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


[Modified by sackdz, 11:32 AM 11/7/2001]

 

Well I just finished my tranny. Here is what I replaced....I put in new ITR differential bearings, fresh cleaning, replaced the main shaft bearing because It was cracked. Just check your bearings and make sure that they are Kosher. You dont need to replace any bolts unless they have signs of wear. I am a little worried though...you say you have never removed an axle. It is prolly going to take you about 3 hours to remove to case and about 4 hours to put it back on. Good luck with the C-clip.


[Modified by Blown90hatcH, 10:19 AM 11/7/2001]

 

I know it will probably take me forever, but as long as forever is shorter than winter, it's a ll kosher .

Shops/vendors that sell the JDM FD include new mainshaft, 1st gear, and mainshaft bearings (I believe). Like I said I'm also going to replace at least the 3-4 synchro, if not the 1-2 as well. Are the synchros sold piece by piece or the whole assembly together? (I recall 3 pieces to each synchro) If so, do I need to get all 3? I know I won't know for sure till i'm in there.

 

Have you priced the FD? That is gotta cost a grip of loot. Again, this will be by inspection. No need to replace if it isnt broken/wornout.

 

Uhhh, JDM FD Gear with mainshaft and bearings ~$450-500.
3-4 Gear synchro ~$166.87

 

The best advice I have to you (besided having a Helms manual and a friend to help with the install), is to take your time and check everything twice. Make sure your clearances are correct. Spin the gearset after you have it installed in the casing, make sure it doesn't make any noise. Also, how many miles are on your tranny? If you have over 70,000, I would replace every bearing in that sucker. Even if the bearing looks good, ripping the tranny apart is too much work not to replace a couple of bearings. Believe me, I learned the hard way.... . Here's a few pictures to show you what you are getting into. Feel free to e-mail me anytime with questions. g2guru@hotmail.com . Best of luck.

 

I would definitley replace any bearing you remove, and especially the input shaft bearing in the case. The diff. carrier bearings would probably be ok- you can check them when it is torn apart to verify they are smooth. You should also replace the input shaft seal (underneath the bearing you have to remove first). If your trans shifts fine- you shouldn't need any gearsets. If you rag the **** out of the trans (slam 2nd gear alot), it may be a good idea to replace 2nd gear (around $300 in a D series trans). I would buy a new nut that is staked- you can reuse it but that is ghetto. Be sure to fill that sucker with some Honda tranny fluid.

 

Hey dplatt- could you post a closeup of 2nd gear synchro teeth? How many miles and how much drag racing? I wanna see the wear on the teeth.

 

How about some close-ups of worn 2nd gear sync's from a brandy new S2000!

But you already seen this for yourself fixhondas!

 

What trans is that?

 

Because the synchros looked fine, I didn't replace any on my friends ITR JDM final drive swap. It had less than 8000 miles on it and was in perfect condition. On my other friends tranny it was a different story. Sorry.

 

Another question. I plan to just install the 3-4 synchro for now. Going into 3rd gear grinds at even low rpms now, and 4th is starting to at redline. If the synchro is bad enough, may I need to replace 3rd gear itself? Also, my tranny has about 40-50k on it. What else should I replace? So far gears 1 & 2 are fine, but it would suck to have a problem with them later. The 1-2 synchro is nearly twice the price of the 3-4 though

 

Hey breakstuff, I noticed that the gear's synchro teeth are lopsided on my set of S2000 gears too. I didn't pay any attention to the new set I installed, the set I removed didn't really look abused- were the teeth on your new gearset lopsided like that?

 

Heya fixhondas,

Its pretty strange how a car can make such a grinding noise going into a certain gear and when doing the visual inspection, all involved gears and synchro's look normal.. only thing i noticed with this set was what appeared to be a crappy mold with tiny pits and abrasions on the gear attached to the base of the 2nd gear hub.. The synchro's and mating gear are always cut at an angle to improve shift quality, sometimes when you get a new set of gears it requires a little bit of filing to wear down the sharp edges.. just don't file too much!

 

TTT, I'm trying to get a list together. What about gaskets, CV boots, etc?

 

get axle seals, slap some cv boots on if they are cracked, you might also get a new rear main seal (under flywheel) it is a good idea to replace it now. You'll need some Hondabond for the case- I use hondabond 4 (runny stuff) for the case halves and HT for the few bolts that seal the case.