Manual Transmission Acura RSX I

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How to Troubleshoot Circuits at the ECM

Special Tools Required

Backprobe set 07SAZ-001000A (2 required)

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1. Remove the passenger's dashboard lower cover (see «PASSENGER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION»(/acura/rsx/i-2001-2004/remont/exteriorinterior-trim/#dashboard) ).
2. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C).
3. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal.

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1. Park the vehicle on level ground, and turn the ignition switch to LOCK (0).
2. Remove the oil filler plug (A) and filler plug washer (B), check the condition of the fluid, and make sure it is at the proper level (C).
3. If the fluid is dirty, remove the drain plug (D) and drain it.
4. Install the drain plug with a new drain plug washer, and refill the transmission fluid to the proper level. Fluid Capacity 1.5 L (1.6 US qt) at fluid change 1.7 L (1.8 US qt) at overhaul Always use ACURA Manual Transmission Fluid (MTF). Using engine oil can cause stiffer shifting because it does not contain the proper additives.
5. Reinstall the oil filler plug with a new filler plug washer.

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1. Disconnect the back-up light switch connector.
2. Check for continuity between the No. 1 and No. 2 terminals of the back-up light switch 2P connector. There should be continuity when the shift lever is in reverse.
3. If necessary, replace the back-up light switch. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to threads of the switch, and install the switch on the transmissions housing. NOTE: Do not install the back-up light switch if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.

Transmission Removal

Special Tools Required

1. Engine hanger adapter EQS00BRSX0 *
2. Engine support hanger, A & Reds AAR-T-12566 *
3. Subframe adapter EQS02C000011 * * Available through the Honda Tool Equipment Program 1-888-424-6857.

Note. Use fender covers to avoid damaging painted surfaces.

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1. Make sure you have the anti-theft code for the radio, then write down the customers radio station presets. Disconnect the negative cable from the battery first, then disconnect the positive cable from the battery. Remove the battery.
2. Remove the intake manifold cover (see step 6 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
3. Remove the air cleaner housing (see step 7 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
4. Remove the intake air duct (see step 8 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
5. Remove the battery base (A).
6. Disconnect the transmission ground cable (B).
7. Disconnect the back-up light switch connector (A), the vehicle speed sensor (VSS) connector (B), the reverse lockout solenoid connector (6-speed model) (C), and the output shaft (countershaft) speed sensor connector (D). 2002-2004 models: 2005-2006 models
8. Remove the cable bracket (A), then disconnect the cables (B) from the top of the transmission housing. Carefully remove both cables and the bracket together to avoid bending the cables.
9. Remove the harness clips.
10. Carefully remove the slave cylinder without bending the clutch line. Do not press the clutch pedal once the slave cylinder has been removed. Other models: 2005-2006 model 6-speed models
11. Remove the engine wire harness cover (A) by lifting up on the lock tab (B), then slide the harness forward off the air cleaner housing mounting bracket (C).
12. Remove the water pipe mounting bolt (A), and lower the water pipe slight. Loosen the air cleaner housing bracket mounting bolt (B), and remove the mounting bolt (C).
13. Remove the brake booster and evaporative emission (EVAP) line bracket mounting bolts (D), and attach the special tool to the threaded hole (E) in the cylinder head.
14. Install the engine support hanger (A) to the vehicle, and attach the hook to the special tool.
15. Remove the two transmission upper mounting bolts.
16. Remove the transmission mount bracket (A) and the transmission mounting bolt (B). 2002 model: 2003-2006 models
17. Remove the air cleaner bracket (C).
18. Raise the vehicle, and make sure it is securely supported.
19. Drain the transmission fluid. Reinstall the drain plug using a new drain plug washer (see «TRANSMISSION FLUID INSPECTION AND REPLACEMENT»(/acura/rsx/i-2001-2004/remont/manual-trans/#manual-transmission) ).
20. Remove the splash shield.
21. Remove the three way catalytic converter (TWC assembly (see step 29 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
22. Remove the driveshaft (see «DRIVESHAFT REMOVAL»(/acura/rsx/i-2001-2004/remont/axle-shafts/#drivelineaxle) ).
23. Remove the intermediate shaft (see «INTERMEDIATE SHAFT REMOVAL»(/acura/rsx/i-2001-2004/remont/axle-shafts/#drivelineaxle) ).
24. Remove the front engine mount bracket mounting bolt.
25. Remove the three bolts securing the transmission rear mount.
26. Support the front suspension subframe with the subframe adapter and a jack.
27. Make reference marks (A) on the front suspension subframe (B) and mounting bolts (C), then remove the front suspension subframe.
28. Remove the clutch cover. 5-speed model: 6-speed model
29. Remove the front engine mount.
30. Place the transmission jack under the transmission, and remove the transmission mounting bolts. 5-speed model: Four lower bolts 6-speed model: Two rear and two lower bolts
31. 6-speed model: Remove the harness bracket (A), then remove the intake manifold bracket (B).
32. 6-speed model: Remove the two front transmission mounting bolts.
33. Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate, then lower the transmission on the transmission jack.
34. Remove the transmission rear mount (A) and the transmission rear mount bracket (B).
35. Remove the release fork boot (A) from the clutch housing (B).
36. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).

