Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Honda S2000 L4-2.2LFACTORY OEM SERVICE PROCEDURE
Mainshaft Reassembly
Mainshaft Reassembly
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
NOTE: Refer to the Exploded View as needed during this procedure.
1. Support 2nd gear (A) on steel blocks, then install the ball bearing (B) using the special tools and a press as shown.
NOTE: The thin edge of the outer race faces 6th gear.
2. Install the 39 x 44 x 26 mm needle bearing, 6th gear, synchro ring, and synchro spring.
3. Install the 5th/6th synchro hub (A) and the sleeve (B) by aligning the stops (C).
4. Press the 5th/6th synchro hub using the special tool as shown. After installing, check the operation of the 5th/6th synchro hub and sleeve.
5. Install the synchro spring, synchro ring, 42 x 47 x 30.5 mm needle bearing, 5th gear, distance collar, and 4th gear.
6. Install the 2000-2003 models: double cone synchro (A), 2004 model: synchro ring, and the synchro spring (B) as shown.
7. Install the 3rd/4th synchro hub (A) and the sleeve (B) by aligning the stops (C).
8. Press the 3rd/4th synchro hub using the special tool as shown. After installing, check the operation of the 3rd/4th synchro hub and sleeve.
9. install the 2000-2003 models: double cone synchro (A), 2004 model: synchro ring, and the synchro spring (B) as shown.
10. Install the distance collar (A), the 35 x 40 x 35 mm needle bearing (B), and 3rd gear (C).
11. Install the angular ball bearing (A) with the thin edge of the outer race facing 3rd gear (B). Use the special tool and a press.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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