S2000 L4-2.2L (2004)
Synchronizer Hub: Customer Interest
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.