ats close ratio gearset for itr + 4.9 final drive - fitment issues with 4th gear...
 

I have just completed installing the following gears in my itr transmission: 1,3,4,5.

This transmission also already has an ATS lsd and ATS 4.9 final drive.

I have one major concern with this gearset, and it can only be explained by the photos below - please have patience as they look similar but are not all the same.

I've got everything back into the case.

Here's the lower gears on the shafts:

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Here's a good pic of 2nd and 3rd:

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Another slightly different angle of 2nd and 3rd:

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Another angle with me taking measurements:
(the alignment is off by 2mm lower on the countershaft for all gears EXCEPT 4th - BUT when the snap ring grabs the countershaft bearing, everything will align perfectly - EXCEPT 4th.)

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

(4th gear is 16mm thick at the teeth)

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Now if I pull up on the countershaft to simulate how it will sit in the case with the snap ring aligning it properly:

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Notice how everything lines up PERFECT, EXCEPT for 4th gear!

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Another angle of what I am describing:

http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

My biggest concern is the misalignment of 4th gear. I suspect because I have an older ats gearset, and that this is the reason people were breaking 4th gear. In measuring, I noted that it was off by 3mm at the bottom and 5mm on top - for a total of 8mm of the surface area of the respective main and counter parts of 4th gear. What does that mean? That 1/2 of the total area of the teeth for 4th gear aren't touching. https://honda-tech.com/forums/images/smilies/emsad.gif This sucks, because I bought this gearset brand new (although it was mfr'd a long time ago) from a member of this board.

In emails with yasu @ ats-usa, I have found out by telling him the part #'s, that he thought 4th gear was the one that would break on my set. *shrug* I can't very sell it with good conscience. And I need to get this tranny back together asap. So I'm going to risk it. I expect with a good beating, 4th will eventually fail. At that time, maybe I can get a partial replacement discount from ATS for a faulty part or something... http://images.honda-tech.com/set1//smile/emcrook.gif

If I had more time, I'd disassemble the transmission and take the countershaft part for 4th to a good machine shop and have them cut 3mm off the bottom of the gear and then I'd put it on the top part by sliding it on or having it welded on. That would clear up the any clearance issues... at least I suspect. Thoughts?

nobody knows, eh? http://images.honda-tech.com/set1//smile/emcrook.gif

Here's the reply from Yasu @ ATS/ ACROSS USA:

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote &raquo;</TD></TR><TR><TD CLASS="quote">That gap is I think normal.
The old 4th had a slightly different dimension. The gap between 4th
and 5th was 4.2mm for the old model and the gap for the current ones
is 1.2mm.

You can run them, but as I mentioned the old 4th is not strong enough.
I would suggest to purchase a new 4th which is reinforced with temper
shot and which is slightly different dimension.

Best regards,
Yasu </TD></TR></TABLE>

Now does anyone else wonder why ATS 4th gear was changed?

Perhaps it is due to fitment issues as shown above.....? http://images.honda-tech.com/set1//smile/emcrook.gif

Re: (Black R)
 

up for you man, i really wish i could help

Re: (SkankyEJ7)
 

old thread but was end result with 4th ?

damn none of the pics show up eh? :/

here's the updated thread of my resolution:

https://honda-tech.com/zerothread?id=1597005




Modified by Black R at 8:59 PM 8/22/2008