HELP - I'll be installing the JDM FD this winter, and at least the 3-4 synchro as well. But I've never done anything as mechanically complicated. I've never even pulled axles before. I consider myself mechanically inclined, just lacking experience. I'm confident in my skills, and I have a great resource here on H-T. However, I know I'm bound to run into some roadblocks, and I'd just like to be as prepared as possible.

I've read over the helms a couple times, and like always, it says to replace miscellaneous things during assembly, etc. I know there are some things that people ignore, and are easy to get away with (i.e. exhuast manifold gaskets). But when it comes to something complex as a transmission, I don't want to take any chances. What items should I be replacing and what can stay? Honda likes to sell washers and lock nuts for $38.49 ea. (plz note sacarsm). But if it's not something critical and is visually still in good shape, can it stay?

Alternatively, would it be better to make a list of all the "Replace" parts and order them all before installation? What have you guys done?

I regret not having the manual in front of me, but you guys know what I mean, share your expertise.

Thanks-
Ed

 

When I installed my 4.785, the only things I replaced (other than the FD) were the crush washers on the outer casing. Everything else can be reused w/o problem.

Of couse if you are replacing the syncros, you'd be replacing those as well.

It's easy stuff, just follow the helms and you'll be fine!!


HTH
Jeff

 

I 'm pretty sure a gear puller is needed for the job, but I've heard you can get away without a press. The service manual says to shim each and evey gear on both shafts... anyone do this, or do the gears just "go where they're supposed to" once on the shaft?

 

Gear puller & bearing seperator:



Press:



I wouldn't do it without the press. I have no idea how you would get second and third off the countershaft . . .

As far as shimming the gears, Didn't do any of that (don't even remember that in the instructions . . .)




[Modified by jeff652, 8:45 AM 11/7/2001]

 

uhmm.. 2nd and 3rd are easy as hell to pull off, 4th and fifth can be taken off with a simple bearing puller and put back on with a good sized socket and a BFH in 2 minutes (if that). THe hardest part about the job.. that fuggen snap ring It's really not hard, remove the whole starter (unlike what helms says) and remember, the FD -> diff bolts are reverse threaded!

 

ditto everything dave said.

bearing puller is needed. hydraulic press is not needed.

D

 

D & FD Weekend Crew:
What is your take on my first question? Did you guys replace any of the misc parts? Should I get a new housing gasket? Hondabond?

 

I Hondabond

We didn't replace anything except for a synchro (2nd/3rd). Left the 70K axle seals/etc. Lub up everything when you put it back together.

Having said that, it's not a bad idea to replace those things, we just didn't.

 

Thanks for all your help guys, I'm sure I'll be back with more questions :\
Anyone have anything else to add?

 

yes. drink lots of .

You will need a vise as well. Oh and those FD -> diff bolts are reverse threaded! (haha)

 

Asspenny and I may require some of you other FL boys assistance when we get around to doing ours....

we can have a keg waiting.... that should hold about 4-5 of us for the night

 

First thing I need to get before we start a little adventure is another car. Also for tools make sure you get a pair of snap ring pliers, should make taking the c clip off alot easier....

Another question, what is used to seal the two cases back together? Hondabond?

 

Hondabond HT

 

Got a pair of snap ring pliers... if i can find them :\
Wut is Hondabond HT ??

 

I see a lot of people say this... but you really only need some regular ol' pliers. I have some 11' pliers that get used on just about every job I do. About the best tool I have.

Make sure you have a really clean workspace. Before I put my tranny back together I got about 5 quarts of Manual transmission fluid. I took the cap off of one of the bottles and screwed on a spray squirter like from a 409 bottle or something. I used one whole bottle just cleaning out the tranny & you wouldnt imagine the crap that came out of the crevices. I used a non-lint cloth to clean with. I also cleaned out the magnet area & the magnet well. You'd be surprised how much this thing actually catches.

Have fun!!!! Getting the tranny out was the worst part for me. Taking it apart was cool. Seeing all the gears and getting to see how it worked was the best!!

Pete

 

Yeah?

Did you take photos and do a write-up/ how to on it?

You hear this c-speedracing? This would be a great article to have in your how to section!

 

Black R: I would have done one but no digicam.. and I would do one but my beater gets my money before my teg.

 

Did the entire job with wrenches, a vice, screwdrivers, and some BFHs.

Bearing pullers are not needed but experience is if you¡¦re not going to use them. I fortunately had the help of an experienced Honda racer who stripped down the entire counter shaft with a pair of screwdrivers, a block of wood, and a hammer!

Here was the routine:
- Install the countershaft in the vice using wood blocks to bite into the FD gears
- Remove the retaining bolt
- Insert two clean flat head screwdrivers on either side of the gap between the first and second bearings and press down on them at the same time and slide the top bearing off.
- Tried the same thing with the lower bearing without success so we moved to the next step with the second bearing still on the shaft
- Re-install the retaining bolt loosely and take the countershaft out of the vise.
- Place the shaft upside down on a concrete floor (or something VERY strong and hard)
- Using a BFH and wooden block strike down on 4th gear. rotate the countershaft after every hit so that you slide off the gears evenly. After about 2 minutes of pounding you should have 4th, 5th and the second bearing off the counter shaft.
- Everything else on the countershaft slides of without force.

Putting it all back together happens in basically the same fashion. But be sure to put things back together correctly!

It's not that difficult but make sure you have snap ring pliers if you want to reduce some frustration.

Regards,

 

Baby: LOL I cheap **** bearing puller will make it a bit easier and def. faster.. worth the few bucks IMO But a BFH and socket is all you need to reinstall the stuff. (well two BFH's work good for 4th/5th with two people hitting it in sync.)

 

Hondabond High Temp. The high temp formula of course

 

hehe, keep this thread going guys!

Pretty soon I'll have enough notes to do it my damn self!

 

Had the bearing of in less then 10 seconds!!

Had the rest of the counter shaft apart in less then 3 minutes!

Had it all put back together in less then 10 minutes!

Bearing pullers are for wimps!

Regards,

 

Baby: We took off both bearings, 4th and 5th gear is about 45 seconds max, all at once.

 

Yah, well I was lying! We had the entire job done from the removal of the first bolt to the first test runs in less then 15 minutes. But I didn't think anyone would believe me!

And we didn¡¦t break anything!

Ok, I¡¦m sorry that was a little below the belt.

Why do I have the feeling that watching both camps would have been a bit like watching junk yard wars?

Regards,




[Modified by BABY NSX, 2:12 PM 11/7/2001]

 

LOL. If you had the whole thing done in 15 minutes I want your autograph! haha.

As for breaking stuff.. I wasn't holding the wrench! lol.

"Tonight on Junk Yard Wars... two Honda groups fight to install a new final drive, syncros, countershaft, flywheel, clutch and pressure plate the fastest! Should be exciting!"