Transmission Installation

Special Tools Required

1. Engine hanger adapter EQS00BRSX0 *
2. Engine support hanger, A & Reds AAR-T-12566 *
3. Subframe adapter EQS02C000011 * * Available through the Honda Tool and Equipment Program 1-888-424-6857.

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1. Make sure the two dowel pins are installed in the clutch housing.
2. Apply super high temp area grease (P/N 08798-9002) to the release fork (A) and the release bearing (B). Install the release fork, the release bearing, and the boot (C).
3. Install the transmission rear mount bracket (A) and the transmission rear mount (B).
4. Place the transmission on the transmission jack, and raise it to the engine level.
5. 6-speed model: Install the two front transmission mounting bolts.
6. 6-speed model: Install the intake manifold bracket (A), then install the harness bracket (B).
7. Install the transmission mounting bolts. 5-speed model: Four lower bolts 6-speed model: Two rear and two lower bolts
8. Install the front engine mount.
9. Install the clutch cover. 5-speed model: 6-speed model
10. Support the front suspension subframe with the subframe adapter and a jack.
11. Install the front suspension subframe (A) in its original position by aligning it with the marks (B) you made in the removal procedure.
12. Install the three rear mounting bolts for the transmission rear mount.
13. Install the front engine mount bracket mounting bolt.
14. Install the intermediate shaft (see «INTERMEDIATE SHAFT INSTALLATION»(/acura/rsx/i-2001-2004/remont/axle-shafts/#drivelineaxle) ).
15. Install the driveshaft (see «DRIVESHAFT INSTALLATION»(/acura/rsx/i-2001-2004/remont/axle-shafts/#drivelineaxle) ).
16. Install the three way catalytic converter (TWC) assembly (see step 20 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
17. Install the splash shield.
18. Install the transmission mount bracket (A) and the transmission mounting bolt (B). 2002 model: 2003-2006 models
19. Install the air cleaner bracket (C).
20. Install the two transmission upper mounting bolts.
21. Remove the engine hanger and special tool from the engine.
22. Install the brake booster and evaporative emission (EVAP) line bracket mounting bolts (A), and the air cleaner housing bracket mounting bolt (B). Tighten the air cleaner housing bracket mounting bolt (C), and install the water pipe mounting bolt (D).
23. Install the engine harness cover.
24. Apply super high temp area grease (P/N 08798-9002) to the end of the slave cylinder rod. Install the slave cylinder. Be careful not to bend the clutch line. Other models: 2005-2006 6-speed models
25. Install the harness clip.
26. Install the cable bracket (A) and cables (B).
27. Apply a light coat of super high temp area grease (P/N 08798-9002) and Honda silicone grease (P/N 08C30-B0234M) to the cable ends, and install new cotter pins (C).
28. Connect the back-up light switch connector (A), the vehicle speed sensor (VSS) connector (B), the reverse lockout solenoid connector (6-speed model) (C), and the output shaft (countershaft) speed sensor connector (D). 2002-2004 models. 2005-2006 models
29. Connect the transmission ground cable (A).
30. Install the battery base (B).
31. Install the intake air duct (see step 42 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
32. Install the air cleaner housing (see step 43 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
33. Install the intake manifold cover (see step 45 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
34. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion. Connect the positive cable to the battery first, then connect the negative cable.
35. Refill the transmission fluid (see «TRANSMISSION FLUID INSPECTION AND REPLACEMENT»(/acura/rsx/i-2001-2004/remont/manual-trans/#manual-transmission) ).
36. Check the shift lever and clutch operation.
37. Check the front wheel alignment (see «WHEEL ALIGNMENT»(/acura/rsx/i-2001-2004/remont/wheel-alignment/#front-suspension-and-rear-suspension__wheel-alignment) ).
38. Enter the audio anti-theft codes, then enter the customer's audio station presets, and set the clock.
39. 2002-2004 models: Do the ECM idle learn procedure (see «ECM/PCM IDLE LEARN PROCEDURE»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#idle-control-system) ).
40. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(/acura/rsx/i-2001-2004/remont/windows/#power-windows__resetting-the-power-window-control-unit) ).
41. Test-drive the vehicle.

