2000 Honda Insight 5 speed manual transmission fix (ISB, 2nd gear grind, clutch)

[California98Civic]

I need to dismantle my old 1998 Civic DX transmission and address a synchro snag--very minor--on thrid gear of my 1993 Civic CX transmission. This is a nice tutorial, even though not the Civic (very similar).

It is amazing how seemingly small changes and defects can have detectable consequences. That grove on the tab would be minor in lots of other places on a car. The precision of the moving parts in really cool. What was the "function" of those tabs, though? Seems surprising that there would be no consequences for grinding them off.

[MetroMPG]

Good writeup!

So is it ready to put back into the case and in the car?

I took apart a transmission once: the original from the Flea, with the idea I was going to have a new, taller 5th gearset made up (by modifying the 2nd gearset from another trans). I never completed it though, and now that 5k miles / 8k km transaxle is scattered in pieces across my garage.

[Daox]

Originally Posted by California98Civic

What was the "function" of those tabs, though? Seems surprising that there would be no consequences for grinding them off.

The synchro is a dual cone design. The dual cone allows more surface area for the syhchro to work. This supposedly gives smoother and quicker shifting. The downside to the modification is its now a single cone design. So it will require a bit more pressure on the shift lever to get it to go into gear. The Insight guys who have done it say its hardly noticeable.

[Daox]

Originally Posted by MetroMPG

Good writeup!

So is it ready to put back into the case and in the car?

Thanks!

Its not quite ready. I still need to replace the input shaft bearing and seal. I also ordered output shaft seals as well. Those won't be here until next week. And, beyond that I want to braze the second skin on the case before it goes back in.