Jeff C

Well I had a mishap with my newly installed clutch. The splines on the clutch disc completely stripped out and took a little of the splines off the mainshaft in my tranny. Not cool. I did not want to install the new disc with the manishaft partially stripped so I bought a new mainshaft from Acura, $230. I figured that while I was in the tranny I would do a little how-to. A lot of people are afraid to go inside a tranny for fear all the parts inside, I guess. This is my attempt at show-and-tell. Btw, this is on a ‘92 GSR YS1 cable transmission.

First thing first, disconnect the battery and put Nikki in the house

Here are the tools that I used.


A shot of the patient and its new inard part


The first thing that I did was remove the clutch lever and release bearing by removing this bolt right herrr


then I removed the back up light switch


remove clutch cable bracket


then remove a few other misc bolts around the case



then this sealing bolt


which reveals the dreaded snap ring


lastly remove all the bolts that hold the transmission housing to the clutch housing



this is a good point for a drink of water


ok, now crack the two halfs apart


using the reverse snap ring tool (a must) spread the snap ring and the countershaft should clunk as it drops off the snap ring


closer look


and pull the trans housing up, you may have to wiggle it a little, and there you have it…the inards are exposed


then start removing the pieces around the counter and mainshafts,

first the reverse changer holder


then the reverse idler gear


then the shift piece/shift arm holder/select arm……stuff



now remove the countershaft w/ gears and synchros, mainshaft w/ gears and synchros and shifter forks all at once



and there sits the whole clump


another good point for a drink of water


here is the new and old mainshafts together. Also I have removed all the gears and synchros off the old shaft and have placed them upside down, in order, off to the side


here is the old mainshaft, you can see the shininess, that is where is has a little wear from the clutch disc strpping out


now, grease the new mainshaft up with assembly lube and start putting the gears and synchros on



here is the final assembled mainshaft


clean the hondabond off, wipe some old grease off, and lube up the sockets where the counter and mainshafts and shifter fork go into the tranny


now put in the countershaft w/ gears and synchros, mainshaft w/ gears and synchros and shifter forks all at once


here is the tranny with all the inards in and lubed up ready for the tranny case to go back on



now, if you get something out of order the helms manual, which I know you bought before you attempted this, has a nice exploded view with descriptions for everything inside and out of the tranny


Just put it back together in reverse order and don’t forget Hondabond and to torque all the bolts down correctly. If something is hard to put back together, then that probably means something is not right so double check. I hope now that you realize that working on the transmission is not all that bad. I may have forgot something so take your time.

Overall, it took me about an hour, and I was farting around. Level of difficulty would be about 2.5 on a scale of 10, at least I think so.

Roger

good job. I like the portion when you had a drink of water. we did one of these last week and it took us about an hour with afew drinks from the hostess.

PhatOptimo

Snap ring pliars are not needed. Needle nose pliars will get the job done.
That white grease is not needed, MTF is.
Screw the water wheres the
Trannys are childsplay .
Good pics except the H2O.

bartek_b

very nice writeup

Chiovnidca

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Jeff C &raquo;</TD></TR><TR><TD CLASS="quote">
Overall, it took me about an hour, and I was farting around. Level of difficulty would be about 2.5 on a scale of 10, at least I think so. </TD></TR></TABLE>
Yea, five speeds are easy. Did you clean, inspect and check the clearances before you put it back together? Usually when I see a mainshaft torn up like that there are usually syncros getting on the loose side and/or bent shift forks.

7PSI CRX

Excellent job.


Good clear pics!


Ive got a question or two if you don't mind.

1 - Think you can point out for me the bearings that give the dreadful "whine" on my old '91 Si tranny?
(I want to attempt the rebuild, but don't want the tranny sitting apart while I wait on the bearings. I want the parts on hand so I can get it back together the same day so I don't forget how things go. Letting it sit on a bench for a few days can only lead to possible problems)

2 - And I assume those bearings on the shafts slip off, no press needed?

3 - And the bearings that remain in the case, are they easily replaceable, or a press is necessary?