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Note. Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench. 6-speed model is shown, 5-speed model is similar.

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1. Remove the detent bolts (A), springs, steel balls, and the back-up light switch (B).
2. 2002-2004 models: Remove the vehicle speed sensor (VSS) (A) and O-ring (B).
3. 2005-2006 models: Remove the 20 mm bolt (A) and the 20 mm washer (B).
4. Remove the change lever assembly (A), the 8 x 14 mm dowel pins (B), the clutch line clip bracket (C), and the interlock bolt (D).
5. 2002-2004 models: Remove the drain plug (A), the filler plug (B), and the 10 mm flange bolt (C).
6. 2005-2006 models: Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), the output shaft (countershaft) speed sensor (D), the plain washer (5-speed model) (E), and the O-ring (F).
7. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
8. Remove the harness bracket (A) (6-speed model only), the transmission hanger A (B), and the transmission hanger B (C).
9. Remove the 32 mm sealing cap (A).
10. Expand the 72 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.
11. Remove the transmission housing (C) and the 14 x 20 mm dowel pins (D).
12. 5-speed model: Remove the reverse lock cam.
13. Remove the reverse idler gear (A) and the reverse gear shaft (B).
14. Remove the reverse shift fork.
15. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift forks (C) from the clutch housing (D).
16. Remove the 28 mm spring washer (E) and the 28 mm washer (F).
17. Remove the differential assembly (A) and the magnet (B).
18. Remove the oil gutter plate (A), the oil guide plate M, and the 72 mm shim (B).

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1. Measure the clearance between the reverse idler gear (A) and the reverse shift fork (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2. Standard: 0.20-0.59 mm (0.007-0.024 in.) Service Limit: 1.3 mm (0.051 in.)
2. Measure the width of the reverse shift fork. If the width is not within the standard, replace the reverse shift fork. If the width is within the standard, replace the reverse gear. Standard: 13.4-13.7 mm (0.527-0.539 in.)

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1. Measure the clearance between the change lever (A) and the select lever (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2. Standard: 0.05-0.25 mm (0.002-0.010 in.) Service Limit: 0.50 mm (0.020 in.)
2. Measure the groove of the change lever. If the groove is not within the standard, replace the change lever. If the groove is within the standard, replace the select lever. Standard: 15.00-15.10 mm (0.591-0.594 in.)

Change Lever Assembly Disassembly/Reassembly

Prior to reassembling, clean all the parts in solvent, dry them, and apply grease to the contact surfaces as shown.

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6-speed model

Note. Do not assemble the shift arm cover if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket. Prior to reassembling, clean all parts in solvent, dry them, and apply grease to the contact surfaces as shown.

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Shift Fork Clearance Inspection

Note. The synchro sleeve and synchro hub should be replaced as a set.

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1. Measure the clearance between each shift fork (A) and its matching synchro sleeve (B). If the clearance exceeds the service limit, go to step 2. Standard: 0.35-0.65 mm (0.014-0.026 in.) Service Limit: 1.0 mm (0.039 in.)
2. Measure the thickness of the shift fork fingers. If the thickness is not within the standard, replace the shift fork. If the thickness is within the standard, replace the synchro sleeve. If one arm of the shift fork shows more wear than others, the fork may be bent and needs to be replaced. Standard: 7.4-7.6 mm (0.29-0.30 in.)
3. Measure the clearance between the shift fork (A) and the shift arm (B). If the clearance exceeds the service limit, go to step 4. Standard: 0.2-0.5 mm (0.007-0.020 in.) Service Limit: 0.62 mm (0.024 in.) NOTE: 6-speed model is shown.
4. Measure the width of the shift arm. If the width is not within the standard, replace the shift arm. If the width is within the standard, replace the shift fork or shift piece. Standard: 16.9-17.0 mm (0.665-0.669 in.)

Shift Fork Disassembly/Reassembly

Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces.

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Mainshaft Assembly Clearance Inspection

Note. If replacement is required, always replace the synchro sleeve and hub as a set. 6-speed model is shown, 5-speed model is similar.

