Popping out of 5th after LSD install

934 Views 33 Replies 6 Participants Last post by transzex, 14 d ago

rgm_93si

Discussion Starter · 1 mo ago

2

I installed an MFactory LSD, a Synchrotech carbon synchro kit as well as various OEM bearings and any items that were not included in the kit in my 93 Si hatch with a D16Z6. I referenced the service manual and several videos. The installation went smooth as well as the first test drive where I went through all the gears keeping it under 50mph. However, on the highway it pops out of 5th between 55 and 65mph. The transmission was not making any noises or grinding and shifted smoothly. I drained the fluid and checked to make sure the snap ring was on the counter shaft bearing which it was. I pulled the transmission again and opened it up and there is no sign of an issue. The car has new Hasport motor mounts, energy suspension bushings on the shift rods and a K-tuned shifter. I’ve had no prior issues with the transmission which has less than 150k miles.
The first thought was that 5th gear may be bad so I am attaching some pictures. To me it looks fine, but maybe there is an expert out there that can verify. At this point I am stumped, the only other thing I can think of is to take it to a tranny shop and have them look for any issue. If anyone knows of anything else I should be checking, I would appreciate their input.

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21 - 34 of 34 Posts

rgm_93si

Discussion Starter · #21 · 15 d ago

Out of desperation I took it for another drive thinking that if there was an issue maybe it would cause the transmission to heat up. Outside temp here is in the 80's, took it for a drive. I then used a laser thermometer and took readings at various places on the transmission case. Temps ranged from 134 to 145 so I guess that's ruled out.

drtalon123

· #22 · 15 d ago

Are you able to hold it in 5th, pushing on the gear lever hard? Or is it still able to forcibly push itself out of gear, like with very strong force?

mattliston

· #23 · 15 d ago

That description of a hard kick to nuetral is something Bone might have a trick up his sleeve for, or at least something to look into.

rgm_93si

Discussion Starter · #24 · 15 d ago

I've tried to hold it in gear with a little force only to have it kick out. I haven't tried holding it in with a lot of force because I wasn't sure if I would do damage. I could try it tomorrow.
Thanks everyone for their input.

mattliston

· #25 · 15 d ago

rgm_93si said:
Out of desperation I took it for another drive thinking that if there was an issue maybe it would cause the transmission to heat up. Outside temp here is in the 80's, took it for a drive. I then used a laser thermometer and took readings at various places on the transmission case. Temps ranged from 134 to 145 so I guess that's ruled out.

Do you have a safe way of getting the car into the air, supporting the control arms so the axles are close to ride height, and running the car in gear?

Dont let the suspen sion hang. It puts stress on the axle seals from the joints hanging low, and can create a leak. No real point in making a reason to change the axle seals, especially since 95% of the aftermarket doesnt understand quality control

EDIT I have seen people use a threaded stud in place of one of the half arm's bolts, and use that as a support brace. Just be super careful to not have anything touch the tire of course!!

rgm_93si

Discussion Starter · #26 · 15 d ago

i don't have anything other than stacking blocks of wood under the lower arm which may be a little risky.

mattliston

· #27 · 15 d ago

Wheels removed should in theory give enough room to brace the control arms. But if you think even a tiny bit it might not be enough, dont do it!

transzex

· #28 · 15 d ago

mattliston said:
detent springs? condition, age, etc..

detent springs are captured in the shifter fork assembly.

You mentioned OK and 4 hours from home, what is your general location?

You did put the little rod back in for 5th fork right? That is part of the lockout system.

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rgm_93si

Discussion Starter · #29 · 15 d ago

I did put the roller back in the spring. (It was also popping out of 5th before I disassembled the shift fork.) My thought is transmission was fine until I installed new LSD and carbon synchros and synchro sleeve. Now not fine. Could it be those?
I'm located south of Kansas City.

transzex

· #30 · 14 d ago

I could see the 5-R slider being an issue, but it would have to be really screwed up to be popping out of gear.

rgm_93si

Discussion Starter · #31 · 14 d ago

I think it's time to contact a nearby transmission shop and have them check it out.

transzex

· #32 · 14 d ago

I doubt anyone will find something that I cannot.

That said, another random text today, another transmission customer referred to me.

rgm_93si

Discussion Starter · #33 · 14 d ago

I agree that a local shop might now be the best choice, but at this point I don't know what my options are. This is my first build and I'm fairly new to the site. From the digging around the site, I know you are the transmission expert and are about 10 hours away, but I don't know if you accept and work on member's transmissions.

transzex

· #34 · 14 d ago

I'm about 10 months behind right now.....I've only built two trans. since July 4th or so. Covid took me down for about two months then I've lost 6 weeks so far since my crash.

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