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

[Daox]

I figured that I would break this topic off from my main build thread because its dealing with a few common issues that the 1st gen Insights have. My 5 speed manual transmission currently has a slightly noisy input shaft bearing that will need to be replaced as well as the notorious 2nd gear grind. I'll be doing the synchro modification to get rid of the grind as its a zero cost mod. I haven't removed the transmission yet, but I imagine I'll probably be replacing the clutch while I'm at it. At the very least I'll be doing something with the flywheel and pressure plate as clutch engagement is not super smooth.

So far I have two nights after work working on the transmission removal. I've been taking my time on it.

I started by removing the airbox.





Then the starter came off.





Then the clutch slave cylinder.





I then removed the battery box because I had difficulty with the shifter linkages. This isn't necessary if you can get to it, but it does make it easier. However, pulling that box is kind of a chore too. It is very hard to squeeze out of its slot.





And, to remove the shift cables I ended up just unbolting the bracket that holds them to the trans vs trying to remove the cables from the bracket (which I found to be quite hard).





Along the way I unplugged multiple sensors and a couple brackets for the wiring. Take note that apparently you do not need to disconnect the 3 big orange wires going to the IMA system. I thought you did, but the service manual says nothing about removing them.

So, the next step was to pull the axles out. But, wait... lets drain the trans fluid first.





Pull the wheel off, and you'll see the axle nut you need to remove. I removed everything (all brake components) as I'll be going through them, lubing the slides and inspecting things. Insert a punch to deform the axle nut so it can spin off. An impact wrench really comes in handy to remove these nuts, but this one didn't seem to require a ton of oomph as it came off fairly easily.





Next, I disconnected the hub from the strut so I could pull the hub away and give room to get the axle out. Give the axle a good tap with a hammer to loosen it from the hub before pulling it out. Despite the car being 17 years old, it came out quite easily.





Repeat that for the other side and you're almost ready to pull the transmission out.

[California98Civic]

Oh, cool, memories of my transmission swap! But what is the "synchro mod"? That sounds interesting. I have third gear synchro grind that I would love to solve when next I pull the thing off.

[SH@UN]

Damn that's alot of work.

[Daox]

There is lots more work to come yet!

Last night I unbuttoned the rest of the things holding the transmission to the engine, but I didn't have time to actually pull it out. Here is what I did:

With the passenger axle out, I removed the guard around it so I could get at the transmission bolt. The top 10mm snapped off so I'll have to figure something out or just not put it back on.





I also removed this aluminum panel as it will get in the way of the transmission dropping out. Its very likely that there are more underside panels to remove but I think I'm missing a few.





I also went ahead and removed the CAT. I wanted to inspect it to see what condition it is in. Turns out it looks great. Unfortunately, I also snapped a stud in the head (the right one) while taking it off, so I'm definitely going to have to fix that. Thankfully there is enough stud left there that I have something to grab on to. I also snapped one of the bolts that holds the springs on the other end. They're basically shoulder bolts. Worst comes to worst I can make my own shoulder bolt with a bolt and some tubing for the same effect. I'm more concerned about the stud in the head.





With that all removed, I was able to remove the 3 larger bolts holding the transmission to the engine block.





Next, I took the bolts out of the rear engine mount. I may still have to remove the rest of the mount, but I'm going to give it a shot with the mount attached to the transmission.





One more thing I unbolted for clearance to get the transmission out. Just a couple 10mm bolts. I've been using my Makita cordless impact to back a lot of these bolts out on this project and it really works well. It won't get the larger ones out, but 10-12mm and even some 14mm it backs right out, and it does it fast.





Finally, I took the top bolts out of the transmission (two of them), and removed the transmission side of the engine mount.





This should make it totally ready to pull. I ran out of time before I had to head out last night though, so I didn't get that far. So, tonight is the night!

[California98Civic]

When I swapped my sixth gen Civic transmission I remember surprise bolts that were hidden from view, not in my instructions, and holding the transmission to the engine. Be patient and search if you get stuck. I think it was near the dust shield.

Why are so many bolts snapping? You using a power tool?

[Daox]

Originally Posted by California98Civic

Why are so many bolts snapping? You using a power tool?

Its 17 years old and has lived in salt its entire life. I'm actually surprised its not worse.

Oddly enough the power tool is able to remove most bolts without snapping them. The hammering action must help break the rust up before the bolts snap. I've only snapped one bolt with the impact. I've snapped two with normal wrenches.

[Natalya]

In some places the rust looks worse than my Canadian G1.

[California98Civic]

Originally Posted by Daox

Its 17 years old and has lived in salt its entire life. I'm actually surprised its not worse.

Oddly enough the power tool is able to remove most bolts without snapping them. The hammering action must help break the rust up before the bolts snap. I've only snapped one bolt with the impact. I've snapped two with normal wrenches.

I suspected it might be the climate and rust. Wow am I lucky my 1998 car spent all but its first three years south or southwest of the rust belt!

[Daox]

Yes you are! I once had the pleasure of fixing up a 2002 Civic a few years ago. I think I posted about it here. It was from Texas and looked brand new (minus sun damage). It was the most pleasant old car I've ever worked on. Everything came apart so easily.

[Daox]

Alright, I worked on this thing for about 2.5 hours last night and... nada. That trans is not wanting to come off. I double and triple checked the service manual for anything that I may have missed. I looked over things in the engine bay thinking I might have missed a bolt. Everything looks fine, but that trans will not slide off. I've supported it, not supported it, wiggled it, hammered it. I'm not sure what I'll try next, but it sure is being stubborn!