While on the freeway 98 Civic
Axel popped out thought the clutch failed
Axel is about 2yrs old maybe 8k miles on it.
Why would it pop out at all and why at 65 mph?

 

also no wear marks or damage no metal shavings

 

Rules sticky. If your car isn't a bone stock '98, then clarify that now, before any of us waste any more time.

Did the CV come out of the transmission? Did it pop out of the wheel hub? Did the CV itself separate?

 

Make sure the "joints" of the axle expand and retract freely and don't bind. Pop that **** back in. Create a speed bump with a board or something in your driveway. Roll over it a few times with the wheel turned at multiple angles. The axle requires significant direct force at the transmission to pop out. Either it wasn't in all the way, the axle is not expanding freely and causing too much force at the connection, or the locking mechanism is worn out.

 

This^

 

Stock d16y8
Came out of the tranny
Installed over a year ago

 

Locking mechanism meaning snap ring? No signs of damage.
Could this be caused by the tranny ?
No problems shifting or popping out but it occasionally makes a sound like the old toy cars you would pull the plastic strap thru, sorta zipping sound .OCASSIONALLY!!!

 

no issues popping out what?

 

The set ring is the locking mechanism for the half shaft inside the tranny.
Was a new set ring used when the half shaft was placed 2yrs ago?

The half shaft contracts/expands via the spider in the inner joint.
If the rollers are badly worn, it may not expand sufficiently when
necessary.

If the tranny and half shaft emerged unscathed from this episode,
you might want to try and inspect the inner joint. You can save the
boot and buy replacement ear clamps at Belmetric.com. You can
get the small parts (set ring, axle nut, split pin, etc) from
Majestic Honda.

Was the seal damaged? Might want to pick up a new one at
Majestic while you are at it.

To handle the set ring replacement, borrow/steal/buy a pair
of lock ring pliers. Once in position, introduce ATF to the groove
of the set ring. This will allow the ring to "float" and oppose
gravity when you are trying to install it; that is, the ring will
be more centered and not shift toward the down-facing aspect
of the shaft.