Transmission:
YS1 (from a '92-'93 GS-R)

Problem:
Replaced the 2nd gear. New 2nd gear is .0015" taller than old one.
Replaced 2nd gear double synchro.
Used old synchro hub/sleeve.
2nd gear binds whenever I tighten down the countershaft locknut to 80lb*ft - you should be able to turn it relatively easy by hand

Solutions I've tried:
Replaced the 2nd gear distance collar with a new one (pt. no.: 23918-P21-000). It measured +.0008" compared to the old one and gave me a bit more 2nd gear rotational freedom (with the old one, it was frozen solid) when torquing the locknut down to 80lb*ft.

Dilemma:
But, to make up for the total .0015" increase in height of the new 2nd gear, I still need another +.0007" (at least) to clear the new 2nd gear....then another extra couple of thousandths to give me proper 2nd-to-3rd gear clearance.

Question I need to ask anybody who's run into this problem before:
Has anybody ever had to replace the 1st-2nd gear synchro hub to free up the 2nd gear from binding when you tighten down the countershaft locknut?

 

interesting, I've never ran into anything of the sort. Only 1st gear jamming because I had pieces of wood jam in there from the vice

 

The only option I have is to just try I guess. The 2nd gear distance collar and synchro hub are the only two things holding up the countershaft 3rd gear so that it doesn't get too close to the top of 2nd gear. I've eliminated the distance collar as the sole cause, so that leaves just the synchro hub as suspect.

If somebody had a good, clear picture of the 2nd gear-side of a brand new 1st-2nd gear synchro hub, it would probably help a lot.

 

Why not use 23917-P21-000 which is .002" thinner?

23917 = 29.02-29.04mm or 1.1425-1.1433" thick
23918 = 29.07-29.09mm or 1.1445-1.1453" thick

Seems the 23917 is a OEM replacement, the 23918 is thicker for worn componets.

 

I've already tried, on accident. I ordered the shorter one first then not knowing that there were two part numbers for different heights and later realized that a shorter distance collar was only making the problem worse. I tried it anyways and it would start binding up with just 50lb*ft of torque on the locknut. Another 10lb*ft and I couldn't even turn it by hand anymore.

The 3rd gear sits on the 2nd gear distance collar and the 2nd gear distance collar sits on the synchro hub. The 2nd gear is supposed to just float in between with a few thouth of clearance in between 2nd and 3rd gear.

 

I see what your saying, I only quickly scanned the manual I have.

BTW how many "Hondas" running around Bloomington IN? Seeing alot of people from there lately.

 

---interesting, I've never ran into anything of the sort. Only 1st gear jamming because I had pieces of wood jam in there from the vice----

LOL

 

There's not that many of people that are really into racing. I've got a couple of friends that are into it pretty seriously, but it's mostly people into the trend.

There's a girl I know that's from Cincy that lives and works here now. She graduated from UC in engineering. I'm almost embarassed to admit that her car is faster than mine....in a straight line.

 

Is her name Missy

 

I call her Missy sometimes , but her real name is Nichole.