Good day, I got the trans out yesterday and opened it up in my work shop. What I found was that the outer race on the main shaft end bearing had come off and was working its way in to the transmission. When it met with the 5th gear hub, it caused damage to the teeth on the hub. It appears that the shaft was able to slide back at some point and it actually started to do a bit of end mill type work on the aluminum of the housing. I've attached some photos. It's hard to see in the pictures, but about half of the outer race was exposed from the housing. Upon close inspection of the bearing I found that there is no "lip" on one side of the bearing to retain the balls. Apparently I had it installed the wrong way. The one side with a "lip" should have been facing outboard. There was plenty of aluminum shavings and some steel shavings in the case. The heat from the hub apparently passed in to the 5th gear as it shows some "blueing". I think it will be alright though. I checked several places on line and it is no longer available. I have a new bearing, hub, synchro ring and spring, and sleeve on order. They come as a set.
[ATTACH=CONFIG]84682[/ATTACH][ATTACH=CONFIG]84683[/ATTACH][ATTACH=CONFIG]84684[/ATTACH][ATTACH=CONFIG]84685[/ATTACH]

New parts arrived today. Assembled everything and put the beast back together again. I'll put in back in the engine bay tomorrow as it's a bit late in the day now. It's raining outside to boot. I am working under a car port. We're supposed to have good weather tomorrow. I made dang sure that I got the new bearing on where the outer race cannot slip off again.

Good to hear! Thanks for posting hopefully it will keep others from making the same mistake.

Absolutely phenomenal job! Better than any shop manual I've used. The 5/16 roll punch made the pin removal easy and straightforward. So nice to start the job with all the tools needed. This kept my '95 Civic going, with 350,000 miles over the 18 yrs I've had the car. Many, many thanks! So glad Google found your page. Keep up the great work!!

47,000mi Later...

Transmission started making a noise only when under power. It got pretty bad so I parked it until I could work on it. When I did get it out I found the ring gear and final drive gear set were missing a few teeth. Also found most of my bearings were pretty worn. This car did dyno at 300whp so a premature failure isn't surprising. But this still seemed a little soon. I did some research and found people who broke gears while drag racing were running syncromesh like me. The solution for them was to run a much thicker oil. I'm not sure I want to say what right now. All in all it held up well for all the abuse the poor thing took. She's rebuilt and back in the car with thicker oil. Also shout out to LSD motorsports clutch for being almost dead but never slipping, and OBX LSD for still being in good shape.

carnage
http://i4.photobucket.com/albums/y10...psvh1vpbv6.jpg

Where did you find the friction dampers? Do you still have a part number? I am rebuilding a zc trans and swapped the 5th gear out for a si. Wish I had an hf around or I'd really be having some fun swapping gears. Thanks for the DIY. I needed to get my bearings straight from when I took it all apart

I reused my old ones this time around but when I did the DIY I got them from http://www.hondaautomotiveparts.com/

Thanks! I got them ordered. Can't wait to get it back together.

stupid photobucket. here's a link to pictures
https://postimg.org/gallery/ngozxatw/

Hey how do i remove the watermark on the pictures (photobucket)? Ow saw it too late (fixed)