I have a 00 civic with a d16y8 in it and it had the stock s40 trans in it. A few months ago it started popping out of 2nd gear when let of the throttle. I eventually got tired of the problem and the inconvenience (no more auto-xing) so i replaced it. the new trans i got also began having the same problem after about a week??!! so i went ahead and had the original rebuilt with carbon lined synchros and replaced the worn out rear motor mount with a new oem one with Poly inserts. The problem is this one is doing the same exact thing! it is still popping out of gear when you let off the throttle. I had the guy who rebuilt it take another look at it just to make sure everything in the tranny is sound and he said everything is good in it. No bent shifter forks or anything like that. I know this isnt a common issue in transmissions and for me to have had basically 3 now that pop out of gear all in the same way is very strange to me? other possible problems i need to look at? Im going to try some new shift linkage later today but thats all i can think of. Also, the motor is rock solid and not moving too much so i know its not that. Any other advice??

 

Was the 2nd gear, 1-2 synchro sleeve, or the countershaft bearing replaced? Or you JUST had synchronizer rings replaced with nothing else diagnosed?

Was it missing a 2nd gear synchro spring? How were the dogteeth to the gear? Dogteeth to the sleeve? Was the countershaft bearing good?

And don't tell us for sure they were fine unless you personally saw them. :p Sounds to me that the guy who rebuilt it missed something.

 

he told me when he rebuilt it that the inside of the tranny was fine and didnt need rebuilding but i went ahead and got the new synchros cuz it was already apart. he told me the synchro sleeve and everything else was good and didnt need replaced. Ive also already had the trans taken back out and had him look everything over again to be 200% sure everything was good and he said everything checks out. at this point, I figure its either the shift linkage or he was wrong and something isnt right. Anything else you think could be wrong? or am i dead on that its either one of those two things? Im trying new linkage today and if thats not it is there anything else to look at to check for before pulling the tranny again? again this is the third trans ive had that does this same EXACT thing...?

 

Did he replace the bearing on the top of the stacks?

 

yes

 

ok just talked to him, synchro spring is not missing and is in there. the synchro sleeve was still good and in spec so we re-used it. the countershaft bearing was replaced. i personally purchased it from honda. dog teeth were also good in both recent trans. along with this one

 

OK. That's fine. The gentleman that fixed it is an actual professional with transmissions, correct? Not just a basic mechanic?

What would have happened to the shift linkage though? The shift linkage won't just bend by itself through regular (or even hard) use. Unless your engine mounts were really trashed, but even then, the shift linkage has bushings that will absorb most of that shock before it gets damaged.

The fact that it pulls out of JUST one gear tells me that the problem is 98% internal to the trans. Given that you said the engine mount is now fixed (so that isn't a problem) I'd take it up to 99%. lol

Are they all brand new transmissions from the factory? No. They are used.

Every single used transmission will have some damage and wear to them. Countershaft bearings and input shaft bearings fail routinely. And dogtooth damage is always present unless the trans was babied AND has low mileage. Three used transmissions with the same problem? Not probable. But completely possible. So you can't rule it out given that each one could have similar 2nd gear synchro wear or a bad countershaft bearing... or a combination of both.

 

yes he's very knowledgable of transmissions and is the man that everyone around my area goes to. like i said the bearing was replaced as well as a brand new synchro. it feels almost as if the gear is engaging but no completely 100% and when you let off the gas, it slips out. it doesnt slip into neutral but disengages and grinds til u move it. the rear mount was completely trashed and im guessing may have caused the linkage to bend being that i have stiffer linkage mounts (poly mounts for linkage)

 

The countershaft bearing needs to be staked, its walking out.

 

exactly what i was thinking. although if you have the issue on another trans it way be something on the linkage itself. but more than likely its internal. how are the detent springs?

 

exactly what i was thinking. although if you have the issue on another trans it way be something on the linkage itself. but more than likely its internal. how are the detents?

 

im not familiar what the detent springs are. The mechanic who rebuilt it told me the only thing that needed replacement was synchros and bearings. we also replaced the 1-2 shifter fork to be sure it wasnt bent at all. he said everything else was in good shape and if it needed replacement he would have had me order it. i will be doing the shift linkage this afternoon and will get back this evening with with either some good news or bad news...

