Hi - I recently got back my transmission from a well-known transmission company on this website. I have 600+ whp Integra Type R. About 2 years ago, reverse stopped working in my transmission, so I pulled it out and decided to fully build it. I understood that most companies only make gears 1-4, but I asked for a 5th gear custom ground also so that the whole transmission was solid. I used to track the car (not drag race).

I've had the transmission back and in my car 5 times in the last 2 years now. The first 3 times, I would go to drive the car and it would immediately pop out of 5th gear with just the slightest throttle input. At the time, it was pretty clear that since this was their first pass grinding a 5th gear, that the dog teeth needed adjustment.

As of recent - 4th and 5th time in my car - the car seems to drive fine just cruising around. Even on the highway at 65-80 mph, the car drove fine. But before we got too excited, I turned around to head home and hammered the throttle decently - 1st through 3rd gear to almost redline and then hit 4th for a second and popped into 5th to slow down. And then the issues happened again. It popped out of 5th gear. I shifted down to 3rd and hit it again, hit 4th and then it popped out of 4th gear this time also. So clearly, there is something more going on than just 5th gear now. It's like once it got warmed up/hot that it didn't want to stay in gear (though driving home casually it was better).

I am at a loss, so the only things I can think of I am mentioning below to get some input:

1) Nothing else has changed on the car from when I pulled the OEM trans out ~2 years ago.
2) I have semi-solid Hasport motor mounts and when I re-install the transmission, the transmission motor mount is a pain to line up and I have to get a prybar and work it to get the bolts in place (until it's at the proper height and then it's fairly aligned). It's always been that way, but any thoughts?
3) OEM shifter - pretty much like brand new and didn't change anything there. Car goes into gear just fine.
4) I have a Competition twin disc clutch that is a nightmare to drive. I installed a custom clutch stop which stops the clutch about .25-.5" from the firewall/fully depressed to protect the clutch -- but it engages almost 100% within millimeters from that stopping point. Hence, easy to stall. I will also point out that the clutch pedal feels weird sometimes, but all-in-all, it seems to be fine. Fluid hasn't been leaking or going down (filled it up 6 years ago when I restored the car and it is the same level). I looked under the dashboard this AM and the rubber boot may have a little fluid around it (it just looks a bit dirty), but nothing that would suggest the master cylinder is failing badly. I did some reading on "freeplay", but I don't think that's my issue; however, I am just not 100% sure. Again, NOTHING is different about my car from when I pulled out the OEM trans.
5) I checked all the lines - no bends or kinks.
6) Slave cylinder is newer and isn't leaking.

Back on the freeplay - could it be that I need more freeplay? Or you guys think that it's just got to be the transmission at this point? I am going to look for a stock trans to throw in and test at this point. Lost for any other ideas.

 

you "hang" the engine and transmission using the 2 side mounts and then install the rear T bracket

that should aleviate some of the installation prybar use

what are you using for transmission fluid? and how much did you put in?

from what i know about transmissions and someone can correct me if i am wrong
5th gear will get hot and pop out of gear if there isnt enough transmission fluid

 

Well, 1) The entire engine was installed 6 years ago the way you said. Not sure why it's a bit tight, but this popping out issue was never around before now and all I've done is lean the engine down on the trans side to remove the trans (rest of engine is still in).

2) I am using the fluid given to me by the builder - Torco MTF. 2 quarts in there filled until it starts pouring out some and then we threw the bolt back in. If you think that may be causing something, I can always loosen the rear mount, but would seem odd that's causing this.

I can try to jack up the car on 1 side and put even more fluid in there perhaps but I just don't think that's the issue. I would also point out the company that built it also drove all the way to my house when I re-installed it last time and helped hold the funnel while we filled it and was in there car while we were driving to witness the pop-outs.

 

i dont think its the mounts causing the issue. i was more informing how to go about installing them a bit easier

you can fill a bseries transmission from the top by removing the speed sensor and using a long funnel. no spillage and much easier to do

ive always ran OEM honda MTF

so since said company was there to witness this occurring did they not offer up any solutions?

 

Oh, ok thank you. Yea I will probably loosen all the mounts and let the engine settle in a slightly better position. Thanks for the thought there.

I mean, they (and the gear manufacturer) have tried 5X now rebuilding the trans. Nothing is working. To their credit, they have probably lost money at this point shipping the thing back and forth, trying different parts, their invested time, etc. But at the end of the day, I paid a lot of money for something that's still not right 2 years in and I haven't taken extra measures for my lost time, time spent, etc yet. I am at my wits end.

I may adjust the motor mounts, re-bleed the clutch (and/or just swap the MC for a new one). But I just don't think that's the issue.

 

any way you can check the temp of trans fluid?

 

We didn't, though I suppose we could have. But we only drove for about 10 mins during the winter in Connecticut.

 

for some reason i thought you had some straight cut gears installed.
reason i asked was to my knowledge, straight cut gears get more friction and heat...but not that how with just 10 mins of driving.

at this point, i would bring it to another trans shop for inspection. they maybe see something that the builder doesn't. im not knocking on the initial builder, but its always good to get some fresh eyes on it.

 

Are these gears dog face engagement? Or normal synchros?

If dog face they might not have the proper undercut to lock the dogs in when loaded.