One of the things I've been waiting to get for Black Mamba is an aftermarket header. After observing for sometime I reckon that most of the Japanese aftermarket headers have relatively smaller collector (2.3inch) compared to American brands like SSR, Skunk2 & HyTech (2.5inch). These brands are expensive due to the exceptional build quality and Malaysia's killer import tax regime. Some of them like HyTech/SSR are even made to order, hence the sky-high price.
Thankfully though, we have a few creative creatures around this world who actually took the opportunity to make money by replicating things average joe like me couldn't afford. Hehe. A good example is the header. I'm referring to the KiddRACING header from the States (Most K-series owner would know it come from Taiwan anyway haha). It was replicated from HyTech header, produce impressive power and cheaper by almost half from the price. Here in Malaysia I have seen more than 10 DC5s and FD2Rs using this header and also TDM (another Taiwan made header under same manufacturer of KiddRACING). As far as I know none of them DID NOT MAKE any power after installing it. So, who wouldn't want a cheap header that produces power right?
As I was pondering on getting the header from Singapore, fellow DC5 owner Andrew offered to customised a header based on KiddRACING/TDM but with improved built quality and welding finish. Most importantly the design is revised to clear the bigger front anti-roll bar (Most DC5 owners with aftermarket anti-roll bar (>23mm) might experience the header touching the bar due to it's size). Deposit was given and few months later the header is ready. Honestly, I couldn't comment further as Andrew will be doing test fitting on his car soon before distributing the headers. But would you just look at how meticulously-awesome the thing is? I seriously couldn't wait to receive the call from Andrew soon. For now on, drool on the pics and keep following this blog. Haha.
Mamba's 6 speed gearbox has been serving me well for the past 3 years. With the right maintenance of oil change every 5000km it has never caused me a problem. However earlier this year I am experiencing hard engagement with the gears at high RPMs and occasionally second gear 'crunching' occurs when the rev goes beyond VTEC point (refer link here for the common second gear issue with Acura RSXs). Knowing the fact that the gearbox has never been 'flushed' or dismantled before, I laid out the plan to acquire the relevant parts for this major work.
After couple of months saving, I decided to get the much more affordable 4-puck Exedy racing clutch set to replace the worn-out OEM clutch. Together with this and as advised (more like racun) by a goodfriend of mine, I purchased a set of shorter final drive from Civic Type-R FD2.Since my 2.4 project has not yet being put in place, I said why not try the 5.062 final drive to replace the existing 4.764?. So unreluctantly I get a new set from another friend who decided not to install it on his DC5. Nevertheless, I did not purchase the synchro set for 1-2 gears as it costly and I would like to see myself the condition of the gears before splashing the cash out.
I headed on to Tung Chun Racing JB (where else) during the festive holiday for this work to be carried out. Enjoy the pics and videos.
This is what you should get for the final drive package a) Final gear ring set b) Countershaft. Ensure the ring set has 81 teeth!
Gearbox dismantled in less than 45 mins!
Look at those blueish sludge. Gears taken out.
Taking out the ol' 4.764 final drive.
The bearing in the middle is the Countershaft bearing. There's no need for this to be purchased since we share the same 6 speed gearbox with FD2R.
Ready to be cleaned.
OEM clutch. Probably few hundred KM more before it dies.
Improve your grip with this clutch.
Part No for your reference mate.
Obviously original. But please beware of fake Exedy clutches.
The pressure plate.
Hey how did I miss those two clips on the radiator cover??
Super clean!
Facelift DC5R gearbox code. Prefacelift (2004 and earlier) has different code.
Gears and syncros were inspected and it turns out everything are in good condition. Thank god!
Putting back the gearbox on.
Fresh MTF-III oil. Will no longer use Redline Lightweight Shockproof oil from now on.
While waiting for everything to be fixed, I found some interesting stuffs in the workshop worth sharing with this blog readers.
Tung Chun's race prepped DC5R. I was being told the rollcage was fabricated by an English dude who made cages for BTCC cars. Interesting.
Would you like the big ass potruding intake on your K20 sir?
Drag-ready, estimated 350whp with an-extra 200cc on K24 block. Not your average K-series man. Haha
Finally, after 2 hours of waiting Mamba is ready to roll out. Alignment was done at the nearby tyre shop.
Post Installation Comments:
1. The car's accelaration was improved tremendously after installing this final drive. The revs keep on climbing and it doesnt drop as much as before when you shifting gears. I could feel more 'pulling' power when the car is launched compared to before. Some sort like newfound excitement for me seeing the needle goes towards the redline effortlessly I could say! Totally faster than before. And of course, the new clutch does help to provide smoother gear change. Please check Mamba's videos below to compare the revs and speed. First video is before the final drive being installed.
2. I've heard some people saying 'shorter final drive will kill your top speed'. I'd say it's not true. Why? I could still go beyond 200km/h easily, and faster than before (I mean seriously, how fast could we go on the normal road right?). However, we must remember the rule of the thumb - shorter final drive, higher RPMs. The rev is noticably higher by +-500rpm than before. Previously on 6th gear @ 100km/h it was 3000rpm. Now on the same gear and speed the rev has increased to 3500rpm. Due to this, I have noticed that the engine note is slightly louder when I'm travelling long distance. Not very comfortable I could say. I also think that the torque advantage decreases as I keep on changing to higher gears. Anyways, check out the speed vs rpm table below for the 5.062 final drive. If I'm not mistaken, Spoon Sports produce (or more likely rebrand) the same final drive.
3. The other factor that I have yet to properly analyze is the fuel consumption. As far as I'm concerned it is still economical after almost 2 weeks driving. 28 litres of Shell RON97 fuel could take me close to 300km so it's good. I will try to calculate the consumption for urban driving when I'm free.
4. Back again to the second gear crunching issue. Surprisingly the problem still exist despite having the synchros in good condition. But it only happened when the car has been driven more than an hour or so. Other gears are super crisp. Not very sure if I should replace the synchros, or try to replace harder gearbox mount to reduce the vibration. See how it goes.
5. Last but not least the pedal feel with the racing clutch on is very light. I could say it's almost like using stock OEM clutch. The car doesn't jerk furiously or the engine dies when the pedal is released suddenly like other super single clutch. Very easy to drive around with this clutch so it's recommended for those who drive their car daily. :)
Costs:
1. Exedy 4 puck racing clutch - RM1,350 - Tung Chun Racing, JB 2. Honda MTF-III gear oil - RM100 - Tung Chun Racing, JB 3. FD2R 5.0 final drive - RM1,XXX (Friend's price muahahah) 4. Labor - RM450
Hope this post will help you decide on installing FD2R or other aftermarket final drive.
