Ok, I'm trying to assemble my hybrid tranny finally, got it all there and the top case will not go on no matter what I do. I have tried each component (diff, counter shaft, main shaft, forks) independently or with just the diff and they all pretty much work. The mainshaft is a little hard to get in but it works. When it's all assembled, it seems like the mainshaft is too far from the diff, like it's being pushed away, and the bearing will not seat in the upper case no matter how hard I push on it. I've never had this much trouble and I've done a lot of transmissions before. Any ideas?

YS1 case
ITR 10 bolt LSD
4.40 Final drive
99 B16 1-4 gears
YS1 (93 LS) 5th gear
all new bearings, synchros, seals etc
all shims done

 

When you are putting the gear housing on...you are pushing down trying to get the circlip into the recess on the bearing right? Try using a flathead screwdriver to lift up on the mainshaft.....99 times out of 100 it'll pop right in instantly.

 

I'm not sure what you mean... are you referring to the countershaft bearing with the snap ring? I can't even get it that close, the mainshaft bearing just will not begin to go in its place. I'll try pushing up on it a little I guess, I've just never had an issue like this.

 

Had the same problem. It turned out to be the case. The main shaft bearing would never sit right.

I would check to see if the input bearing is level and the correct bearing (I have seen that too).

 

I just tried another outer case from another YS1 I have. I know these both had working transmissions in them before which is why I didn't suspect the case(s). The bearing was new, and I even swapped for another one and it's doing the same damn thing. I'm thinking the input shaft bearing (the clutch-side mainshaft bearing) is not seated right, it's actually very slightly difficult to install and remove the mainshaft.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by downest &raquo;</TD></TR><TR><TD CLASS="quote">I just tried another outer case from another YS1 I have. I know these both had working transmissions in them before which is why I didn't suspect the case(s). The bearing was new, and I even swapped for another one and it's doing the same damn thing. I'm thinking the input shaft bearing (the clutch-side mainshaft bearing) is not seated right, it's actually very slightly difficult to install and remove the mainshaft.</TD></TR></TABLE>

Thats what I am thinking. I know honda makes a bearing that is the same size, but taller.

One thing to check is if the shift selector is binding. That would cause your issue too.

 

The selector is binding slightly side to side, like when it moves between the three forks. This isn't more than normal though for when the upper case isn't on to hold the rods in place with the detent *****. I'm 99% sure the problem is in the upper mainshaft bearing, but I can't figure out why it's doing that. I went back and re-pressed in the lower ISB with an old bearing on my press.

As a side note, I pulled the S1 out of my car in like 20 minutes because I got so pissed about putting the new tranny together. I thought that was a pretty good time lol.

 

 

Well I figured out that problem, I had three trannies apart and wasn't paying attention, I used a YS1 mainshaft instead of the B16 one, so second gear was pusing the shafts apart. Now I got it all back in, tested it, it won't go into reverse, and when I ran it on the lift in neutral idling it would die when I let out the clutch. I'm kinda stumped but I guess I'll pull it off tomorrow and see. I've done plenty of trannies with no issue, so this is really bothering me right now, I'm sure I just overlooked something stupid.

 

Ok well it looks like the stopper ring got out of alignment. What happened is the mainshaft end bearing stuck in the case when I put it together to bench shift it, and I know from my D series that pulling those out can be a PITA without breaking them. So for final assembly I just slipped the case on with the circle thing on the top and let it go into the bearing in the case. I have another stopper ring, so I can replace it, but I want to know if that makes sense as the problem I'm having with the tranny binding or dragging when the clutch is engaged, and the reverse not engaging as well.

 

Glad you found it. It is always the dumb things

 

Well I realised that I kinda need that bearing on the end of the shaft in order to get it together without upsetting the ring. So I got out my slide hammer and tried to pop it out, it separated the inner race and bearings from the (Still stuck) outer race. Any good way to remove the outer race from the case? What a pain in the ***, I'm about sick of this.

 

Ok... made a tool to get the bearing out, that was no problem. Got everything back together, still binding in reverse on the bench. So I realised that the countershaft second gear wasn't spinning free like it should, it was binding on the synchro. So I disassembled the C-shaft and found that the new synchro wasn't allowing any slip, so the second gear was effectively locked to the shaft. I don't know why, it was NEW, in a rebuild kit I got from a friend of mine. Anyway, my old second was fine so I tossed that one back in, threw it together, and it worked fine on the bench. Got it back in the car, and I'm doing two wheel burnouts now! I'm glad I took a break and decided to tear it all down and check, otherwise I never would have suspected that.

 

What rebuild kit you use?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Turbogixxer &raquo;</TD></TR><TR><TD CLASS="quote">What rebuild kit you use?</TD></TR></TABLE>

I'll look tomorrow on the box when I get back to the shop. I got it from a friend who had it sitting around his shop for a long time. It's for a B17 (YS1) tranny, all the synchros are identical to the ones I took out, and the bearings were all NTN like the stock ones. The seals were identical as well.