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Robbed from CTRO but I think its amazing....
theta said:Name of the project was to install DIY-style a Quaife ATB LSD, Clutch Masters FX300 and ACT Prolite 8.8lbs flywheel without previous experience :lol:
Here we go...
First, I bought a new Quaife ATB:
Then I bought a cheap unused transmission from a local Honda racing dealer.. not necessary but anyways. I dismantled the tranny in preparation for Quaife installation:
A machining shop removed the vss gear and final gear from the old differential, installed them on the Quaife and pressed new bearings:
Then I carefully reinstalled the Quaife+Final gear back in to the tranny:
Don't forget this gear unless you decide you don't need the reverse gear anymore
Added some liquid gasket and installed the case:
Then I had to put the tranny away while waiting for the clutch to arrive:
Finally, the Clutch Masters FX300 kevlar -clutch and pressure plate arrived:
I had bought the ACT Prolite flywheel earlier:
Then it was time to eat the brave pills and attack the car with all the tools I've got :lol: I started by loosening the 36mm hub spindle nuts while the car was still on the ground:
I set up the rest area and opened up the service manual from the laptop 8)
Then it was time to jack the car up. And this time I raised it as high as I possibly could with jacks and stands.
I could almost sit under the car. This was the first time that I had no space problems while working under the car :lol:
Removed the front wheels:
Took the battery and the AEM CAI out:
Brakes off, not necessary but makes the job a tiny bit easier further down the road:
Ripped off the anti-roll bar from the endlinks and bushings and let it hang over the exhaust manifold.
Removed the splash shield:
Disconnected all wiring from the tranny (VSS, reverse sensor, reverse gear lock solenoid):
Disconnected the shifter cables:
Removed the clutch slave cylinder:
Supported the engine with a jack and block of wood. Also drained the tranny of fluid:
Removed the two upper transmission bolts:
Removed the upper tranny mount:
Removed the shift cable brackets:
Removed the 36mm hub spindle nuts:
Disconnect the front lower control arms from the subframe:
Then I carefully pulled from the hub while banging the driveshaft out of the hub with a plastic hammer:
Then I used a prybar to remove the left driveshaft from the transmission (do not pull on the driveshaft!):
I then removed the right driveshaft together with the intermediate shaft:
Removed the four subframe bolts and dropped the subframe on my forehead :lol:
Removed the rear engine mount & esmm's:
Removed the front engine mount:
Then I removed a couple of more bolts from around the transmission and pulled the transmission away and out from the engine bay:
Installing the new clutch and flywheel was very easy, here's the old clutch and pressure plate:
Then I ripped out the stock flywheel with a 17mm 12-point socket. The bolts are fairly tight so I had to jam the engine from the crankshaft pulley nut with a socket and a big ass breaker bar since I didn't want to buy the Honda ring gear holder:
Installed the new ACT flywheel, cleaned it with brake cleaner first:
Add one clutch and pressure plate using the alignment tool:
VSS-sensor, engine mount bracket and some other stuff was swapped from the old tranny on to the new one:
I then used a nice electric truck to lift the transmission up and mount it to the engine. Too bad that I forgot one of the dowel pins on the first try and couldn't get the tranny installed.. this cost me few hours of hard manual labor
After this it was just a matter of reinstalling all the removed stuff in reverse order, add some redline oil in the tranny, bleed and adjust the clutch, read some prayers and hit the road for a test drive :lol:
I guess if you work your ass of and don't face any problems you could do this project in about 8-10 hours on the first try. I guess it took something like double that for me on the first try since I worked alone and forgot the damn dowel pin :x
Hope you liked the pics, I sure as hell didn't enjoy "preparing the car" for the shots :lol: