First off... the swap went well engine now runs strong and idles with no codes.

As I put it into 1st and pull off I hear this loud frightening thud! then the car just rolls to a halt as if it is in neutral.

Car still running fine but not going anywhere? I an now constantly getting the clutch engaged (I can shift freely into any gear, and as i do so and press the gas, my speedometer needle goes up??) I pop the hood to see wassup, and I notice oil coming from the tranny where the right axle goes in.

I push the car back in my yard.... jack it up remove wheel and axle. I now notice that my axle does not lock into place? (that C clip could be a possible cause?) Well whatever the case may be... The Right Axle is not completely seated and flush as the left axle against the tranny.

My two concerns....

WTF happened to my axles? I am using the Stock Si tranny with the brand new axles I had in there working and seatng properly before?

WTF is up with my Tranny... do you think my Throw Out bearing somehow got disengaged from its home and is now flopping around freely in front of the fork? When I press the Clutch pedal in I can feel the clutch engage and the bearing rotation noise disappear, but when I release it theres a abnormally loud grinding. But the clutch is still engages and I can shift into any gear?! I tried adjusting my clutch cable to several positions from tight pedal response to very loose pedal response, but still no go.

If anyone can help me figure this out, I'd greatly appreciate it, (especially the axle thing) Thank you.

 

To me it doesn't sounds like a transmission problem. Since the tranny is working, that's why you get a speed reading on the speedo, since the speed sensor comes out of the tranny. Must be the connection from the tranny to the wheels, so probably your axle situation!

What's going on with your axles, I don't know. I don't have experience in that area.

 

maybe your cv joint broke and the because there's no resistence the diff is only turning that side maybe? maybe something wrong with the diff itself. i'd pull the axles and see what their condition is, then take a peak inside the tranny itself, see how it looks.

 

as serious said, pull the axles to see what's up. maybe the cv joint went bad while putting the axles back in?

let us know how that goes so we can recommend further advice (if need be).

 

It almost sounds like the axles arn't all the way in, hence the grinding. I'd say jack the car up, secure the rear tires with blocks and the e-brake, start it and go through the gears. Much easier to dignose a problem with non-moving car vs. a moving one. The reason I say to do this is because after towing a Ford Escort accross country, I had a weird gringing noise while in motion. I thought it was the trany, but it turned out to be the hubs. I saved myself a few $$ by jacking the car up using my ears. Good luck!

 

Guys... Axles and CV Joints are good. I checked them today, both ends. They are new (remanufactured from MIDAS) it seems that the left "longer" axle seats nice and flush as it suppose to, but the shorter right axle is about 1/4 inch away from the tranny casing (axle splines go in but it does not click and lock in place. (sigh)

Furthermore....
Why am I constantly getting clutch now? That shouldnt be? This leads me to believe a release bearing/fork issue? I have adjusted the clutch cable to various settings to give the same result.
Keep in mind the drove about 150ft out of my driveway with ease. As soon as I made it to the street and decided to go...it revved to about 3200rpms engaged 1st gear.. never made it to 2nd and then the above statement occurred.

I cant believe that this crap is happening after all the hard swap work is done

 

pull the snap ring off the axle that is not in the tranny all the way. once the ring is off make sure the axle slids all the way into the tranny. if the axle does fit all the way in, replace the snap ring and get that axle in all the way.

if the axle doesn't fit all the way you have found you problem.

 

Well... I finally got the ZC swap COMPLETELY running and road worthy. It turns out that the sanp ring seized on the right axle. I just took out the axle, pryed off the snapring with a scribe and cleaned the groove and sanded off any burs and crud that was in there. replaced the snap ring and re-installed the axle. Mind you that upon reinstallling I had to sit my fat *** on the floor and leverage my leg and foot and kinda stomp the axle into the locked position after the splines were threaded. it just didnt wanna go for a few seconds there. and I didnt think hammering was doing anything but stressing the CV and axles inner bearings. One good foot shove with the axle all lines up did the trick. bolted everthing back up and car was alive and kickin.
I dropped 2 bottles of injector cleaner in the gas tank and filled up with Sunoco 94 and ran her for about 20mins to kinda clean out the injectors. Everything else worked out great. ZC feels really nice. I guess I need to get a Teg ECU to really feel the power as I am running my Si ECU.

I'd like to thank all you fellas who helped ma along the way to getting this job done right. It was greatly appreciated.

BDR.

 

def. get the teg ECU. and if you really want a quick car, do the ZC/Si hybrid trans.

http://hybrid2.honda-perf.org/tech/zcsifdswap.html