M/T - High Shift Feel Effort/Gear Clash
Group: TRANSAXLENumber: 01-40-001-1
Date: OCTOBER, 2001
Model: 2000-2001 ACCENT 1.5L & 1.6L
Subject:
2000-2001 ACCENT 1.5L AND 1.6L MANUAL TRANSAXLE SHIFT FEEL IMPROVEMENT - SERVICE KIT PARTS AND ASSEMBLY PROCEDURE
This Technical Service Bulletin supersedes 01-40-001.
This bulletin clarifies the purpose of the dual cone synchronizer currently installed in 1.5L and 1.6L Accent manual transaxles, and provides information about installation of a dual cone synchronizer kit for previous production vehicles. Service kit parts information and the assembly procedure for the double cone synchronizer are included.
DESCRIPTION:
Effective January 29, 2001 production, a dual cone synchronizer assembly has been installed in 1.5L and 1.6L Accent manual transaxles. The purpose of the dual cone synchronizer is to lower the shift feel effort between 1st and 2nd gear as a result of increased synchronization capacity and to increase 1st and 2nd synchronizer durability.
NOTE:
Installation of the dual cone synchronizer kit on vehicles manufactured prior to 01/29/01 can only improve a gear "clash" condition between 1st and 2nd gear. Installation of this kit will not change the normal shift "feel" of the Accent manual transaxle.
PARTS INFORMATION
ASSEMBLY PROCEDURE:
Assembly method for double cone assembly to 1st speed gear side.
1. Assemble the synchronizer inner ring and the 1st speed gear.
2. Assemble the double cone and 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. Assemble the synchronizer spring and the synchronizer outer ring. (Synchronizer spring is not directional.)
NOTE:
The waved synchronizer spring is flattened and acts as a synchronizer key when installed.
4. Assemble the double cone assembly and 1st speed gear. When installing, align the grooves in the synchronizer inner ring with the lugs on the outer ring.
Completed sub-assembly
Assembly method for synchronizer hub to synchronizer sleeve
5. Locate 3 low teeth on the synchronizer hub:
The 3 low teeth "B" are not marked with black as shown in the photograph. They must be identified by counting 5 teeth in either direction from the "A" slots.
NOTE:
Do not attempt to install synchronizer keys (P/N 43372-22003) on new kit into the "A" slots.
6. Locate 3 sets of two consecutive chamfered teeth on the synchronizer sleeve.
7. Install synchronizer hub into synchronizer sleeve: Align 3 low teeth (identified in step 5) with 3 sets of 2 consecutive chamfered teeth on the synchronizer sleeve (identified in step 6).
NOTE:
The hub side with 2 oil grooves must face the 2nd gear side and the side with 3 oil grooves must face the 1st gear side.
8. Assemble the synchronizer hub & sleeve and the 1st speed gear side in steps 1 through 4. When installing, align the 3 lugs in the synchronizer outer ring with 3 grooves in the synchronizer hub.
Completed sub-assembly.
Double cone to synchronizer hub & sleeve assembly
9. Assemble the synchronizer spring and the synchronizer outer ring. (Synchronizer spring is not directional).
NOTE:
The waved synchronizer spring is flattened and acts as a synchronizer key when it is installed.
10. Combine the synchronizer inner ring and double cone assembly with the synchronizer outer ring.
11. Install the double cone assembly into the hub and sleeve assembly by aligning the three lugs on the synchro outer ring with the three grooves (marked "A" in step 5) in the hub assembly.
12. After aligning 4 holes in the 2nd speed gear with 4 lugs in the double cone assembly, assemble the 2nd speed gear.
Completed assembly of 1st and 2nd speed gears.
WARRANTY INFORMATION
DISCLAIMER