M/T - Intermittently Pops Out of 4th Gear
01-100June 13, 2008
*Applies To:
2001-07 S2000 - ALL
2008 S2000 - From VIN JHMAP214.85000001 thru JHMAP214.85001499*
Transmission Pops Out of 4th Gear
(Supersedes 01-100, dated May 13, 2005, to update the information marked with black bars and asterisks)
PROBLEM
The transmission intermittently pops out of 4th gear while driving at a steady speed or going over bumps.
CORRECTIVE ACTION
Replace the mainshaft 3rd gear set and 4th gear.
PARTS INFORMATION
REQUIRED MATERIALS
Honda Manual Transmission Fluid
(1.7 quarts required per vehicle):
P/N 08798-9016, H/C 4928271
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 213109
Flat Rate Time: 8.2 hours
Failed Part: P/N 23451-PCY-000
H/C 6234322
Defect Code: 03214
Symptom Code: 03701
*Template ID: 01-100A (2001-03 82000)
01-100B (2004-08 82000)*
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
[NOTICE]
Before you unplug the connectors for the primary and secondary heated oxygen sensors, mark or tag the connector locations to ensure correct reinstallation. Incorrect reinstallation would permanently damage the ECM.
NOTE:
If you use a printed service manual for this repair, make sure you use the 2OO0-O8 S2000 Service Manual. This manual has an updated transmission reassembly procedure.
1. Remove the transmission:
^ Refer to page 13-6 in the service manual, or
^ Online, enter keywords M/T REMOVE, and
select Manual Transmission Removal from the
list.
2. Disassemble the transmission, and remove the countershaft and the mainshaft:
^ Refer to pagel3-14 in the service manual, or
^ Online, enter keywords M/T DIS, and select
Manual Transmission Disassembly from the
list.
3. Disassemble the mainshaft:
^ Refer to page 13-29 in the service manual, or
^ Online, enter keywords M/T DIS, and select
M/T Mainshaft Disassembly from the list.
4. Reassemble the mainshaft with the new mainshaft 3rd gear, hub, and sleeve, and the new mainshaft 4th gear:
^ Refer to pagel3-31 in the service manual, or
^ Online, enter keywords M/T MAIN, and select M/T Mainshaft Reassembly from the list.
5. Reassemble the transmission:
^ Refer to page 13-56 in the service manual, or
^ Online, enter keywords M/T REASSEMBLY, and select Manual Transmission Reassembly from the list.
NOTE:
When you reinstall the select return spring in step 7 of the Manual Transmission Reassembly procedure, make sure you preload the spring by crossing the ends over the pin in the shift arm rod and then insert the 8 x 40 mm pin between the spring ends.
6. Reinstall the transmission:
^ Refer to page 13-67 in the service manual, or
^ Online, enter keywords M/T INST, and select
Manual Transmission Installation from the list.
7. Fill the transmission with 1.7 quarts of Honda MTF.
8. Test-drive the vehicle to make sure the transmission works properly.
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