ATTENTION:
I've set up this simple forum as a back-up for the 3G community on Preludepower.com

For ease of use you can quickly log in using your Facebook account, up there /\ OR just register an account like usual.

D2A4 - Rebuilding and Upgrading Information (Work in Progress)

Everything related to engine builds, engine swaps, transmission builds, and turbo charging
Post Reply
User avatar
MustardCat
Site Admin
Posts: 108
Joined: 16 Aug 2017, 20:34
Location: Mount Vernon, WA
Contact:

D2A4 - Rebuilding and Upgrading Information (Work in Progress)

#1

Post by MustardCat » 26 Feb 2021, 02:45

When rebuilding the transmission some of the main things you are likely to replace are bearing, seals, synchronizers, and possibly shims. In most cases you will probably not need to replace the gears themselves. A lot of the D2A4 internals aren't available from Honda any more and the ones that still are could be discontinued at any time. Below I will try and list out the things you will need for a typical rebuild and give alternate to genuine Honda when they are found.


MT Transmission Housing:
Image
20. Oil Seal (For axle) Size: (40X58X8) Honda# 91206-PX5-005
11. Shim (For differential) Size: 78mm O.D. / ?? I.D. Thickness: Was available in many sizes between 1.20mm - 2.37mm



MT Shift Fork:
Image
6. Ball detent spring - Discontinued, but can be substituted with springs from other Honda MTs. Requires: 2.



MT Shift Arm - Shift Lever:
Image
8 and 7. Shift arm return springs - Discontinued from Honda but they can be upgraded with H series aftermarket ones: https://youtu.be/XN1Dxdq8NK4
15. Dust Seal Size: (16X23X5) Honda# 91209-PE9-005
16. Oil Seal Size: (16X27X14) Honda# 91215-PK5-000



MT Mainshaft - Gears:
Image
17. Bearing, Ball Size: (63/28C) Honda# 91002-PG1-018
18. Bearing, Ball Size: (28X78X20) Honda # 91004-PX5-008
19. Bearing, Needle Size: (38X43X26) Honda# 91104-P21-008 Requires: 3
20. Bearing, Needle Size: (37X42X14.8) Honda# 91108-P21-008


MT Differential:
Image
7. Shim (For differential) Size: 68mm O.D. / ?? I.D. Thickness: Was available in many sizes between 1.90mm - 2.47mm
8. Shim (For differential) Size: 75mm O.D. / ?? I.D. Thickness: UNKNOWN
9. What is this? Missing info from online parts diagrams.
12. Bearing, Taper Size: (40X75X24.5) Honda# 91005-PK5-004 Discontinued, searching for replacement.
13. Bearing, Taper Size: (40X68X22) Honda# 91006-PX5-008


MT Countershaft Gear:
Image
8. Shim/Washer Size: 54mm O.D. /40mm I.D Thickness: Was available in many sizes between 1.96mm - 2.08mm Discontinued, searching for replacement.
12. Bearing, Special Ball Size: UNKNOWN Honda# 91003-PG2-008
13. Bearing, Needle Size: (25X56.4X19) Honda# 91102-PG2-008
14. Bearing, Needle Size: (40X46X27) Honda# 91105-PX5-000 / 91105-P16-008
15. Bearing, Needle Size: (44X50X24) Honda# 91107-PK5-008 Discontinued, searching for replacement.


MT Clutch Housing - Clutch Release:
Image
12. Bearing, Needle Size: (33X62X22) Honda# 91103-PG2-004
13. Oil Seal (For axle)Size: (35X56X8) Honda# 91205-PL3-A01
14. Oil Seal Size: (28X41X7) Honda# 91216-PH8-005


INFO: Drivetrain.com has a rebuild kit listed for the D2A4, unfortunately I was told it's discontinued when I tried to order.

User avatar
MustardCat
Site Admin
Posts: 108
Joined: 16 Aug 2017, 20:34
Location: Mount Vernon, WA
Contact:

LSD Install Info

#2

Post by MustardCat » 26 Feb 2021, 17:05

The site has a tutorial with some information about how to install and LSD from an Integra Type-R: http://prelude3g.com/p3g/powertrain/itrlsd/itrlsd.htm


Steve Belliveau posted some more information and pictures about his install on the Facebook groups:

P.S. I've blueprinted the stock diff and dc2 lsd. The standard writeups don't state that the Speedo drive gear is positioned wrong by 1.2mm, and the lsd is 3.53mm smaller than the stock diff. The write-up says to make a custom shim for the tranny case side bearing. The better option is what I'm doing, a 3.5mm shim between the bearing and lsd, so I can use stock shims for proper preload adjustment.
Image
Image
Image
Image


The custom shim I'd need ideally would be 3.65mm thick, 40mm ID, and anything 55mm-63mm OD.

Can do, once I get the shim lol. I actually found a factory Honda part that I think might work with some minor alteration. Just need to wait til Monday to see if an associate of mine who owns a transmission shop has something close enough to what I need or not.

The write-up doesn't show any pics of what you need to modify on the tranny case to make it fit, so below are some pics of that. Feel free to share them, or add to the thread on preludepower. All it took was a dremel with a small milling bit, and about 20 minutes including the cleaning after. This is done on the clutch side case, and you simply use the shim as a guide, simply removing metal to open the hole up to match the size of the shim's hole...


Before, without shim in place
Image


Before, with shim in place
Image


After, without shim in place
Image


After, with shim in place
Image


The milling bit I used with the dremel
Image


Here's my blueprint of the diffs. You can see what's the same and what's different, and why the case needs to be modded and why a custom bearing shim is necessary. The most important part though is the bearing seat to ring gear seat, which is identical, and is the only reason we can actually use these.
Image


The difference in the vss gear seat is also important, and can be accomplished properly by simply not pressing that gear down all the way. I'll be putting the stock 1mm bearing shim under it when pressing it on so it stops evenly 1mm above the seat, so it will be located properly for our tranny.

User avatar
MustardCat
Site Admin
Posts: 108
Joined: 16 Aug 2017, 20:34
Location: Mount Vernon, WA
Contact:

Synchronizer Replacement/Upgrade Info

#3

Post by MustardCat » 26 Feb 2021, 17:28

Steve Belliveau posted some information about using synchros from other cars on the Facebook groups:

Anyone that wants carbon syncros in their d2a4, the syncrotech kit for "92-97 Accord with single cone 2nd" will work.

The Synchrotech part number for this kit is: SYN115



So far I've confirmed that all 92-01 prelude shift sleeves fit the d2a4 perfectly. So that's great news for anyone looking to rebuild if the sleeve's engagement teeth are worn.
Syncrotech makes sleeve kits for the h22, they're hardened, stronger than stock, and fit the d2a4 as well. Our sleeves are all 6.5mm though, so make sure the 3-4 sleeve does not say it's for the 7.5mm fork.

User avatar
MustardCat
Site Admin
Posts: 108
Joined: 16 Aug 2017, 20:34
Location: Mount Vernon, WA
Contact:

Preludepower.com Threads

#4

Post by MustardCat » 26 Feb 2021, 18:17


Post Reply