I have an '02 with 5,000 miles on it. After about 1000 miles, I started getting a severe grind into 2nd gear at high RPMs. I averaged probably 3 grinds per day. I took it to the dealer, but they said it was fine, and told me that the 2nd gear grinding problem was fixed for '02. They also told me that it was probably my driving style.

I decided that I was going to investigate adjusting the clutch to relieve the problem. I found that the clutch pedal can be adjusted in two ways. The pedal height and play can be adjusted by tightening / loosening the clutch switch and master cylinder plunger. I noticed that the pedal height was limited by the clutch switch, and the master cylinder plunger was too loose, so the first couple inches of travel did nothing towards disengaging the clutch. This meant that by the time the pedal hit the floor, the clutch was disengaged only slightly.

By loosening the clutch switch, I increased the total travel in the clutch pedal. By loosening (making it longer) the master cylinder plunger, I eliminated the excess play in the clutch pedal. These two things combined made the clutch disengage much higher in the pedal stroke.

The end result is that I am able to fully disengage the clutch much sooner and more completely between gears, which has completely eliminated my 2nd gear grind.

 

Hmm, that is an interesting solution. I may have to try it and see if it alleviates any of my 2nd gear grinding.

 

Wow, I've been here 3 years and I've never seen this, you may be onto something. Kinda' reminds me of Karl on Slingblade..."Karl, we've tried everything, we've checked the points, plugs, wire and everything, see what you can come up with..."...Karl..."it ain't got no gas in it" .

Thanks for the info dude.

Andrew

 

I have 2002 too (3k miles on it) and I get the 2nd gear grind maybe 20% of the times I redline in 1st gear! VERY embarassing, especially when I'm racing someone! They said they fixed it for the 2002, but I don't think they have. You may well have a great solution in the works for a lot of people here! I'm going to copy this thread and take it to my dealer and see what happens! Thanks man!!

 

By doing this, would the clutch engage at a higher point too? Takes longer to engage and may burn clutch more easily?

Thanks.

 

Did this 2 months ago, it changed the pedal height ( higher ) and like you said, it make the disk disengage faster.
But in my case it didn't solved the problem (second gear grind ) maybe it was too late and the syncros was out ! So i took it to the dealer to have the tsb done.
See the tread : https://www.s2ki.com/forums/showthread.php?...&threadid=51515

 

New member, and I've owned an 02 S2k for not much more than 36 hours at this point. The clutch had a ton of slop in it. Found this thread and it feels like a proper clutch should now. The only problem is you have to be a bit of a contortionist to get underneath the dash. Great solution, thanks!

~Andrew

 

Remember you need some free play or you will burn the clutch. Half an inch max is about all I can see to remove. I played with this a few years ago and it did nothing for me, but I hated having my clutch pedal not even with the brake pedal so I put it back to stock adjustment. After owning the car for 5 years and still on the original trans, it hasn't gotten any worse and it is most noticeable after the trans is hot. At times 2nd will grind at as low as a 4-5k shift.

 

oh yeah, it's got a little play in it, but before it was horrendous.

 

hmm, i should try this too.

its bad because im already adjusting to 'lag' before i let off the clutch on redline 1-2 shifts.