OK, I'm an idiot... while rebuilding my 89 Si transmission I decided to put in a phantom grip equiped differential that I got a good deal on. The guy I got it from wasn't sure exactly what it was out of, but he thought it was from a cable ZC trans. It fit perfectly (after putting my ring gear on it) So I figured everything would be good.
Well, yesterday was swap day. Got my engine and tranny all together, pulled the old combo with no problems, new combo dropped right in.... then it came time to put the axles back on and guess what, they don't fit the ZC splines!!! this is going in a '91 civic STD with the 23 spline hubs and I'm pretty sure no one makes an axle that has the zc splines on one side and the small 23 spline on the other. And I really don't feel like custom building some.

So, now I'm tearing the tranny back out and putting the old Diff back in it. I was thinking about putting the Phantom grip plates on to the Si diff, but I'm not sure if I want to go through the trouble of tearing the diff apart.

Anyway, I just posted this in hopes that others could learn something from my mistake. Feel free to comment if you wish.

 

just save yourself a future headache and ditch the phantom grip. then go get a quaife or a kazz.

 

got the lsd swapped to the Si diff, but when I split the tranny case, I aparently didn't spread the clip apart far enough that holds the countershaft bearing and the bearing shattered! (honest, I didn't put that much pressure on it!!!) maybe it just didn't like being pulled apart and put back together about 6 times because I forgot this or wanted to add that etc.

anyway, new bearing should be here tommorow.

If anyone's really bored and wants to see how I'm doing, I'm posting pics @ http://groups.msn.com/Thumpu77sphoto...ntproject.msnw



I've been told that before, but my budget can't handle a Quaife or Kaaz... besides, the D16a6 I'm putting in is still basically stock, and the car's going to see little-to-no track time.


[Modified by thumpu77, 10:00 PM 2/27/2003]

 

honestly i wouldn't even bother with the phantom grip at all then. i have heard a few stories of the phantom grip exploding diffs.

 

OK, got it all in today.... the engine ran great (suprizingly great) after taking care of a couple of leaks. warmed up fine, time to take it out on the road!!! 1st gear, fine. 2nd gear, fine. 3rd gear, a little bit of noise from the tranny, but ok. 4th gear, WONT GO IN!!!!! 5th gear, pops out when i hit the gas!!!

has anybody had this problem when swapping a 4-speed for a 5-speed? My friends that own a tranny shop think there might be a problem with using the 4-speed linkage. is the linkage different? if it is, which models can I get linkage from? 4-door? crx? or just hatch?

if the linkage is not different, any other ideas? The tranny is completely rebuilt with new syncros, bearings, and seals. the shift forks all looked good and straight, it's got 2 quarts of honda mtf, I put new ES poly shift bushings and motor mount inserts in.

help!!!!

 

the shifter forks in the tranny are shot. or so i think

 

yeah make sure you didnt crack the forks by accident.the linkage has nothing to do with it

 

did you try to see if the inner zc shaft's inner joint would switch over, if they were the same, get new inner boots and swap those onto the non zc shafts (probably wont work, but worth a shot)

 

the forks looked great when I did the rebuild.

 

 

ok, I swapped the 4-speed back in, and as i was draining the si trans, there was metal shavings (mostly aluminum) in the oil. got the tranny apart and this is what we found:





You can't see it very well, but in the first image is the main shaft bearing and the inside ring is pushed further into the hole than the outer ring. what's weird is it still rolls smoothly. In the second pic you can see that the metal shavings are from the 5th gear fork and the ring that the fork rides in. And in the third pic you can see that the ring is discolored from heat and the hub's teeth are kind of chewed up on the ends (matching marks on bearing in pic #1)

Here's what we THINK happened:
In the many (too many) times that I tore the tranny apart and put it back together because I forgot this or wanted to change that, I may not have gotten the main shaft to line up with the bearing properly and forced (did I say that?) it together bending the inner ring of the bearing further into the hole than the outer ring. which left a lot of play in the main shaft, causing it to move around too much (thereby causing it to pop out of gear) also, leaving enough room for the hub to scrape against the bearing's outer ring, causing the heat and wear.
why it took out the shift fork I don't know.

Anyway, I need a 5th gear shift fork, ring, and hub, and a new bearing for the end of the main shaft. the sad thing is, I sold my DX tranny i had laying around that had all of these parts in it (for $10.00 nonetheless)

anybody have any extras laying around?

 

bump for the weekday guys

 

that sucks son, what are you gonna do now? rebuild it again?

 

Gonna give it one more try... I've got too much invested in this tranny to give up on it. All of the bearings, seals, and syncros are brand new.

here's a couple more shots of the carnage:

 

i have a DX on ym car right now, an SI that needs rebuil since its stuck on 2nd and a 4 speed....
cant give u the one on the DX bc i am using it... i am using maybe some internals off the speed to fix the Si.... too bad i dont have 5 gears on that one.... and the Si well. thats the one getting fixed.... if i manage to get that Si working good. when i take that DX out and open it... if u still need those parts let me know....
but i will be workingn on it the next 6-8 weeks.. i guess u wont wait that long..
anywyas good luck..... try checking local shops with blown engines and **** to see if u can get a tranny cheap...

 

thanks, but I've just about got all of the parts lined up allready.... I've just got to clean all of these aluminium particles out of it!!!

 

Wow thumpa...you are my hero...
Sorry about the tranny...I really feel your pain
I'm about to start rebuilding my Si tranny..so I'll
hopefully learn a few things along the way.

( Now if I can just find a bloody engine.... )

 

Here's an update for anyone interested:

opon pulling the main shaft bearing (the one at the 5th gear end, not the input shaft end) I realized exactly what had happened...



as you can see in the pic, the center hub for the bearing is larger at the bottom than it is on top, this allows the bearing to resist lateral force being placed on the wider end. Well, when I installed the bearing into the tranny case, I installed it so that the main shaft went into the smaller end, which has almost no resistance to lateral force. thereby causing the bearing to fall apart as soon as I hit the road.

In other words....
Chalk another one up for the king of installing things backwards!!!!!

first this, then my thermostat in "D16A6 rebuild overheating", and I'll probably find something backwards to solve my "vibration woes" problem!!!