Bluejack

Hi all

At higher revs, I've been having trouble with 2nd gear popping out when lifting off the accelerator. It seems to be getting more regular and, given I use the car for sprints and hillclimbs occasionally, now needs sorting.

It's a MY05 car and I gather this is a known issue with a service bulletin describing a fix (replacement ring gear i think) - which clearly my car has never had.

Question is - any ideas how much you're looking for a gearbox rebuild? I'm pretty attached to the car and like it's originality too so not keen on a replacement box (which is a shot in the dark anyway).

A second question is whether it's worth considering a Spoon gearbox rebuild? Research suggests it is, but that's hitting £3k plus without any extra labour...

Any thoughts welcome, thanks!

Chuck S

No TSB regarding this I could find here. If you have a line to one post it in the Library.

There were similar problems on the MY 2000 cars in 4th gear where the TSBs indicate this is an 8.2 "standard hour" job (billing for labor) so a rebuild won't be cheap to replace an inexpensive part. With UK prices as depressed as they are vs US prices a £3,000 gearbox + 8.2 hours in labor approaches 50% of what some cars are selling for. I'd look for a local box.

-- Chuck

noodels

FYI,
the ring gear is part of the flywheel,and has no connection on gear selection..

Bluejack

It's TSB 05-009, text as follows:

Synchronizer Ring: All Technical Service Bulletins
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

Anyone come across this before and had the work done?

noodels

egay 37k mls 380 pounds
372809301246

Bluejack

Thanks, a second hand box is always an option but want to fully explore the rebuild idea first.

Nick Graves

By the time you've paid a tranny specialist and bought the prats, the S/H one would be more expedient.

But it's up to you, of course.

Bluejack

Thanks, it's just had a fluid change as I'd heard that can help (and it was due anyway) but unfortunately no improvement for me. It is still intermittent, but it does get in the way of driving quickly, so I think I'm going to have to do something...

Irish TuneR

Not sure that service bulletin would help since an AP2 gearbox is different to an AP1 which is what Europeans have. Could have the same internal part as gears 1-4 i believe are the same, 5/6 are longer and the secondary shaft is different.

Chuck S

Curious what gearbox oil is being used.

-- Chuck