2 problems, 1 solution

Well, the 1 solution will not fix the two problems, but I believe we have fixed one problem. The other issue is going to be tougher, but I think I can do it.

My neighbor, Fransisco, made me a new coupler out of some hard steel and it looks great. It is longer and covers most of the shaft. He also got me a hardened cobalt alloy key which is pretty hard. Hopefully it will not snap. The coupler fits nice and snug, although I thought he was going to make it a tad small and we were going to heat it up to get it on. He thinks the two set screws with loktite and the full length key and coupler will keep it all together very well. It fit perfectly and I feel confident this problem is solved. The coupler is welded to the other piece from the original coupler that mates to the transmission. He added two pins between them which will help secure them together when the torque is added from the motor.

Motor, adapter plate and coupler attached and ready to go

Close up of the coupler

He also made a 1/4" aluminum plate that goes between the motor and the adapter plate. My original plate was not wide enough and the coupler bottomed out, so I added some large square washers the first time. Now I have a nice 9" round 1/4" thick plate that is perfect.

We got the motor back in the car and applied power for a test. Uh oh..... still got the noise. We are pretty confident in the new coupler and its connection and we did not hear any noise from the electric motor by itself, so it must be the transmission. I have suspected something is up with the tranny for a while and it just happened that I had two problems. The tranny and the coupler. Well, we had to take the motor out and once we did, Paco, that is what we call Fransisco, spun the tranny shaft, and sure enough, we heard the same noises as I have heard from the beginning. Paco's mind started spinning and then he said, "I think you have some bad bearings on the transmission shaft." We spun it a few more times, and sure enough, that is exactly what it sounds like. Could be bearings somewhere else in the transmission, but when we listened it sounded close to the shaft. Also, the shaft had some play in it. He said that was not good.

So, we fixed the coupler issue, but have found, and I think identified, another problem. I now have to figure out how to pull the half shafts, and get the tranny out. It cannot be used, so I might as well open it up and take a look. Maybe it will be an easy fix with some new bearings just on the shaft and I won't have to muck around in the gear box at all. I have never done this, so I will be watching some videos and seeking help on some Honda CRX forums.