Need some advice with what all should I replace. It's the "rare" manual 5 speed transmission from a 90-91 civic ex, with the 4.02blahblahblah final drive. I bought it from the junk yard, pulled it from the car myself. No idea on mileage, but the internals are spotless, even the bearings are tight and smooth, save for the following;

This tranny has had a second gear grind when shifting up or down above if not rev'd matched, or letting the rev's drop down to near idle and slowly clicking into gear since I installed it. I suspected a cracked shift fork, which i was correct on when I tore it apart, but should I replace the 2nd gear, syncro and selector as well? I have pix:

cracked fork: (how does this even happen??)


Here's my main concern, 2nd gear looks quite worn, I imagine the selector thing (I don't know the proper name >.<) has matching wear, should I replace this?



Thanks guys!

 

1/2 fork is still available. 3/4 has been discontinued.

All gears have been discontinued as well.

I would find a complete 1/2 gear set in better shape. Your 2nd dogs are pretty rounded.

 

I have the gear set from my old si transmission that's in good shape still that i plan on swapping in, along with my hf fifth gear so i have an actual fifth gear for some freeway fun.

how does that fork actually break though? some one just banging the crap out of gears and not shifting/clutching correctly? would it be worth it to buy a new fork? or is it safe to junk yard this part?

 

Remember to shim the mainshaft when you swap the gears. You'll need to keep the EX bearings as they are smaller than the Si.

Forks usually break from driver error or a failing clutch. I would order a new one from Honda. Most used forks will be worn past the service limit.

 

shim the main shaft? what do you mean? i'm only replacing one gear (well technically two) not the dif and gearset

 

First and second gear are built into the mainshaft. You need to keep the mainshaft and countershaft 1/2 gears together as they develop wear patterns with each other and mixing and matching gears will cause problems.