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1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
2. Measure the clearance between 2nd (C) and 3rd (D) gears with a feeler gauge (E). If the clearance is more than the service limit, go to step 3. If the clearance is within the service limit, go to step 4 . Standard: 0.06-0.16 mm (0.002-0.006 in.) Service Limit: 0.25 mm (0.010 in.)
3. Measure the thickness of 3rd gear. If the thickness is less than the service limit, replace 3rd gear. If the thickness is within the service limit, replace the 3rd/4th synchro hub. Standard: 23.92-23.97 mm (0.941-0.944 in.) Service Limit: 23.80 mm (0.937 in.) 5-speed model: 6-speed model
4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 5. Standard: 0.06-0.16 mm (0.002-0.006 in.) Service Limit: 0.25 mm (0.010 in.)
5. Measure distance 1 on the distance collar. If distance 1 is not within the standard, replace the distance collar. If distance 1 is within the standard, go to step 6. Standard: 24.03-24.08 mm (0.946-0.948 in.)
6. Measure the thickness of 4th gear. If the thickness is less than the service limit, replace 4th gear. If the thickness is within the service limit, replace the 3rd/4th synchro hub. Standard: 23.92-23.97 mm (0.941 -0.944 in.) Service Limit: 23.80 mm (0.937 in.) 5-speed model: 6-speed model
7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 8. Standard: 0.06-0.16 mm (0.002-0.006 in.) Service Limit: 0.25 mm (0.010 in.)
8. Measure distance 2 on the distance collar. If distance 2 is not within the standard, replace the distance collar. If distance 2 is within the standard, go to step 9. Standard: 24.03-24.08 mm (0.946-0.948 in.)
9. Measure the thickness of 5th gear. If the thickness is less than the service limit, replace 5th gear. If the thickness is within the service limit, replace the 5th synchro hub (5-spped model) or 5th/6th synchro hub (6-spped model). Standard: 23.92-23.97 mm (0.941-0.944 in.) Service Limit: 23.80 mm (0.937 in.) 5-speed model: 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number: 3000001-3004679: 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, and 2005-2006 6-speed models
10. 5-speed model: Measure the thickness of the MBS distance collar. If the thickness is not within standard, replace the MBS distance collar. Standard: 23.95-24.05 mm (0.943-0.947 in.)
11. 6-speed model: Measure the clearance between 6th gear (A) and the angular ball bearing (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 12. Standard: 0.06-0.16 mm (0.002-0.006 in.) Service Limit: 0.25 mm (0.010 in.)
12. 6-speed model: Measure the thickness of the distance collar. If the thickness is not within the standard, replace the distance collar. If the thickness is within the standard, go to step 13. Standard: 24.03-24.08 mm (0.946-0.948 in.)
13. 6-speed model: Measure the thickness of 6th gear. If the thickness is less than the service limit, replace 6th gear. If the thickness is within the service limit, replace the 5th/6th synchro hub. Standard: 23.92-23.97 mm (0.941-0.944 in.) Service Limit: 23.80 mm (0.937 in.) 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number: 3000001-3004679: 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, and 2005-2006 6-speed models

Mainshaft Disassembly

Note. 6-speed model is shown, 5-speed model is similar.

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1. Remove the angular ball bearing (A) and the tapered cone ring using a commercially available bearing separator (B) and bearing puller (C). Make sure the bearing separator is under the tapered cone ring (5-speed model).
2. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th synchro hub (5-speed model) or 5th/6th synchro hub (6-speed model) (B). Use of a jaw-type puller can damage the gear teeth.
3. Support 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.

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1. Inspect the gear and bearing surfaces for wear and damage, then measure the mainshaft at points A, B, C, D, and E. If any part of the mainshaft is less than the service limit, replace it. Standard: Ball bearing surface (transmission housing side): 27.987-28.000 mm (1.1019-1.1024 in.) Distance collar surface: 31.984-32.000 mm (1.2594-1.2598 in.) Needle bearing surface: 38.984-39.000 mm (1.5348-1.5354 in.) Ball bearing surface (clutch housing side): 27.977-27.990 mm (1.1015-1.1020 in.) Bushing surface: 20.80-20.85 mm (0.819-0.821 in.) Service Limit: A: 27.93 mm (1.100 in.) B: 31.93 mm (1.257 in.) C: 38.93 mm (1.533 in.) D: 27.92 mm (1.099 in.) E: 20.75 mm (0.817 in.)
2. Inspect the runout by supporting both ends of the mainshaft. Then rotate mainshaft two complete turns while measuring with a dial gauge. If the runout is more than the service limit, replace the mainshaft. Standard: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)

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Special Tools Required

1. Driver, 40 mm I.D. 07746-0030100
2. Driver attachment, 30 mm I.D. 07746-0030300

Note. Refer to the EXPLODED VIEW as needed during this procedure.

