Canada - M/T - Shift Feel Improvement Service Procedures

GROUP
TRANSAXLE

NO.
02-40-009

DATE
NOVEMBER 15/02

MODEL
ACCENT

SUBJECT

2000-2001 ACCENT MANUAL TRANSAXLE SHIFT
FEEL IMPROVEMENT SERVICE PROCEDURES
(F/FIX)





This bulletin replaces bulletins 01-40-002 & 01-40-004 and provides the service procedure for the installation of the double cone synchronizer assembly and the poppet ball (5th and reverse) to counteract the following conditions that may occur on the 2000-2001 Accent manual transaxles (M5AF3).





AFFECTED VEHICLES:














PARTS INFORMATION:

ASSEMBLY PROCEDURE FOR DOUBLE CONE SYNCHRONIZER ASSEMBLY (1ST AND 2ND):

NOTE:
For removal of transaxle assembly, refer to the ACCENT Shop Manual.





1. Assemble the synchronizer inner ring onto the 1st speed gear.





2. Install the double cone onto the synchronizer inner ring. Align the 4 lugs on the double cone with the 4 holes in the 1st speed gear when fitting the double cone onto the synchronizer.





3. Install the synchronizer spring and the synchronizer outer ring (the spring is non-directional).

NOTE:
The wavy synchronizer spring is flattened and acts as a synchronizer key when it is installed.





4. Assemble the double cone assembly and the 1st speed gear. When installing align the grooves in the synchronizer inner ring with the lugs on the outer ring.





5. Locate the 3 low teeth (B) on the synchronizer hub. The 3 low teeth are not marked in black as shown in the photo they must be identified by counting 5 teeth in either direction from the "A" slots.





6. Locate the 3 high teeth on the synchronizer sleeve. They are 3 pairs of slightly concave teeth sitting 120 degrees apart.





7. Install the synchronizer hub into the synchronizer sleeve by aligning the 3 low teeth (marked "B") on the synchronizer with the 3 high teeth (marked "C") on the sleeve.

NOTE:
The hub side with 2 oil grooves should face the 2nd gear side and the hub side with 3 oil grooves should face the 1st gear side.





8. Install the synchronizer hub and sleeve to the double cone assembly already installed to the 1st speed gear side. When installing, align the 3 lugs in the synchronizer outer ring with the 3 grooves in the synchronizer hub.





9. Assemble the synchronizer spring and the synchronizer outer ring.





10. Assemble the synchronizer inner ring and double cone assembly to the synchronizer outer ring.





11. Install the double cone assembly into the hub and sleeve assembly by aligning the 3 lugs on the synchronizer outer ring with the 3 grooves in the hub assembly.








12. Assemble the 2nd speed gear by aligning the 4 holes in the 2nd speed gear with the 4 lugs in the double cone assembly.

SERVICE PROCEDURE FOR POPPET BALL (5Th AND REVERSE):





1. Install the transaxle case assembly.





2. Align the center groove on the shift rail (5th and reverse) with the poppet on the transaxle case assembly.





3. Insert the steel ball.





4. Install the poppet spring.





5. Install the seal bolt.





WARRANTY INFORMATION: