55 AM
The Blues Meeting Dellgary Acura TSX 3 08-28-2011 11:39 AM
Mr Civic's EF Mr C1vic Honda CRX / EF Civic (1988-1991) 20 07-06-2011 05:42 AM


Tags
bearing, d16y8, differential, fluid, honda, housing, pics, rebuild, rebuilding, removing, reverse, s40, selector, tranny, transmission

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -8. The time now is 09:44 PM.



2014 Copyright, InternetBrands Inc.
Powered by vBulletin® Version 3.8.7 AC1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.

Honda and the Honda marquee are registered trademarks of the American Honda Motor Company, Inc. Neither American Honda Motor Company nor its subsidiaries or affiliates shall bear any responsibility for Honda-Tech.com content, comments, or advertising. Honda-Tech.com is not affiliated with American Honda Motor Company in any way. American Honda Motor Company does not sponsor, support, or endorse Honda-Tech.com in any way. Copyright/trademark/sales mark infringements are not intended or implied.
Emails & Contact Details