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1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th synchro hubs.
2. Install the needle bearing and 3rd gear on the mainshaft.
3. 5-speed model: Install the synchro ring (A) and the synchro spring (B).
4. 6-speed model: Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).
5. Install the 3rd/4th synchro hub (A) by aligning the synchro ring grooves (B) with the fingers in the 3rd/4th synchro hub (C).
6. Install the 3rd/4th synchro hub (A) using the special tool.
7. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/ 4th synchro hub set.
8. Install the synchro spring (A). 5-speed model: 6-speed model
9. Install the synchro ring (B) (5-speed model) or the double cone synchro assembly (B) (6-speed model) by aligning the synchro ring fingers (C) with the grooves in the 3rd/4th synchro hub (D).
10. 5-speed model: Install 4th gear (A).
11. 6-speed model: Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes in 4th gear (C).
12. Install the needle bearings, the distance collar, and 5th gear.
13. 5-speed model, 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, and 2005-2006 6-speed models: Install the synchro ring (A) and synchro spring (B).
14. 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number: 3000001-3004679: Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 5th gear (C), then install the synchro spring (D).
15. Install the 5th synchro hub (A) by aligning the synchro ring grooves (B) with the fingers in the 5th synchro hub (C).
16. Install the 5th synchro hub (A) using the special tools.
17. 5-speed model: Install the 5th synchro sleeve.
18. 6-speed model: Install the 5th/6th synchro sleeve.
19. 5-speed model, and 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, 2005-2006 6-speed models: Install the synchro spring (A). Install the synchro ring (B) by aligning the synchro cone fingers (C) with the grooves in the 5th synchro hub (5-speed model) or 5th/6th synchro hub (6-speed model) (D).
20. 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number: 3000001-3004679: Install the synchro spring (A). Install the double cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 5th/6th synchro hub (D).
21. 5-speed model: Install the MBS distance collar and tapered cone ring.
22. 6-speed model: Install the distance collar and the needle bearing.
23. 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number 3000001-3004679: Install 6th gear (A) by aligning the synchro cone fingers (B) with the holes in 6th gear (C).
24. 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, and 2005-2006 6-speed models: Install the 6th gear (A).
25. Install the new ball bearing (A) using the special tools and a press (B). 5-speed model: 6-speed model

Countershaft Assembly Clearance Inspection

Note. 6-speed model is shown, 5-speed model is similar.

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1. Measure the clearance between 1st gear (A) and the distance collar (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2. Standard: 0.06-0.16 mm (0.002-0.006 in.) Service Limit: 0.25 mm (0.010 in.)
2. Measure the thickness of the distance collar. If the thickness is not within the standard, replace the distance collar. If the thickness is within the standard, go to step 3. Standard: 23.03-23.08 mm (0.907-0.909 in.)
3. Measure the thickness of 1st gear. If the thickness is less than the service limit, replace 1st gear.
4. If the thickness is within the service limit, replace the 1st/2nd synchro hub. Standard: 22.92-22.97 mm (0.902-0.904 in.) Service Limit: 22.87 mm (0.900 in.)
5. Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 5. Standard: 0.06-0.16 mm (0.002-0.006 in.) Service Limit: 0.25 mm (0.010 in.)
6. Measure the thickness of the distance collar. If the thickness is not within the standard, replace the distance collar. If the thickness is within the standard, go to step 6. Standard: 28.03-28.08 mm (1.104-1.106 in.)
7. Measure the thickness of 2nd gear. If the thickness is less than the service limit, replace 2nd gear. If the thickness is within the service limit, replace the 1st/2nd synchro hub. Standard: 27.92-27.97 mm (1.099-1.101 in.) Service Limit: 27.87 mm (1.097 in.)

Countershaft Disassembly

Note. 6-speed model is shown, 5-speed model is similar.

Scheme 143

Scheme 144

Scheme 145

Scheme 146

1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).
3. Support the ball bearing (A) (5-speed model) or 6th gear (B) (6-speed model) on steel blocks (C), then use a press (D) and an attachment (E) to press the countershaft out of the ball bearing.
4. 5-speed model: Remove the 35 mm shim and the distance collar.
5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 5th gear.
6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 3rd gear.

Scheme 147

Scheme 148

1. Inspect the gear and bearing surfaces for wear and damage, then measure the countershaft at points A, B, and C. If any part of the countershaft is less than the service limit, replace it. Standard: Ball bearing surface (transmission housing side): 30.020-30.033 mm (1.1819-1.1824 in.) Distance collar surface: 39.937-39.950 mm (1.5723-1.5728 in.) Needle bearing surface (clutch housing side): 5-speed model: 40.000-40.015 mm (1.5748-1.5754 in.) 6-speed model: 35.000-35.015 mm (1.3780-1.3785 in.) Service Limit: 29.97 mm (1.180 in.) 39.883 mm (1.5702 in.) 5-speed model: 39.95 mm (1.5723 in.) 6-speed model: 34.95 mm (1.3760 in.)
2. Inspect the runout by supporting both ends of the countershaft. Then rotate the countershaft two complete turns while measuring with a dial gauge. If the runout exceeds the service limit, replace the countershaft. Standard: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002 in.)

