Just a quick question in regards to diff shim and case clearance.

Does anyone know is all the K series transmissions have the same diff to case clearance specifications? I have the manual for the 04-08 TSX and if the specs were the same for the TSX and 06-11 SI then I could just use this manual and not have to buy the 06-11 manual for the one specification.

Thanks

 

Maybe, the problem is the TSX is a unique magnesium case. I have TSX and CR-V (K24) manuals. Let me go check.

 

2004 TSX 0-0.10mm
2003-05 Element 0-0.10mm
2005-06 CR-V 0-0.10mm

I would say they are all the same.

 

I have the 06 civic manual. What spec specifically are you after? And would it be found in the specs section or is it typically found in the tranny section?

 

Specs in MT, the 80mm shim clearance. Was the last spec listed in my manuals.

 

My 6 speed diff states 80mm shim.

With the following shim list:

 

80mm shim. 0.00 to 0.004" (zero to four thousandths) free-play between the differential bearing and the transmission case w/ shim installed. Be careful not to take ZERO as gospel... you could be stretching the case from a thicker than original differential install height !!!

 

Thanks Ryan! That is promising that the magnesium case is listed with the same clearance.

Hey Tom, I have an 09 pnn4 trans that I am doing a few things to, I have the TSX manual that has the specs listed and it looks the same as the pic you provided. I just wanted to verify that I had the same ref material in my manual as the 06-11 SI trans calls for. Thanks for the info!



Thanks JR, Ill stick with the current 80mm shim and make sure that I am within range with the installation of my OS-Giken (the ref material from OSG states to follow the factory service manual for installation).

 

Isn't it kinda funny that they use the same 80mm shims from the 1988 Civic Si?

PL3

 

I guess if the machines are already tooled and it worked, re-use of that is a cost savings to Honda... That is pretty cool.

 

Ok I have the new diff in and I am checking the clearance. The manual says 0-.10 I cannot get a .0015 feeler in between the shim and the outer race on the bearing so I guess I can assume its 0. Has anyone run with 0 shim to bearing clearance? I also made sure to bottom the diff and bearings out (on the diff and in the case). Seems like it was too easy. :D

 

Ahem
https://honda-tech.com/forums/transm...inner-3348005/

 

As I stated above, you CANNOT assume it is ZERO. It could be LESS than zero and stretching the case. The proper solution is to use a much thinner shim and re-check. Once you know what thickness gets you somewhere between true zero and infinity, you can SUBTRACT the clearance you want (lets say .002" and be right down the middle) and add the remainder of what you measured to the current shim thickness to get the proper shim size. THEN and only then, are you set correctly.

 

Doh I didnt even reread my own thread. Thank you both! I've been in the heat of the garage and not thinking clearly. I really appreciate the help. This is my first tear down and installation of an aftermarket diff on a K series transmission so this is super helpful.
I like the sanding method, do either of you prefer a certain clearance? Say .05mm?

 

Ok so I got it buttoned up. I ended up using the 1.2 mm shim and came out with .051 mm or .002 in of thrust clearance. A few pics for ref.

Something that others might find useful... once you have some clearance, go straight to your .004 feeler and see if it fits. If it does, go up in feeler thickness until you get drag. Take the difference in thickness between your .004 in gauge and the thicker gauge that currently has some drag, then add that difference to your current shim thickness. Once you have done that, you will have the right shim thickness part number to select to get thrust clearance between 0-.004 in. (Kinda like JR says above )

just enough drag on the feeler


Thanks for the help to those that posted in the thread, much appreciated!

 

That is EXACTLY what I said !!! LOL

 

Haha! Just wanted to reiterate.

Thanks for keeping me on the slim with the non-assumption of 0 clearance!

 

I "Sent One" assuming zero clearance once... it cost me a bundle. After installation and setting the car on pavement, the clutch was released in first gear and the car lurched and promptly pushed the right side axle out along with a large doughnut of aluminum from the transmission case... followed by a huge puddle of tranny fluid. REALLY. BAD. DAY.

Your post brought back that nightmare memory. I just thought I would save you from yourself.

 

Yeah that would not be a good day, I think I owe you a beer. Saved me about 3800-4K if the trans had grenaded.. in this case, I would have been stretching the case by .4mm. Did you ever figure out how much you were off to cause that to happen?

 

Nope... the entire bearing contact surface came out with the aluminum doughnut. I think the measurement was "MORE than enough to cause a big problem" !!!!

 

Got it all buttoned up and took it for a test rip, with the plate differential unloaded on the stands, the transmission is really noisy. Once you apply load its quiet. A 30 min drive and everything works great! Shifts are perfect with the new syncros, the OS Giken definitely feels different in a good way. The 5.4 FD and shorter 6th gear is bananas....

 

Every Honda I have had on the lift makes chattering noises when the drivetrain is unloaded. Backlash and power pulses and such. Certain engine speeds are worse than others. Light weight flywheels really amplify it.

5.4 FD is SHORT! What does that top out at? 95 mph? On a street car I disliked the 4.7 and went to a 4.4. Still looking for a 4.1.

 

Haha it is short. Nope, with my tire and the 6th gear that I am running its 154.1 mph. I don't drive the car on the street much, only when I am bedding in brakes, scrubbing tires or testing out a new part. Yeah the new diff clicks on tight slow speed turns. From what I hear, it should reduce over time as the plates break in.