Shak's next project, my 2nd DC5R.

[John_K20A]

Re: Shak's next project, my 2nd DC5R.

I can still remember our faces when the doc was sussing out the gearbox in the street LOL. Remember Shak!

[plAythiNG]

I enjoy how slow these updates are comming along. They happened quite awhile ago and its good to reflect back and feel it all over again!

That Gold is so hot!

[Shakeel]

I can still remember our faces when the doc was sussing out the gearbox in the street LOL. Remember Shak!

Yeah lol... All you could hear was kurrrrrrr and clunk. He gets out of the car and laughs "Yeah it's f**ked".

I enjoy how slow these updates are comming along. They happened quite awhile ago and its good to reflect back and feel it all over again!

That Gold is so hot!

Yeah I'm enjoying taking my time. Takes a while for me to remember each and every detail!

You know what they say "Old is Gold"

[Timmy_B]

13th June 2012:
I was returning back to class after a lunch break with a friend in the car. We were stopped at a set of traffic lights. The lights go green, I proceed to take off then BOOM.. All I heard was something snap and then this constant grinding sound as I continued driving. When I tried to change gears it was so hard, and the car didn't want to go into another gear. I was 30 seconds away from my Tafe parking lot so I just pulled into a side street and went back to class, thinking what I was going to do. During the next break I called up my good friend John (John_K20A) and asked him what he thought I should do as I was in complete shock and terribly confused.. I suddenly thought of taking it to the great Phillip Donato (a.k.a dR Honda), as he replaced my starter motor not long before. John called up Phil and told him the situation, Phil was more than happy to have the car towed to his workshop to inspect the damage and begin repairs. I was really pleased after hearing this, mind you it was the night of Origin Game 2.

Later that night the car was towed to his workshop for the dR to begin his diagnosis..

More to come soon..

.................................... thats old news.
You ended up with TSX 6th and 5.1 FD

I WANT 2013 NEWS DAMN IT!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[Shakeel]

.................................... thats old news.
You ended up with TSX 6th and 5.1 FD

I WANT 2013 NEWS DAMN IT!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Sorry Tim, you'll have to be patient

You also ruined the surprise haha


So it turns out my gearbox pooped itself, due to bad repairs on it previously. I ended up deciding to rebuild the gearbox. Yes I could have replaced it with a 2nd hand gearbox but I'd take the risk of not knowing the history and condition of it, which could die on me as well further down the track. I will copy pasta all that dR Honda had put up on the HCCNSW forum, which is where Tim saw the rebuild long ago. Also as Tim said, I opted to go with the accord euro/tsx 6th gear and OEM 5.08 final drive from the FN2R/FD2R. Great quality work to be seen


Part 1 - Rebuilding the countershaft
Hi Guys,

Thought this may be of interest to this young and up coming Honda Site. Feel free to ask questions and Ill answer as thoroughly as possible.

This 6 Speed K Series Transmission has had a short fall with prior repairs carried out by a non qualified Honda Repairer. The owner has decided to go for a fresh positive approach to recondition this Transmission to its former glory and adding a few nice mods to the table.
Enjoy part 1 of the rebuild



This section of the transmission is the countershaft. The transmission suffered a broken countershaft due to non qualified Honda Repairer attacking it with who knows what.

From left to right shown;
• New OEM 1st gear collar and bearings
• New OEM 2nd gear collar and bearings
• New OEM 1st/2nd syncroniser hub
• 3rd, 4th, 5th & 6th fixed countershaft gears
• New OEM (FN2R/FD2R) 5.08 final drive
• New OEM top countershaft bearing


The decided gear ratios for this custom overhaul is as follows;
• 1st - 3.266
• 2nd - 2.130
• 3rd - 1.517
• 4th - 1.212
• 5th - 0.825
• 6th - 0.659
• F/D 5.08

Here are a few pics of assembly and preloads:


First gear is firmly pressed onto the countershaft:




The new OEM 1st/2nd Syncroniser hub is installed and firmly pressed on (ample lubrication to all moving parts):




A must and no no not to install is the 2nd gear friction damper. This transmission did not have one fitted and was left out on the last rebuild (not the first time I have come across this).




This is the correct position for the 2nd gear friction damper:




2nd gear is firmly pressed on with the correct tooling to give preload before syncroniser clearances are inspected:




3rd and 4th fixed countershaft gears firmly pressed on:




Countershaft assembled and preloads and clearnaces to be checked:




Preload clearances now checked as per service manual and now ready for install.




Stay tuned for part 2 the mainshaft rebuild.

[MYDC5R]

I saw this on HCCNSW!
Can't believe dis was ur box!

[Shakeel]

I saw this on HCCNSW!
Can't believe dis was ur box!

Yeah this was my box Carl. Sad that this happened, but i'm glad it has been fixed the proper way now!


Part 2 - Servicing the differential.

Ok time has come to service the differential and replace the crown wheel and differential bearings. Straight forward exercise?




Not a straight forward exercise. This crown wheel has been off before. Most of the bolts where rounded. I Could not remove one bolt. I drilled through the centre of the bolt starting from a 3mm drill bit and working my way up to 11mm by 1mm increments.







