2000 Insight 5 speed repair & build thread

[Daox]

Well, tonight is the last trip in the Insight for a while. It is going to get parked and I'll start pulling the transmission out this weekend.

I have a pretty substantial list of things to look at and repair while the car is laid up. Here are most of them:

- Input shaft bearing replacement (its growling a bit) & seal.
- Possibly a new clutch, the current one is not smooth and its really annoying.
- 2nd gear synchro modification. It grinds downshifting into 2nd gear just like nearly every other Insight out there.
- CAT inspection, and I'll probably do what Ecky did and try to clean it out while its out.
- Grid charger install. I made one, but I never installed it. I hope to cycle the battery a few times as well.
- Run new fuel lines. My temporary fix is still in place and holding fine, but I want a real fix.
- I'll probably pull the injectors and clean them just to make sure that is a non-issue with the running problems I've had.
- Install new buttons on the gauge cluster. Mine must be mashed to get them to work.
- Inspect and fix the driver's side door lock. The power door lock works, but it is just about impossible to use the key to unlock the door.
- Replace gauge & button lights. Half of the buttons on my dash don't light up at night. Makes working the HVAC controls interesting. I already have LED replacements.
- Possibly replace the rear struts. They seem pretty shot. I'm thinking I'll go with the modded Monroes.
- Inspect a TON of stuff, suspension, brakes, engine compression and anything else I can think of. I never really went over the car since I bought it in fall and put it on the road at the beginning of winter.


Thats about it for functional things. There are a bunch of cosmetic things I'd like to get to if I am able:

- Fix my driver's side interior door handle pull. The chrome is peeling off of it. I have a handle from an accord I think that has the same pull. I just have to take the two apart and swap the pulls.
- Fix the headliner. Its peeling near the hatch and its annoying to see it flap when I have the windows open.
- Polish headlights. They're not horrible, but they could be a lot better.
- Paint the trim pieces under the front windows. They're all peely and ugly.


We will see what I actually get done though!

[MetroMPG]

That's a serious list.

I'm allergic to lists over 4 items long.

[Daox]

Yep, its a lot to do. I'll be starting on it tonight. First item on the list is to pull the trans, and figure out if a new clutch is necessary so I can get parts ordered. While thats going on, I'll do the 2nd gear synchro mod and then move on to whatever else makes sense.

[Daox]

I just ordered one of these as part of a modification I'll be doing while the transmission is out.

[Ecky]

What exactly am I looking at?

[Daox]

You're looking at a heater control valve:

Four Seasons 74828 Heater Valve

[California98Civic]

What are you planning to do with that valve?

[Daox]

An idea I had for another car I own, but I figure while I have the transmission out I might as well give it a go.

http://ecomodder.com/forum/showthrea...ant-29872.html

[Daox]

I started a new thread for it, but I've begun to pull the transmission out of the Insight to fix the 2nd gear downshift grind, input shaft bearing, and possibly the clutch.

http://ecomodder.com/forum/showthrea...fix-35260.html

[Daox]

Last night while doing the transmission work, I also pulled the CAT off to inspect it and see what it looked like.





It turns out that it looks very good to me. If you see something I don't please let me know.








Unfortunately, I broke stuff while removing the CAT. I snapped off part of one of the studs in the head, and also snapped one of the bolts that holds the springs on the other end of the CAT. The bolt isn't a big deal to replace/make new (a bolt and tube will suffice), but the stud may be a pain to replace. Suggestions on how to go about replacing it are welcome!