M/T - Notchy Feel When Shifting Gears
02-016May 28, 2004
*Applies To:
2002-03 RSX Type S - ALL
2004 RSX Type S - From VIN JH4DC530.4S000001 thru JH4DC530.4S012577
Notchy Feel When Shifting
(Supersedes 02-016, Gears Grind When Shifting, dated July 1, 2002)
Updated information is noted by asterisks and a black bar.
SYMPTOM
The shifting action feels notchy when moving between any forward gears.
PROBABLE CAUSE
Excessive drag of the 5-6 gear set, and the hardness of the rubber bushings in the shift cable.
CORRECTIVE ACTION
Replace the 5-6 gear set and the shift cables.
PARTS INFORMATION
5-6 Synchro Sleeve Set: P/N 23629-PNS-305
Change Wire (Shift Cables): P/N 54310-56M-033*
Interlock: P/N 24430-PNS-000
Drain Plug Washer: P/N 94109-14000
REQUIRED MATERIALS
Honda Manual Transmission Fluid (1.8 quarts required
per vehicle): P/N 08798-9016
Liquid Gasket: P/N 08718-0001
Super High Temp Urea Grease: P/N 08798-9002
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
*Failed Part: P/N 23626-PNS-305
Defect Code: 00503
Symptom Code: 03230*
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
1. Drive the vehicle when cold, and shift through all of the forward gears. Note the feel of the shifts.
2. Compare the feel of the shifts when the vehicle was cold to the feel at normal operating temperature.
^ If the shifting action feels notchy when the engine is cold but goes away when warm, replace the 5-6 gear set, the interlock, and the shift cables.
^ If you find other symptoms, proceed with normal troubleshooting.
^ If you do not feel a difference between cold and warm, the vehicle is normal.
REPAIR PROCEDURE
1. Remove the transmission.
^ Refer to page 13-5 of the 2002-04 RSX Service Manual.
^ On ISIS, use keywords "trans removal" and select "Manual Transmission Removal (M/T)."
2. Disassemble the transmission.
^ In the service manual, refer to page 13-17.
^ On ISIS, use keywords "trans dis," and select Manual Transmission Disassembly (M/T)."
3. Disassemble the mainshaft.
^ In the service manual, refer to Mainshaft Disassembly on page 13-32.
^ On ISIS, use keywords "main dis," and select "M/T Mainshaft Disassembly (M/T)."
4. Install the new 5-6 gear set.
^ In the service manual, refer to Mainshaft Reassembly on page 13-35.
^ On ISIS, use keywords "main reassembly," and select "M/T Mainshaft Reassembly (M/T)."
5. Replace the interlock.
^ In the service manual, refer to Change Lever Assembly Disassembly/Reassembly on page 13-25.
^ On ISIS, use keywords "change lever," and select "M/T Change Lever Assembly Disassembly/Reassembly (M/T)."
6. Inspect the mainshaft thrust clearance.
^ In the service manual, refer to page 13-52.
^ On ISIS, use keywords "main thrust," and select "M/T Mainshaft Thrust Clearance Adjustment (M/T)."
7. Reassemble the transmission.
^ In the service manual, refer to page 13-54.
^ On ISIS, use keywords "trans reassembly," and select "Manual Transmission Reassembly (M/T)."
8. Remove the center console.
^ In the service manual, refer to page 20-58.
^ On ISIS, use keywords "enter console rem," and select Center Console Removal/Installation."
9. Replace the shift cables.
^ In the service manual, refer to Gearshift Mechanism Replacement on page 13-59.
^ On ISIS, use keywords "shift cables," and select "M/T Gearshift Mechanism Replacement M/T."
10. Reinstall the center console.
11. Install the transmission.
^ In the service manual, refer to pagel3-10.
^ On ISIS, use keywords "trans install," and select "Manual Transmission Installation (M/T)."
12. Do the idle learn procedure:
^ Make sure all electrical items (A/C, audio, rear window defogger, lights, etc.) are off.
^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice).
^ Let the engine idle (throttle closed and all electrical items off) for about 10 minutes.*
Disclaimer