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M/T - Pops Out of 1st or 2nd Gear

05-009

January 12, 2006

Applies To:
2004 S2000 ALL
2005 S2000 From VIN JHMAP2...5S000001 thru JHMAP2...5S0057199

Transmission Pops Out of 1st or 2nd Gear

(Supersedes 05-009, Transmission Pops Out of 2nd Gear, dated July 22, 2005, to update the information marked with the black asterisks).

*SYMPTOM
The transmission intermittently pops out of 2nd gear on high RPM deceleration, or 1st gear while engaging the clutch.

*PROBABLE CAUSE
The manufacturing tolerances on 1st and 2nd gear synchros are at the limit of their specifications.

*CORRECTIVE ACTION
Replace the 2nd gear set.

PARTS INFORMATION

1st Gear:
P/N 23421-PCY-010, H/C 7596869

2nd Gear Set:
P/N 23432-PCY-316, H/C 7596893, H/C 7596893

REQUIRED MATERIALS

Honda Manual Transmission Fluid
(1.7 quarts required per vehicle):
P/N 08798-9016, H/C 4928271

*Hondabond HT (liquid gasket):
*P/N 08718-0001, H/C 2963817 or,
*P/N 08718-0002, H/C 783440101

WARRANTY CLAIM INFORMATION

In warranty:
The normal warranty applies.

Operation Number: 213205
Flat Rate Time: 8.2 hours
Failed Part: P/N 23432-PCY-316
H/C 7596893
Defect Code: 03214
Symptom Code: 03701
*Template ID: 05-009B
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 will permanently damage the ECM.

NOTE:
For this repair, make sure you use the 2000-05 S2000 Service Manual. This manual has an updated transmission reassembly procedure.

1. Remove the transmission:

^ Refer to page 13-5 of the 2000-06 S2000 Service Manual, or

^ Online, enter keyword M/T, and select Manual Transmission Removal from the list.

2. Disassemble the transmission, and remove the countershaft and mainshaft:

^ Refer to page 13-13 of the service manual, or

^ Select Manual Transmission Disassembly from the list.

3. Disassemble the countershaft:

^ Refer to page 13-38 of the service manual, or

^ Select M/T Countershaft Disassembly from the list.

*4. Reassemble the countershaft, install the new 2nd gear, and install the new 2nd gear, hub, sleeve, and 1st and 2nd gear synchros:

^ Refer to page 13-40 of the service manual, or

^ Select M/T Countershaft Reassembly from the list.

5. Measure the clearance of the countershaft assembly:

^ Refer to page 13-35 of the service manual, or

^ Select M/T Countershaft Assembly Clearance Inspection from the list.

6. Reassemble the transmission:

^ Refer to page 13-55 of the service manual, or

^ Select Manual Transmission Reassembly from the list.

NOTE:
When you reinstall the select return spring, make sure you preload the spring by crossing the ends over the pin in the shift arm rod, then insert the 8 x 40 mm pin between the spring ends.

7. Reinstall the transmission:

^ Refer to page 13-66 of the service manual, or

^ Select Manual Transmission Installation from the list.

8. Fill the transmission with 1.7 quarts of Honda MTF.

9. Test-drive the vehicle to make sure thee the transmission works properly.





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