Scheme 149

Scheme 150

Special Tools Required

1. Driver, 40 mm I.D. 07746-0030100
2. Driver attachment, 30 mm I.D. 07746-0030300

Note. Refer to the EXPLODED VIEW as needed during this procedure. 6-speed model is shown, 5-speed model is similar.

Scheme 151

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Scheme 164

Scheme 165

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the distance collar, needle bearing, and 1st gear onto the countershaft.
3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the grooves in 1st gear (C), then install the synchro spring (D).
4. Install the 1st/2nd synchro hub (A) by aligning the synchro ring grooves (B) with the fingers in the 1st/2nd synchro hub (C).
5. Install reverse gear.
6. Install the synchro spring (A).
7. Install the triple cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
8. Install the distance collar (A) and the friction damper (B) by aligning the friction damper fingers (C) with the grooves in the 1st/2nd synchro hub (D).
9. Install the needle bearing.
10. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).
11. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the special tool and a press (C). Do not exceed the maximum pressure.
12. Install 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
13. Install 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
14. 5-speed model: Install the distance collar.
15. 6-speed model: Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.
16. Install the 35 mm shim and the old ball bearing (A) using the special tools and a press (B).
17. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C). Standard: 0.04-0.10 mm (0.0016-0.0039 in.)
18. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 17 is within the standard, replace only the ball bearing. 35 mm Shim THICKNESS Part Number Thickness A 23981-PPP-000 0.87 mm (0.0343 in.) AA 23981-PPP-900 0.91 mm (0.0358 in.) B 23982-PPP-000 0.95 mm (0.0374 in.) AB 23982-PPP-900 0.99 mm (0.0390 in.) C 23983-PPP-000 1.03 mm (0.0406 in.) AC 23983-PPP-900 1.07 mm (0.0421 in.) D 23984-PPP-000 1.11 mm (0.0437 in.) AD 23984-PPP-900 1.15 mm (0.0453 in.) E 23985-PPP-000 1.19 mm (0.0469 in.) AE 23985-PPP-900 1.23 mm (0.0484 in.) F 23986-PPP-000 1.27 mm (0.0500 in.) AF 23986-PPP-900 1.31 mm (0.0516 in.) G 23987-PPP-000 1.35 mm (0.0531 in.) AG 23987-PPP-900 1.39 mm (0.0547 in.) H 23988-PPP-000 1.43 mm (0.0563 in.) AH 23988-PPP-900 1.47 mm (0.0579 in.) J 23989-PPP-000 1.51 mm (0.0594 in.) AJ 23989-PPP-900 1.55 mm (0.0610 in.) K 23990-PPP-000 1.59 mm (0.0626 in.) AK 23990-PPP-900 1.63 mm (0.0642 in.) L 23991-PPP-000 1.67 mm (0.0657 in.) AL 23991-PPP-900 1.71 mm (0.0673 in.) M 23992-PPP-000 1.75 mm (0.0689 in.) AM 23992-PPP-900 1.79 mm (0.0705 in.) N 23993-PPP-000 1.83 mm (0.0720 in.) AN 23993-PPP-900 1.87 mm (0.0736 in.) P 23994-PPP-000 1.91 mm (0.0752 in.) AP 23994-PPP-900 1.95 mm (0.0768 in.) Q 23995-PPP-000 1.99 mm (0.0783 in.)
19. Support the ball bearing (A) (5-speed model) or 6th gear (B) (6-speed model) on steel blocks (C), then use a press (D) and an attachment (E) to press the countershaft out of the ball bearing.
20. If necessary, install the 35 mm shim selected in step 18 , then recheck the clearance.
21. 6-speed model: Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.
22. Install the new ball bearing (A) using the special tools and a press (B).
23. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
24. Tighten the new special bolt (B) (left-hand threads).

Scheme 166

1. Inspect gear teeth on all synchro hubs and synchro sleeves for wear (rounded off corners).
2. Install each synchro hub (A) in its mating synchro sleeve (B), and check for free movement. Make sure you match the three sets of longer teeth (C) (120 degrees apart) on the synchro sleeve with the three sets of deeper grooves (D) in the synchro hub. Do not install the synchro sleeve with its longer teeth in the 1st/2nd synchro hub slots (E) because it will damage the spring ring. NOTE: If replacement is required, always replace the synchro sleeve and the synchro hub as a set.

