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.

 

When I did my tranny, I had to shift the gears to make it slide all the way together. Here is the thread that I followed:

It's for b series tranny, but I am sure some of the principles still apply
https://honda-tech.com/forums/showth...ion+inspection

 

Tried that.

Looks like Aquafina posted something in my other thread in Transmission and Drivetrain that sounds promising though:

https://honda-tech.com/forums/transmission-drivetrain-127/s20-s40-hybrid-cant-get-housing-together-2708913/