You may or may not remember a similar post by me a few months ago-anyhow the problem continues. Just to bring everyone up to date:

1) Problem began with clutch slipping (2002 S2000 with 24K miles). Took car to dealer and they replaced clutch under warranty.

2) Repaired clutch was VERY stiff with some binding at full depression. They then replaced master and slave cylinders.

3) This was no help and they then re-replaced the clutch and everything was perfect. Over the next 3-4K the clutch is now again very stiff with binding at full depression. It also feels to me that the clutch does not engage at the same point of pedal depression each time.

Some additional info:

-car is not run hard or raced
-I do not ride the clutch and I avoid sitting in traffic with the clutch depressed for long periods
-there are no fluid leaks that I can see
-the problem does not seem to change with warm/cool weather or hot/warm/cool engine

The dealership has been great; except that they cant seem to fix the problem. My concern now is that they seem to have replaced the entire cluth mechanism and now they seem to be running out of ideas. They have already "called the Honda engineers" and the district manager has come over to look at it so its not like they arent trying.

I think they need some suggestions-any ideas?

 

Not that you're going to extract this admission out of them but ......................
When they did these clutch jobs, did they lube up the spindle on which the throw out bearing rides? This is a common oversight by Honda techs that come back to haunt several owners.

 

Your answer was the correct one, I think. Hopefully all of this is now over-not lubing the forks seems like a considerable oversight.

 

[QUOTE]Originally posted by drtodd63
Your answer was the correct one, I think.