I'm working with a '92-'95 Civic EX/Si P20 transmission (S20-B000).

We put in a brand new Honda ISB and new Honda axle seals.

Recently we've began working on it again after having abandoned it for a bit. Now we see there was a gear on the mainshaft that was cracked and the bearing at the end of the bell housing on the countershaft.

So we got a brand new Honda bearing and put the mainshaft from a '98 S40-K4F (EX) transmission in since we were on short notice of the cracked gear. We also put in the S40 diff.

Now we're having an issue where the housing won't go together. The two halves won't get any closer than about half an inch or so. It feels like it's caught on something but we don't see what it could be.

Any help would be appreciated.

CLIFFS:
S20-B000 tranny with S40 (EX) diff and mainshaft. Housing won't go together.

 

The tab on top of the mainshaft? The clip at the top make sure you spread it a little bit.... try flipping the transmission over and bumping it on a piece of wood to get it to pop in place. Try to thread a few bolts to put a small amount of tension on it.

 

That's not what I'm talking about.

I can't even get to the snap ring yet. I know how to deal with the snap ring. I need to get the housing down low enough to even reach that though.

I can't even get to that point right now.

 

Mainshaft needs to be shimmed, CS 1/2 need to be changed out for the matching 96-00 gear, 96-00 mainshaft uses a different oil guide plate than the 92-95, make sure the top mainshaft bearing is on correctly (it is tapered).

 

Thank you so much.