Grateful for info... will definitely contact you through PM soon and update this thread. Thx!
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See my car's mod & maintenance thread and my electric bicycle's thread for ongoing projects. I will rebuild Black and Green over decades as parts die, until it becomes a different car of roughly the same shape and color. My minimum fuel economy goal is 55 mpg while averaging posted speed limits. I generally top 60 mpg. See also my Honda manual transmission specs thread.
You have 2nd gear on the D16y engines listed as 1.782. By my count, earlier D15s have 37 and 21 teeth on their 2nd main and counter gears, resulting in a ratio of 1.762.
Just looked up and it looks like the Insight 5th gear is drop-in for the first-gen Fit, possibly second gen as well. The needle bearing for both of them is 35x39x24mm. This would drop 5th gear from 0.757 to 0.710 and highway cruising RPM (65mph) from 3100rpm to 2900rpm - not huge, but 6.5% is nothing to sneeze at.
My guess is that both gear shafts would probably drop in with minimal modification, but I don't think the Fit is appropriately powered to go from a 4.3 FD to a 3.2.
I just happen to have an Insight transmission laying around.
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