Scheme 167

Scheme 168

Scheme 169

Scheme 170

1. Inspect the inside of each synchro ring (A) for wear. Inspect the teeth (B) on each synchro ring for wear (rounded off).
2. Inspect the teeth (C) on each synchro sleeve and matching teeth on each gear for wear (rounded off).
3. Inspect the thrust surface (D) on each gear hub for wear.
4. Inspect the cone surface (E) on each gear hub for wear and roughness.
5. Inspect the teeth on all gears (F) for uneven wear, scoring, galling, and cracks.
6. Coat the cone surface of each gear (E) with transmission fluid, and place its synchro ring on it. Rotate the synchro ring, making sure it does not slip.
7. Measure the clearance between each gear (A) and its synchro ring (B) all around the gear. Hold the synchro ring against the gear evenly while measuring the clearance. If the clearance is less than the service limit, replace the synchro ring and gear. Synchro Ring-to-Gear Clearance (5-speed model only) Standard: 0.70-1.49 mm (0.028-0.059 in.) Service Limit: 0.4 mm (0.016 in.) Synchro Ring-to-Gear Clearance (2005-2006 6-speed models) Standard: 0.70-1.49 mm (0.028-0.059 in.) Service Limit: 0.4 mm (0.016 in.) Double Cone Synchro (6-speed model only) and Triple Cone Synchro-to-Gear Clearance Standard

Mainshaft Bearing and Oil Seal Replacement

Special Tools Required

1. Oil seal driver 07JAD-PL90100
2. Adjustable bearing puller, 20-40 mm 07736-A01000B
3. Driver attachment, 42 x 47 mm 07746-0010300
4. Driver 07749-0010000

Scheme 171

Scheme 172

Scheme 173

Scheme 174

1. Remove the differential assembly.
2. Remove the ball bearing (A) from the clutch housing (B) using the special tools.
3. Remove the oil seal (A) from the clutch side. Be careful when removing the seal so the clutch housing is not damaged.
4. Drive in the new oil seal from the transmission side using the special tools.
5. Drive in the new ball bearing (A) from the transmission side using the special tools.

Countershaft Bearing Replacement

Special Tools Required

1. Oil seal driver 07JAD-PL90100
2. Adjustable bearing puller, 20-40 mm 07736-A01000B

Scheme 175

Scheme 176

Scheme 177

Scheme 178

1. Remove the bearing set plate (A) from the clutch housing (B).
2. Remove the needle bearing (A) using the special tools, then remove the oil guide plate C.
3. Position the oil guide plate C and new needle bearing (A) in the bore of the clutch housing (B).
4. Install the needle bearing using the special tools.
5. Install the bearing set plate (A) with the bolts (B).