Out finally:



Part 3 - Servicing the Mainshaft

The final main component is the mainshaft. The mainshaft shown has been severly damaged due to countershaft failure. Picture shown below is what to look out for with oiling galleries becoming blocked with metal debris (majorly overlooked)




Before rebuilding the mainshaft the clutch housing must be prepared to house all reconditioned components. All debris must be washed out so you dont contaminate your work. This is the time you would replace all your bearings and seals. Seen below is a new mainshaft bearing, countershaft bearing and the installed serviced differential unit.



That's all that dR Honda had commented up to. I'll just upload a couple more pictures taken from his facebook page hondAYard.











While the gearbox was out I took this chance to upgrade the clutch and flywheel.

From memory I went with the exedy 3 puck ceramic clutch, and a exedy lightened flywheel:



I also purchased a Clockwise Motion drop in baffle with Alex (plAythiNG). Probably the easiest, and possibly cheapest thing to do if you're looking for a solution to oil starvation. dR Honda also had nothing but good things to say about them (which is a bonus ).

Didn't take a picture of it myself but here's what it looks like for those who don't know:

[MYDC5R]

Drooolzzz
Looks so good bawzz

[felixR]

Your gearbox must feel really nice now.

[AL92]

Nice, As felix said it must feel really good, also, Doing everything at the same time!

[plAythiNG]

I cant wait for your K-frank update!

[MYDC5R]

I cant wait for your K-frank update!

u love ruining his surprises dont u

[plAythiNG]

Why not Shak! haha

[Shakeel]

Drooolzzz
Looks so good bawzz

Not as good as your car bigger boss

Your gearbox must feel really nice now.

You bet it does Felix, like it just came out of the showroom

Nice, As felix said it must feel really good, also, Doing everything at the same time!

Yeah man it feels great, thanks! It was lucky that I had the chance to do it all, I like to think my motto is do it once and do it right

I cant wait for your K-frank update!

Why not Shak! haha

I don't even know what you are talking about silly guy..

u love ruining his surprises dont u

Don't listen to that troll lol

[Shakeel]

I will try to keep the updates rolling as I try to bring the build thread up to date with where the car is at now. Also alot of you guys keep pestering me for more..
This update is initially a wall of text so read through if you do have time, or just scroll down for the pictures..


I need to take time out to give thanks once again to John (John_K20A). It's at times like these when you can't drive, that you realize who your true friends are. John gladly offered to drive me to the workshop, so I could drop off parts on many occasions. He didn't even take money I would give him for his petrol expenses! So thank you very much John, I really did appreciate the help!


So after a couple weeks later I got the call from dR Honda that the car would be ready mid-day on the 29th of June. This date had its significance as it was also my birthday (happy birthday shak ). What a great present that was, getting my car back on my birthday! So I organized with my friend Wilson to take me to the workshop where dR Honda was waiting for me. Introduced dR Honda to my friend and he immediately suggested the idea of a k-swap build for my friend's Civic EK hatchback haha .


Anyway the dR said to me lets go for a test drive. So I got in the drivers seat, and I must say.. I really did miss the feeling of my recaros hugging me tight..
I started up the car, proceeded to push the clutch in.. wait a minute why isn't it going in? dR Honda laughs at me and says yeah you gotta try harder than that. So I push with all the strength my weak left leg had and viola the pedal went in ! He explained to me that this clutch had a 2 stage spring thingy majig, and since it was brand new would be really hard to push in for a couple days since I wasn't used to it. So we finally got onto the main roads and wow.. I noticed the car accelerating much quicker than before, thanks to the 5.1 FD. We then got onto the highway and I noticed the car pulled alot quicker again. I also noticed a whining noise which I was told also due to the final drive. In 6th gear (accord euro 6th), while cruising at 110 km/h I was at around 3500 rpm. I can only imagine how much higher the revs would be without the 6th gear from the euro. Thank you Alex (plAythiNG) for the advice and telling me to go with these extra goodies.

For all you NSW people the 29th of June was the day of the Showcased event, and JDMST eomm on the level below. I rushed home with my friend, washed my car and decided that I wanted to look cool and run mismatched wheels.. Yes those regamasters finally had their chance to shine. At stock height they looked ridiculous lol.. and I also had to almost max out my camber arms to make them look somewhat appealing to the human eye.. So with the regamasters on I drove to the usual meetup spot at Cabra HJ/Carwash where Fahad, Raf, and Rey were waiting for me. Then we all cruised down together to the meet/show. It was at Showcased where I finally got to see in person one of the cars that inspire me:





Over the next few months I slowly purchased some more parts, was apart ClubITR at WTAC 2012, and nothing much else really haha.

When I look back I think to myself "man what was I thinking.."




WTAC 2012:






Team ClubITR! Spot the blackest mofo if you can





Wait what?! A white guy driving the blackest mofo's dc5r?






JDMST eomm sept/garage88 opening - Fahad your car is floating on type s wheels




Here are the various parts that I bought:

OEM black dipstick -



Some crappy mugen thingy -



Greddy water hose temperature sensor adapter - (There was also a Greddy sandwhich plate but forgot to take a picture of it)



Some Japanese cola -






Defi Advance ZD - After seeing this and what it did in Alex's car I had to have it.





Before:



After:




Wow that was a big update.. If you read through it all thanks, if you just liked looking at the pretty pictures.. thanks again!