Info:
2000 Honda S2000
Mileage: 77,840
Stock

I have researched this topic through other threads and would like some sort of confirmation that I should pursue a clutch replacement or rely on the repair procedures stated in the technical service bulletins (TSB).

Issue: I have been experiencing the issue where my transmission will pop out of 4th gear intermittently, but more so these past few days. I have found the that the technical service bulletin (TSB) 01-100 describes the problem in more detail. This usually happens when decelerating or keeping the car at a steady 3-4k rpm in 4th gear, and it would just pop out into neutral on it's own. I was planning to just bring the TSB into the local Honda dealership service department to have them give me a quote based on the repair procedures and parts listed in the TSB.

However, I have noticed recently that my revs do not match my acceleration. It may just be myself being overly conscience or getting used to the speed of the car, however that may also not be the case. I did some research and read that this issue may be linked to a clutch reaching its end life. Bummer, as I've only put 1,593 miles on the car since purchasing. After searching similar threads it seems cost of OEM parts and service range from $1,000 - $1,400.

I figured, if I were to go the clutch replacement route, they'd have to remove the transmission, so I may as well take care of other underlying issues i've been experiencing below:

clutch buzz issue described in TSB 00-054.
Intermittent grind when shifting into 2nd gear as described in TSB 00-055. Although, this has went away since applying the three finger shift method posted on another thread.

Sorry if this is way too much information, so I'll get to the point. Is this an issue that I can fix via TSB's, or is it time for a clutch replacement? Also, if I seek repairs at a dealership, will I be faced with markups, or should I just buy the OEM parts myself and find another well established shop to do the repair / clutch replacement?

Thanks in advance for taking the time to read and provide feedback!

 

A new clutch won't have any zero, affect on popping out of gear. But yeah, at those miles, if trans is being pulled for service, it only makes sense to replace it, as its very labor intensive, and the labor will already be mostly done already.

You would want to replace disk ansrelease bearing. Use Honda parts only!!! !!! !!!

You would also want to inspect and replace as needed the release bearing guide. The pressure plate may needto be resurfaced.

Note. It should be mentioned that a cheaper, and better long term option may be to just source a used ap2 trans, and swap that in. The ap2 trans has several worthwhile improvements, and gearing that many find more suitable. A decent shade tree mechanic can perform the swap, provided they pay attention to the S specific details. Especially related to type of grease to use, where to put it, and how much.

That goes double for having a shop do the swap, as most mechanics assume their years of experience will trump any silly instructions from some idiots on the internet, or worse, a factory service manual. They often need to be browbeat into submission to follow the instructions diligently. Anything less will lead to having to pull the trans to do it right the second time.

 

Check and change the fluid first. Does it help with the grind and pop out? You could be low on fluid.

However, you likely need a trans rebuild and a clutch, from what I'm reading.

Shop at an online Honda dealer for the clutch parts. Hondapartscheap or bernardiparts.

Don't forget the urea grease and release bearing guide. Always always always replace the guide. Its $30. It would be silly to have to drop the trans again because you misinterpreted a $30 part's condition.

And you may as well get the shifter bushes.

Alternatively to a trans rebuild, maybe source a known good trans. The AP2 trans is an improvement in some ways. You can re-sell your busted trans to someone that wants to fix it. This is much cheaper and easier (assuming the trans you buy is good). Disadvantage to this is you won't have matching VIN's.

 

Oh boy, seems I have a lot more on my plate than I expected. The ap2 trans swap seems like a good idea. Do you know any other place to source one other than ebay?

 

Are you referring to manual transmission fluid and clutch fluid? I checked my clutch fluid yesterday and it was ideal level, and I got my manual transmission fluid changed about 500 miles ago. I could try giving those another go before doubling down on a used ap2 trans swap and new clutch. Thanks for the advice, I'll be sure to replace the guide.

 

I was referring to the transmission oil.

Make sure its at the right level and that you're using the correct type.

If someone used GL5 (non yellow metal safe) gear oil...it may have ruined some synchros since AP1 synchros are brass.

 

Wait, did these symptoms start before or after the trans fluid oil change?

 

Gear popping out is normally caused by synchros. I had same issue in my Dodge Stealth popping out of third while cruising.