A/T - Clunk During 1st To 2nd Gear Upshift
02-004July 8, 2002
Applies To:
1998 3.5RL - Above VIN JH4KA9...WC010839
1999-01 3.5RL - ALL
2002 3.5RL - From VIN JH4KA9...2C000001 thru JH4KA9...2C008332
Clunk During 1St to 2nd Upshift
(Replaces S/B 98-012, Shift Shock, Judder, or Noise During 1st to 2nd Upshift, dated April 27, 1998)
SYMPTOM
A clunk during light throttle upshifts from 1st to 2nd gear.
PROBABLE CAUSE
Characteristic of the second gear accumulator design.
CORRECTIVE ACTION
Replace the secondary valve body.
REQUIRED MATERIALS
Honda ATF-Z1: P/N 08200-9001
PARTS INFORMATION
Secondary Valve Body kit: P/N 27700-P5D-305 [kit contains a secondary valve body (filters for the throttle separator plate and shift valve solenoids A and B are pre-mounted); spring guide with spring; 1st and 2nd accumulator springs; 1st and 2nd accumulator covers (0-rings for the covers are pre-mounted); and mounting bolts for the accumulator covers.]
In addition to the kit, you need these parts:
0-ring (10.7 x 1.9 mm) (2 required for shift solenoid valves A and B): P/N 91308-PY4-003
ATF Pan Gasket: P/N 21813-P5H-000
Drain Plug Washer (18 mm): P/N 90471-PX4-000
0-ring (19.8 x 1.9 mm) (for ATF strainer):
P/N 91308-PA9-003
0-ring (27.5 x 2.4 mm) (for harness connector):
P/N 91311-PY4-003
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Failed Part: P/N 27700-P5D-030
Defect Code: 091
Contention Code: B02
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
DIAGNOSIS
Test-drive the vehicle. Check the shift quality during several light-throttle 1st to 2nd upshifts.
^ If you notice a clunk when the transmission shifts into 2nd gear, go to REPAIR PROCEDURE.
^ If you do not notice a clunk when the transmission shifts into 2nd gear, look for other possible causes of your customer's complaint.
REPAIR PROCEDURE
1. Remove the lower valve body assembly from the transmission (see page 14-112 of the 1996-01 3.5RL Service Manual).
2. Place the lower valve body assembly on a clean work bench. Remove and retain the mounting bolt from the main valve body.
3. Remove all components and mounting hardware from the secondary valve body, then separate the secondary valve body from the main valve body and the main separator plate. Make sure the main separator plate stays with the main valve body. Retain all components and mounting hardware except for these items to be discarded:
^ Secondary valve body (with filters for the throttle separator plate and the shift solenoid valves A and B)
^ 1st accumulator cover (with 0-ring), accumulator spring, and the 6 x 65 mm mounting bolt
^ 2nd accumulator cover (with 0-ring), accumulator spring, spring guide with spring ('99-02 models), and the 6 x 95 mm and two 6 x 65 mm mounting bolts
^ 0-rings (from the solenoid valves A and B)
4. Join the new secondary valve body to the main separator plate and the main valve body. Install the new 1st accumulator spring, then install the new spring guide with spring and the new 2nd accumulator spring.
5. Install the new 1st and 2nd accumulator covers with the new mounting bolts (two 6 x 100 mm and two 6 x 70 mm) and the original 6 x 20 mm mounting bolts you retained in step 3. Push the accumulator covers down, and seat them by hand. Torque the bolts to 12 N.m (8.7 lb-ft).
6. Install the components and mounting hardware you retained in step 3. Refer to page 14-113 of the S/M for details. Torque all mounting bolts to 12 N.m (8.7 lb-ft).
7. Reinstall the lower valve body assembly into the transmission according to page 14-112 of the S/M. Torque all mounting bolts to 12 N.m (8.7 lb-ft). Refill the transmission with Honda ATF-Z1.
8. Test-drive the vehicle to make sure the transmission shifts smoothly with no clunking.
DISCLAIMER