No I haven't even made an attempt.
I'm already 60 yrs old so there is probably no chance in hell this gearbox will ever be run, so it would just be an emergency back up. Besides this is a fun project right now since I've got nothing else on the go. Still waiting for some more snow melt which will happen fast because today was very nice and yesterday it was raining. Hopefully get the first ride in this or next weekend.
Spent half the day today looking after aged parents. Dad went to hospital and came back home about an hour ago. Both in mid 80's now. Mom in good shape but the old man losing mobility fast. It's a full time fn job now.
CO

Hay hope all is well
this is how i would go after the teeth on the gear
preheat with torch in tell your spit bounces off of it this is approx 600° F
find some arc welding rod it call 880 weld mold it is high tensile https://www.weldmold.com/880.html
weld it up and let it cool slowly in oven do not put it in sand as it will anneal it make it soft
will need to recut with carbide cutter

the shaft is most likely case harden approx .05 at most deep
should have it checked for what type of steel it is most scrap yards have one of them Positive Material Identification (PMI) with handheld XRF gun to tell you the type of steel it is
that will help a lot . then you can get the wright filler rod to weld and re harden


Hope this helps as i just skimmed read your post


SpeedChaser

I have not forgotten about this project ------- just delayed it.
Plan on leaving this for a winter project now.
I'm just to busy at the moment with all kinds of stuff.
Also like just doing nothing but lay in the sun when it rarely comes around. Looks like it's gona rain again for a week according to the forecast. Yesterday and today was cold and cloudy. Can't believe it because it's July already and still some snow in the hills. Unbelievable.
So winter project this will be.
CO

Spent the last couple of days playing on this gearbox.
Managed to get the hard surface off the input shaft. Made a slide hammer puller for the bearings in the case. They're in a blind hole so those can be tough to get at.
Next I started to look for a needle bearing and inner race that I could use for this project.
Download a pdf file (attached below) on needle bearings.
Only just began to look at that pdf and not liking what I'm seeing. So far I have not found a combination that I could use. The problem is that I would have to machine out the gear to much or machine down the shaft to much. Nothing at the moment seems to fit what I need for this project. It looks like this might be the show stopper.
CO

Edit: I could not attach the pdf. Apparently the file is to big. We have a 4mb limit here.
CO

The delay on this project is parts.
I have ordered a needle bearing and Inside Race for this shaft and gear that I think will work for me. They told me yesterday that there was a two week back order. Motion Industries showed "In Stock" on the website but I guess that was just a teaser or click bait. If I manage to get this shaft and gear problem solved I'll rebuild the gearbox with new bearings and seals.
Still working on it.
CO

Well I'm progressing on this project.
Got the bearing and inside race and cut the gear and shaft down to what I need.
The shaft and bearing are in the freezer because this is going to be an interference fit, not like the factory job. I have to do it this way, no other alternative. The original Honda shaft and gear were chromed and I obviously can't do that.
The one issue I do have though is that the washers/spacers (#24 & #25) between the gears and between the shaft are damaged. Looks like I may have to make some, the #25 is not available anymore. I will probably use the 2mm spacer (#24) because it may be usable, not sure yet. The 1mm washers I will make out of mild steel. I'm sure the Honda ones are hardened but I'll just case harden mine with Kasnite.
CO

The end result looks like this ---
The shaft with an inside race (interference fit) on it
A gear with needle bearing (interference fit) in it.
The deep blue you see on that shaft was caused by the initial explosion by previous owner.
CO

Well that's interesting --- just spent over an hour looking online for seals for this transmission.
Parts Honda got nothing.
Tried Colonial seals but for some reason they no longer have a search box so now there is no way to check their inventory for the seal you want. Hope they didn't go out of business.
Tried Amazon and they don't ship to me in Canada.
Tried BC Bearing here in Canada and I can only get the #13 input shaft seal and #15 axle seal. But can not get #14 axle seal.
So it looks like seal #14 is going to be the show stopper.
Hope I did not do all this work for nothing. The last thing I thought would be an issue is a seal LOL.
Anyways as you can see by the pictures, the whole gearbox was full of sand and that's why it blew up. You can see that it looks like the axle seals let go. One seal was completely missing when I got this gear box.
CO

That thing is nasty inside! How are the bearings?!?

Site member junkboy66 sells that seal #14. Send him a PM or I can order you one state side and mail it to you.

-Curtis

Thanks for the heads up on that seal and the offer.
Yeah all the bearings wont turn. I pulled two of them and managed to get them to turn but I'll probably buy new. There are other needle bearings in there but they seem to be ok. Have not yet had a close look at them. This is just a fun project for me and keeps me occupied. Just wanted to see if I could weld a gear and install another style of needle bearing. One thing I did notice last night was that the Honda needle bearings are open cage style and this one is a closed open ended style. That means lube might be an issue.
One other thing --- the chrome on that shaft was at least .060" deep.
Just a fun thing to play around with.
CO

Well had a closer look at seal #14, the one that's hard to get but is still available from selected places. That seal is located behind the brake disk area of the gearbox. It still had grease in between the lips and no sign of gravel/sand smagnum. So I'm going to just run it.
I'll be replacing bearings in the case and the other two easy to get seals.
Then have to make two 1 mm spacers for the inside as the other two are toast.
Doubt this gearbox will ever be used in my life time but it's a fun project with a welded gear . Will post as we go.