DCStreetHtch

bump so this is in my topics!!

-Bryan-

tinkerbell

bloody excellent mate!

real good work,

i assume it would be that easy to change a syncro too?

vtec_r

Very nice job

Hybridize

Excellent post!

Mista Bone

nice craftsman #45492 snap ring pliers..........

PHiZ

Thanks for the helpful post!

-PHiZ

I still ain't touching that scary bastard!

Jeff C

PhatOptimo, you can use your pliers and drink your , but i wouldn't trade these snap ring pliers for anything.

Chiovnidca, about 75% of the gears and synchros in there were replace 25k mi ago. There is no play. The problem was the splines on the outside end got a little beat up. The inside are ok.

7PSI CRX, I personally am not familiar with the whining that you are talking about so I cant help you there. Correct, you do not need a press. However, there is a nut on the end of the countershaft, like the axle nut, that is a little PITA. The bearing in the case can easily be tapped out with a mallet.

tinkerbell, yes it easy to replace the synchros. you just need to make sure that you get them back in the correct place cause they are not all exactly the same.

Mista, I am glad you told me about those things awhile back. They are awesome!!

Thanks for the props. I hope that it helps somebody. Now I have to go install the tranny back into the car.

baphomet

great work - I have a new found confidence

Propulsion

ok, not as hard as its cracked up to be...

is putting in a LS 5th gear just as easy?

Jeff C

I am not sure what all is involved in putting a different gear in, ie having to use a different synchro too, but replacing gears is yes, just as easy.

Mista Bone

once you get the gear shafts out, swapping fifth gear only takes about 5-10 minutes. Getting to 30mm nut off is the hardest part.

baphomet

Now I need a Quaife how-to and I'm set

PhatOptimo

Thats got to be a TEG tranny. Bone told me abot thoes pliars a while back. I havent been to Sears to get them yet . Time to install .
Hers a few form my last encounter with my Y1.


All glued up and ready to install




Modified by PhatOptimo at 11:18 PM 10/11/2003

Audi RS4

it looks scary

Jeff C

Mista, thanks for the input. I know how to replace a stock gear with a stock gear, but i was not for sure what would be involved in replacing a stock gear from one tranny with a stock gear from another.

slashDEVslashNULL, i have done a couple to those too. You would take the tranny apart the same way (obviously) and remove the gear sets the same way (obviously). The diff just pulls right out. The biggest PITA about a Quaiffe install is getting the correct shim. How I did it was put the put the Quaiffe in, reassemble the whole tranny and check for shim clearences just like the manual said. If it was good, then remove the case and apply the HOndabond. If it is not, keep trying different shims till you find the correct one with the proper clearences.

PhatOptimo, yes its a teg tranny, YS1. And yes the tool comes in very handy. Thanks for adding the pics too.

advanracing62

good write up! I agree that Trannies aren't anything hard to work on.. just gotta remeber where **** goes!

Burke

those winey gears could be on either side of the diff - mine were, but you will need a puller to get them off. the whine could also be the bearing on the shaft or the ones pressed into the casing. the ones in the casing you can just pop out too.

Wes V

Jeff;

That's a great write-up!! I totally agree with the "water" aspect of it! (no preaching, just a little fun)

Maybe I'm in the wrong generation, but what's a "Nikki"?

About that snap ring;

Can the snap ring be removed / or installed through the access hole? The access hole doesn't look large enough to get it in and out.

You made a comment that you will hear a "clunk" when the countershaft falls free. Am I correct that this is due to already having the cases spread apart? If you just pulled the cases apart, I'm assuming that the gears would fall all over the place as they came off the counter shaft.

When putting it back together, do you have to worry about the countershaft being in the correct position to get the snap ring on? Does the snap ring just flop around free, after bolting the transmission halfs together and before it's snapped into place?

Thanks!!

Wes Vann

MrTodd

I also have the same question as listed above...

In addition to that, I'm also wondering about the 'whine' that my '90 Si (CRX) tranny makes. Someone said that it could be the bearings in the differential??? And you need a puller to get to those? What's a puller?