curlybandit

I was wondering if anyone knew of a shop in the GTA or outside a reasonable distance that can build hybrid transmissions.

I have a 1996 Honda Civic Si with a d16y8 and a manual S40 transmission. The engine was rebuilt about 2 years ago but the transmission is original with nearly 400,000km on it (that's not a typo).

Now before someone jumps on here and says "swap", I don't plan on it. I'm a fan of the much unloved d-series engines and I'm building the car for autocross and time attack. I'd love to see what can be done with an NA single cam.

The synchro for 3rd gear is almost toast and 2nd and 4th are acting up as well. I've just recently filled the trans with GM Synchromesh and although the trans does feel a little smoother, the grind in 3rd is not gone. Slow acceleration and shifting avoids the problem but any upshifting from 2nd at high revs or downshifting from 4th or 5th will always result in a grind.

After researching, I've decided that I would be swapping the 3rd and 4th gears to tighten up the ratios.

Here is what the 96-00 y8 S40 gearing looks like:
1. 3.250
2. 1.909
3. 1.125
4. 0.909
5. 0.702
FD. 4.25

Based on what I've read, this is what I would consider:
1. 3.250 (stock)
2. 1.909 (stock)
3. 1.346 (CRX ZC)
4. 1.033 (CRX ZC) or 1.066 (3rd CX/VX)
5. 0.702 (stock – for long drives) or .0878 (ZXi – for track only)
FD. 4.25 (stock)

Apparently it's a pretty straight forward swap that only requires machining of the 4th gear on the main-shaft for clearance of the 3-4 hub. I know that the difference between 4th and 5th will be substantial but it's manageable. I could always 3 gear shift (2, 4, 5) if it becomes a problem. An LSD would also be installed (i.e. MFactory Helical LSD). From what I've read, I'd likely not consider an OBX LSD.

MFactory and GearX also make final drives for this trans too and I could consider that as well.

I'd like to have an idea of shops that can do this sort of work when the time comes (soon). Are there any places in the GTA or surrounding areas that anyone would recommend?

Thanks!