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Old 06-06-2019, 09:15 AM   #1
Ecky
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6 spd 2nd and 6th pop out

Hi all, new member here.

I just had a 6 speed rebuilt with a lot of new parts, and upon first test drive it pops out of 2nd gear *only on deceleration* and out of 6th gear *only on acceleration*. My mechanic said he needed to buy a shim when reassembling it. He's not super familiar with Honda transmissions but a very good mechanic overall.

Here's what I changed:

New final drive, new (taller) 6th gear, new seals, new bearings, new synchros, LSD added.

When actuating the gears, 2 and 6 feel the same as the others and seem to be going all the way in. I don't know what it means if 2 is popping out only on decel and 6 only on accel. If it were a bad detent, wouldn't it affect other gears?

Note: I didn't try this transmission before having it taken apart, so I don't know if these issues were present before, but the previous owner claims they were not there.

Any ideas?
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Old 06-07-2019, 12:55 PM   #2
IronGumby
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I have an idea, but I really wish I could find the post, but I cannot. Basically upon talking about tranny fluid, synchros, pop-out, etc., this one user on here, I think actually in Japan, said you shouldn't have such and such issues if you properly break in your synchros, or whatever term he used.

I was surprised to learn of such a thing, and he went on to explain that when he got his car (new... lucky), he did something similar to the following (PLEASE ask a mechanic or someone knowledgeable to back this up), but he said he:
Turned the car on
Put it in neutral, clutch out
Then with light/mild pressure, pushed the shifter into each of the gates, for like 2 to 5 sec each? I wish I could remember exactly or find it.

This obviously wears out the synchros (eventually), but he said that's what he did! To prep them for use. He said he only pressed lightly, and the engine will start to bog ever so slightly, because you are effectively using the synchros as a clutch (so don't actually engage the gear all the way!)

I bring this up because of what you said, and the synchros are new. Does your mechanic think you should do this?

You said he's not familiar with Honda transmissions, but the fact he knew to by the shim to me says he knows what he's doing, because that's required to put the tolerance in spec, depending on which shim you install. So here's hoping that maybe it will just take some time or breaking in?
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Old 06-11-2019, 06:58 AM   #3
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I appreciate the reply!

I tried wearing the synchros a bit, and doing it 5-10 times didn't seem to help. Was worth a try I guess. What doesn't add up is that 6th gear holds solid under deceleration, and 2nd holds solid under acceleration. They're engaging and meshing.

I've put around 5,000 miles on the transmission so far since rebuild and it hasn't changed one bit.
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Old 06-12-2019, 05:50 PM   #4
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Hello Mr Ecky,
I have really appreciated your posts and have learned a fair bit about insights from them. Thanks for sharing. I’ll try to return the favor.
For what it’s worth, there is probably no magic bottle of snake oil for this. You’re probably already thinking about tearing it down again. This time make absolutely sure you do all the measurements shown in the service manual. “Measure twice, cut once” is good advice. I use alldatadiy. Costs are affordable. Direct copy of oem manuals.
I’ve made my share of stupid mistakes and had to pull mine out last week and re-measure some stuff. When I first started up the engine there was a bearing noise I didn’t like. Differential clearance too tight. Still a work in progress. Waiting for a diff seal. Maybe tomorrow I get to start it up.

2002 insight
K20a3
04 accord 5speed w/3.4:1 fd
Wiring by self
Used ktuned immo bypass
Custom axles
Motor mounts by self
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Old 06-17-2019, 01:19 PM   #5
IronGumby
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good golly, you have K20 in a sub-2000lb car?! Awesome!!
Why such a tall final drive though? I guess it doesn't really matter though, or maybe you are going for high-speed runs on the salt flats

Sorry to hear the synchros aren't getting any better, Ecky. Sounds like something else is off. Does anything obstruct the travel of the shifter cables on top of the transmission? I know 5th can hit a CAI, but idk about 2nd or 6th...
You could hop in and out of your car with it off and put it in those gears and see
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Old 06-19-2019, 06:53 AM   #6
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There are people putting the 200+ HP k24's in Insights and having fun on race day. Nothing new there.
This k20 is from the rsx base which uses some of the same technology the earlier vtec-e engines had - a 4 valve engine that can switch between 3 valve and 4 valve mode for efficiency at low rpms and more power at higher rpms.

That is the reasoning behind the tall gearing. Get rpms down at highway speeds for greater efficiency. I'm not sure if I'd take this car over 100 mph. What i'm after is some good mpg.
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