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Old 12-03-2015, 08:24 PM   #1 (permalink)
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Default Shift fork wear

I'm almost done building my S40 tranny. While inspecting the shift forks, I noticed the the 3-4 fork wear pretty hard.
From the picture, you think it's fine to run it like that? Or should I replace this fork?

Thanks.
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Old 12-03-2015, 08:38 PM   #2 (permalink)
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what picture?
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new 95 ej1.
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Old 12-03-2015, 10:24 PM   #3 (permalink)
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New fork, 3-4 sleeve, and hub, about $220, I have a Y8 needing it sitting on the bench now I'm going through.

You might be able to get away with modifying the Y8 3-4 fork to accept a 88-95 slider, but some are worn too much to even do that.

96-00 = 7.2mm
88-95 = 6.5mm

the one I have, 5.9mm, TOAST!

$275-300 just in parts so far for a Y8 rebuild. Add in my labor and core....yikes!
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Old 12-04-2015, 04:27 AM   #4 (permalink)
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I added the picture now, you can see.
transzex, your fork is really toast! lol
Mine, if I remember well, is 6.5-6.8 mm thick. I'll measure it again later.
Cant I just weld fill the gap and machine it to factory specs?
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Old 12-04-2015, 07:07 AM   #5 (permalink)
 
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Yes, but it won't last long. Replace it.
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Old 12-04-2015, 07:17 AM   #6 (permalink)
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How bad will it be to run it like that? What's gonna happen?
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Old 12-04-2015, 07:21 AM   #7 (permalink)
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If will break once its gets thin enough then it falls into the gear sets and before you know it, shes fucked.
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Old 12-04-2015, 12:49 PM   #8 (permalink)
 
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It won't break.

The slider and dog teeth will wear so the slider, synchro and gear will have to be replaced.
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Old 12-08-2015, 03:32 PM   #9 (permalink)
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I measured now the fork. It's 6.8mm vs 7.2mm when was new.
Maybe it's not that hard of a wear? Is it ok to use it like that?
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Turbo Ibiza muffler
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P28 street tuned
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Old 12-08-2015, 04:39 PM   #10 (permalink)
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replace it and the slider, why I prefer 92-95's....
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Old 12-08-2015, 05:12 PM   #11 (permalink)
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Thanks for Idea Bone!!!
Also could weld and grind in desperate times.

You'd be surprised how smooth dull teeth shift when sanded smooth and cones scuffed.
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Old 12-08-2015, 05:58 PM   #12 (permalink)
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transzex,
Is it ok to use 92-95 slider from a old gear box and keep the current hub?
What is the best way/tool to grind the fork in order to make it fit?

TheToaster,
I couldn't really understand what did you mean in the last sentence. Can you explain a little bit more?

BTW, all synchros are replaced with synchrotech carbon ones.
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Ebay turbo T3/T4 - A/R 50. boost ~ 0.5 bar
TIAL wastegate
Ebay Exhaust manifold + 2.5" straight pipe
Turbo Ibiza muffler
Greddy type s BOV
P28 street tuned
RC550 injectors
S20 B000 tranny
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Old 12-09-2015, 09:46 AM   #13 (permalink)
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I've done just about every D series Combo,
built ~ 10 boxes or so.. Research and reading goes a long ways.


Disregard the DSO dumbfucks, it turned out great.
https://www.d-series.org/forums/trans...o-install.html

Worked on Subarus, Miata, and KA24DE trans next. Maybe even an R154 here soon...
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Old 12-11-2015, 07:26 AM   #14 (permalink)
 
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Quote:
Originally Posted by JRSC_D16 View Post
transzex,
Is it ok to use 92-95 slider from a old gear box and keep the current hub?
What is the best way/tool to grind the fork in order to make it fit?

If the hub is in good shape yes.

A die grinder.

I no longer use 92-95 sliders in 96-00 transmissions. Wear occurs more quickly when they are used.
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Old 12-11-2015, 08:56 AM   #15 (permalink)
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Quote:
Originally Posted by Aquafina View Post
If the hub is in good shape yes.

A die grinder.

I no longer use 92-95 sliders in 96-00 transmissions. Wear occurs more quickly when they are used.
With 96-00 sliders available now, I haven't resorted to doing it lately either. They were only DD trans as well. Anything performance gets new parts.

Easier and less headaches/worries down the road.
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Quote:
Originally Posted by patprimmer RIP
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Old 12-16-2015, 01:56 PM   #16 (permalink)
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Can someone please tell me what material/electrode to use for welding the fork?
BTW - I've opened another post about this tranny, and I thing it's may be better to merge the posts together, if some admin here is able to do this. Here's a link for the post: https://www.d-series.org/forums/trans...r-rebuild.html.
Thanks.
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95 Civic EH9
ZC stock
Stock I/M
Front big intercooler
Ebay turbo T3/T4 - A/R 50. boost ~ 0.5 bar
TIAL wastegate
Ebay Exhaust manifold + 2.5" straight pipe
Turbo Ibiza muffler
Greddy type s BOV
P28 street tuned
RC550 injectors
S20 B000 tranny

Last edited by JRSC_D16; 12-16-2015 at 02:06 PM.
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Old 01-03-2016, 10:26 AM   #17 (permalink)
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I can't recommend welding it. I can recommend SiNi brazing, though.
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