 

im gonna think your 1/2 changer is bad

 

Aqua is rarely if ever wrong about this kinda stuff, would listen to his advice.

 

Yeah. If the rebuilder is 100% sure that nothing was damaged with the gear, it's probably a countershaft bearing issue - either top or bottom. With the D-series transmissions, there is nothing to keep the CS bearing in the case, well, in the case. lol Usually the other transmissions have a plate that bolts down over a portion of it to keep it from "walking out". The guy still should have seen that if he did synchros - the countershaft and mainshaft would have both been removed at minimum.

 

exactly. he had the trans out again after rebuilding it and looked it all over to make sure everything was good and he said everything checks out. will be trying new linkage in the next hour. will report back with results. if it doesnt fix the issue. i will talk to him about checking out the countershaft bearings again. thanks everyone for all the help. i really appreciate it. H-T always comes through for me! thanks guys! update soon!

 

No problem, man. There are only so many things that would cause it. So just gotta try out stuff that will eliminate any possible causes. Keep us updated, and once it's fixed, be sure to explain what it was just in case anyone else finds this thread.

 

Update: linkage was bent, however, it didn't fix the issue. I told the guy who built it Wat yall were saying about the counters***t bearing and he said that it doesn't get messed up normally and that it wouldn't cause it to slip out of 2nd if it was. Wat exactly do I need to tell him is wrong with the countershaft bearing? And worse case worse, can anyone point me towards someone else in the richmond/central va area who really knows what to do to get this thing fixed?

 

Credit to the user on D-series.org. This is the countershaft bearing in the casing "walking out". It can potentially press up against the countershaft, and usually finds contact with the ring gear of the differential. I've not done enough D-series to know if this walking out will cause a problem with 2nd dropping out, though Aquafina suggests just that.

The 2nd gear problems of dropping out that I've noticed have all been the ones I listed in the first post. The countershaft bearing with the c-clip ring being bad is my most common, followed by worn dogteeth, followed by a broken synchro spring. Broken shift fork fingers (they're aluminum in the older D-series) also cause havoc... though it would have been nearly impossible for the guy to miss that.

 

ok now that uve explained a bit, i understand more what your saying. the c clip ring is good. dog teeth im not positive on but when i personally pulled the casing apart, they were a tad worn from use, but didn not look to be in bad shape. the guy who built it told me the spring was good and that wouldnt be the issue in three transmissions especially when he just put this one together. the spring wouldnt be broken already. and as far a forks go, i have a 96-00 trans with steel forks. we replaced the 1-2 fork anyway cuz it was bent when we took it apart. Im not doubting aquafina at all, but i dont see how it "walking out" would cause only 2nd to slip out of gear. Maybe aquafina could explain?? again i appreciate all the help folks. i also have my last trans already out the car with the casing apart in my shed so if someone could suggest some things i could look for in it since both of these transmissions are having the absolute same exact problem in the same exact way...

 

I suggest not taking a trans to him again.

CSB walkout will cause 2nd to pop out. About 70% of D trannys I do have a CSB that has walked out. Aside from 2nd hand experience via customers transmissions, I know 1st hand from my car that the CSB walking out will cause you to pop out of gear. When it walks out, it pushes the CS up which "locates" the 1/2 slider in the "wrong" position, causing the popout.

I'm not aware of anyone in your area proficient with transmissions, though there are a couple within a few hundred miles of you that you can send it to.

 

I thoroughly looked through a diy thread on rebuilding d16 transmisssions and it didn't seem to dificult. Im fairly mechanicaly inclined and very good at reading following directions. From the looks of Wat I saw, all i would need is a bearing puller correct?? The mainshaft and counter shaft wouldn't even need to be dissassembled correct?? I want to look at the spare trans in my garage and see if the cab is walking out...

 

I agree. If he thinks that the bearing will not cause 2nd to pop out, I would take it to someone else. I have personal seen and repaired these issues at least a dozen times.

 

If the bearing is still good you can just tap it back into place and stake it with a center punch.

 

can u explain this staiking this? wat do i do? take a center punch and and jam it around the bearing? or what? thats the only thing im confused about...?