Installing a LSD in the K series DC5 Base gearbox

As i mentioned in one of my other posts I was lucky enough to stumble on a DC5 which was reasonably new into the wreckers. Unfortunately the intake and ECU were already removed but i decided to get a few other things. One of those was a 5 speed K series box, the best part about this is it was $120… that’s right $120 AUD, less than $100 USD! Being an 06 model it had the speed sensor in a different position but it looked reasonably clean. Before I’d even bought a Honda i also purchased a factory LSD off yahoo japan. This post is how i went about installing it:

Step 1: Remove the selector. This involves removing the 3 bolts on the far end (away from engine). They contain 3 springs and 3 ball bearings. Once these are removed there is a hex bolt on the side this is there to lock the shifter in. You can then remove the 4 bolts which hold the selector in and remove it carefully.

Step 2: Remove the reverse switch (up near where the bellhousing bolts to the engine) and reverse lockout bolt and speedo both on the front side of the engine.

Step 3: Remove all the bolts which hold the 2 pieces of the gearbox together. There are quite a few bolts (maybe 12?).

Step 4: Gently split the box. The hondabond used to seal the box will hold it together but if you gently work your way around the box it should split apart.

Step 5: This is important and needs to be done before you can split the box. There is a hex bolt (12mm from memory) on the end of the bellhousing. This needs to be removed and then there is a circlip which needs to be opened up to allow the bearing to be released and the box to be opened up.

Step 6: Now the box is open. You need to remove the reverse gear which is done by removing the 4 10mm bolts which hold the brackets for it. The gear and shaft will then pull out.

Step 7: Next you need to remove the gears. I taped up the selectors and gearsets and removed them as one. See pic below.

Step 8: Once the gearset is removed you will be able to see the diff. Its simply a matter of removing that and removing the ring gear bolts. Switching the center to the LSD one and re-bolting together. The LSD uses slightly longer bolts so make sure you use the correct ones!

Reassembling is the reverse of pulling it apart, it can be fiddly but if you persevere its not that bad. I gave mine a quick coat of silver to make it look the part…. now i just need to find an engine!