Next project after this will probably be making my own rings for a piston -- will post.
CO

I have not forgotten about this project.
The damaged pieces have been repaired but the hold up is the bearings and seals.
Been waiting for weeks for this stuff but everything is on back order and now it's Christmas almost.
It could be a while before I get back to this. Just waiting for parts.
CO

Just waiting for the youboob video to load up and then will post it here in a few minutes.
This job is almost done. I'm just waiting on seals and then I'll have to take it apart and install the new roller bearings and seal this thing up.
CO

Edit: https://www.youtube.com/watch?v=mQpdllT ... e=youtu.be
CO

This is what it looked like before the repair -- pics below.
This is what happens when you blow your AB bearing.
CO

Here is a closer look at the AB gear repair.
https://www.youtube.com/watch?v=BkPe2Q1 ... e=youtu.be
CO

Making gaskets
https://www.youtube.com/watch?v=zQ5fDJc ... e=youtu.be
CO

FAILURE

I installed this gearbox last week when mine blew up (AB gear as usual).
My brother and I went for a ride up Sowaqua valley yesterday.
On the way up the hill I noticed the rear wheels lock up on me VERY briefly. No other noises. At about the 10km mark we stopped to check it. I noticed oil had come out of the breather hole on the fill plug on the transmission and it oiled up the tool box I have on the back of the machine. It wasn't a lot of oil but enough that you would notice it. When I touched the gearbox it was fire cracker hot. At that point it was all over. We headed back down. Today I drained the oil. It was black as tar and stinky (burnt). This was fresh HP4. I also add a few OZ of metalon oil. We use this at work if a box is running hot. Amazing stuff. I also noticed a VERY small amount of shiny stuff (not good) in the oil. I'm suspecting that I didn't get a good gear mesh between the gears because I don't have a cutter for these gears. It's possible that when the wheels locked briefly that I broke a tooth. It's too bad because this gearbox was shifting so smooth. Damn.
Autopsy coming soon.
It looks like I'm going to have to spend the money to repair my original gearbox properly.
CO

Sorry to hear it failed. Looking forward to seeing your CSI.
Have seen this ? https://www.ebay.com/itm/165010682237

I have never bought anything off ebay. Don't know how.
But I do buy off amazon so it's probably similar.

Just pulled the gearbox 10 min ago.
Will do a video csi in a few hours and post.
In the house having a coffee.
CO

https://www.youtube.com/watch?v=OQRBLAesi38
The welding on the gear teeth of the AB gear was good. It held up.
CO

Edit: I'm not 100% sure but I may have made a mistake on assembly after the gear welding repair. It's possible that I didn't put the right selector gear in the right spot. Apparently it has an unchamfered end on one side. Also the shift fork and the hub have an "R" stamped in them. I checked neither of these during re-assembly . That's all I can think of. I'll have to pull the other gearbox apart to have a closer look. The selector gears in this one are now toast.
CO

Edit again: https://www.youtube.com/watch?v=PR1WRw_MWDY
CO

I can confirm that the failure was caused by me.
I installed the selector gear backwards. This shoved everything one way. One of the IR for the needle bearing actually fused to the shaft and I had to torch it off. Now the shaft is damaged but I'll repair it. There is a lot of damage and I have to now source the parts. Nobody seems to have a blown gearbox laying around so I'll see what I can get locally and buy the rest from Derek.
CO

Update:
https://www.youtube.com/watch?v=vc1TnbH4rt0
The pics below show what I did to "repair" this problem.
The copper shim stock is there so that the weld won't get into the running area for the needle bearings. The trans is together already and I'll install it tomorrow. It's raining right now so it may be a few days before we test it out.
I'm confident.
CO

Did you drill the holes thru to match for the oil feed gallery holes in AB gear?

? is that bearing case tack welded to the AB gear

Wyeeoddy

No - that's why I had the copper washer in place.
I just put spot welds inside the AB gear machined surface so that the bearing can not shift.
I know what you're thinking here. A bearing race is extremely hard and it's high tech metal. Anytime you put a weld on a bearing it will NOT hold and you destroy the bearing.



No - This is a full compliment bearing. That's all I could get that came even close to what I needed for this repair. It does not have the end rubber seals so oil can get in from the ends. I could not find an outer race and bearings like honda had. All I could find was an inner race and a full compliment needle bearing. Nothing else even came close and I looked for a long time. Honda has a chromed AB gear so when I machined the damaged AB I had to replace that chroming with something for a bearing to ride on. The solution was that full compliment needle bearing. Honda also chromed the shaft so that's why they could use those open needle bearings. So when I machined the damaged shaft I had to replace that chroming as well. The solution was that inner race. This was not a simple repair.
By the way that chroming is about 1/32" thick. It was real tough to machine.
CO