Mainshaft Thrust Clearance Adjustment

Special Tools Required

1. Mainshaft holder 07GAJ-PG20110
2. Mainshaft base 07GAJ-PG20130

Scheme 179

Scheme 180

Scheme 181

Scheme 182

1. Remove the 72 mm shim (A) and oil guide plate M from the transmission housing (B).
2. Thoroughly clean the spring washer (A) and washer (B) before installing them on the clutch housing side ball bearing (C). Note the installation direction of the spring washer.
3. Install the 3rd/4th synchro hub, the distance collar, the 5th synchro hub (5-speed model) or 5th/6th synchro hub (6-speed model), the distance collar, and the ball bearing on the mainshaft. NOTE: Refer to the mainshaft reassembly Exploded View (see «MAINSHAFT REASSEMBLY»(/acura/rsx/i-2001-2004/remont/manual-trans/#manual-transmission) ).
4. Install the mainshaft in the clutch housing.
5. Place the transmission housing over the mainshaft and onto the clutch housing.
6. Secure the clutch and transmission housings with several 8 mm bolts. NOTE: It is not necessary to use sealing agent between the housing for this procedure.
7. Lightly tap on the mainshaft with a plastic hammer.
8. Attach the special tool to the mainshaft as follows: Back-out the mainshaft holder bolt (A), and loosen the two hex bolts (B). Fit the holder over the mainshaft so its lip is towards the transmission. Align the mainshaft holder lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
9. Fully seat the mainshaft by tapping its end with a plastic hammer.
10. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
11. Zero a dial gauge (A) on the end of the mainshaft.
12. Turn the mainshaft holder bolt (B) clockwise; stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft thrust clearance. NOTE: Do not turn the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving. Applying more pressure with the mainshaft holder bolt may damage the transmission.
13. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, select the appropriate shim needed from the table, and recheck the thrust clearance. Standard: 0.11-0.17 mm (0.004-0.007 in.) (Example) Measure reading: 1.93 mm (0.0759 in.) Subtract the total clearance measurement from the middle of the clearance standard 0.14 mm (0.0056 in.). 1.93-0.14=1.79 mm (0.0704 in.) Select the shim closest to the amount calculated. For this example, the 1.80 mm (0.0709 in.) shim is best.
14. With the oil guide plate M and the appropriate size shim installed in the transmission housing, check the thrust clearance again to verify the clearance is within the standard. 72 mm Shim THICKNESS Part Number Thickness A 23931-P21-000 0.60 mm (0.0236 in.) B 23932-P21-000 0.63 mm (0.0248 in.) C 23933-P21-000 0.66 mm (0.0260 in.) D 23934-P21-000 0.69 mm (0.0271 in.) E 23935-P21-000 0.72 mm (0.0283 in.) F 23936-P21-000 0.75 mm (0.0295 in.) G 23937-P21-000 0.78 mm (0.0307 in.) H 23938-P21-000 0.81 mm (0.0319 in.) I 23939-P21-000 0.84 mm (0.0331 in.) J 23940-P21-000 0.87 mm (0.0343 in.) K 23941-P21-000 0.90 mm (0.0354 in.) L 23942-P21-000 0.93 mm (0.0366 in.) M 23943-P21-000 0.96 mm (0.0378 in.) N 23944-P21-000 0.99 mm (0.0390 in.) O 23945-P21-000 1.02 mm (0.0402 in.) P 23946-P21-000 1.05 mm (0.0413 in.) Q 23947-P21-000 1.08 mm (0.0425 in.) R 23948-P21-000 1.11 mm (0.0437 in.) S 23949-P21-000 1.14 mm (0.0449 in.) T 23950-P21-000 1.17 mm (0.0461 in.) U 23951-P21-000 1.20 mm (0.0472 in.) V 23952-P21-000 1.23 mm (0.0484 in.) W 23953-P21-000 1.26 mm (0.0496 in.) X 23954-P21-000 1.29 mm (0.0508 in.) Y 23955-P21-000 1.32 mm (0.0520 in.) Z 23956-P21-000 1.35 mm (0.0531 in.) AA 23957-P21-000 1.38 mm (0.0543 in.) AB 23958-P21-000 1.41 mm (0.0555 in.) AC 23959-P21-000 1.44 mm (0.0567 in.) AD 23960-P21-000 1.47 mm (0.0579 in.) AE 23961-P21-000 1.50 mm (0.0591 in.) AF 23962-P21-000 1.53 mm (0.0602 in.) AG 23963-P21-000 1.56 mm (0.0614 in.) AH 23964-P21-000 1.59 mm (0.0626 in.) AI 23965-P21-000 1.62 mm (0.0638 in.) AJ 23966-P21-000 1.65 mm (0.0650 in.) AK 23967-P21-000 1.68 mm (0.0661 in.) AL 23968-P21-000 1.71 mm (0.0673 in.) AM 23969-P21-000 1.74 mm (0.0685 in.) AN 23970-P21-000 1.77 mm (0.0697 in.) AO 23971-P21-000 1.80 mm (0.0709 in.) AP 23972-PPP-J00 1.83 mm (0.0720 in.) AQ 23973-PPP-J00 1.86 mm (0.0732 in.) AR 23974-PPP-J00 1.89 mm (0.0744 in.) AS 23975-PPP-J00 1.92 mm (0.0756 in.) AT 23976-PPP-J00 1.95 mm (0.0768 in.) AV 23977-PPP-J00 1.98 mm (0.0779 in.) AW 23978-PPP-J00 2.01 mm (0.0791 in.) AX 23979-PPP-J00 2.04 mm (0.0803 in.) AY 23980-PPP-J00 2.07 mm (0.0815 in.) AZ 23981-PPP-J00 2.10 mm (0.0827 in.) BA 23982-PPP-J00 2.13 mm (0.0839 in.) BB 23983-PPP-J00 2.16 mm (0.0850 in.) BC 23984-PPP-J00 2.19 mm (0.0862 in.) BD 23985-PPP-J00 2.22 mm (0.0874 in.) BE 23986-PPP-J00 2.25 mm (0.0886 in.)

Transmission Reassembly

Note. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. 6-speed model is shown, 5-speed model is similar.

Scheme 183

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Scheme 186

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Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

1. Install the magnet (A) and the differential assembly (B).
2. Install the 28 mm spring washer (A) and the 28 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer.
3. Apply tape to the mainshaft splines (D) to protect the seal. Install the mainshaft and the countershaft (E) into the shift forks (F), and install them as an assembly.
4. Install the reverse shift fork.
5. Install the reverse idler gear (A) and the reverse gear shaft (B) by aligning the mark (C) with the reverse gear shaft hole (D).
6. 5-speed model: Install the reverse lock cam.
7. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see «MAINSHAFT THRUST CLEARANCE ADJUSTMENT»(/acura/rsx/i-2001-2004/remont/manual-trans/#manual-transmission__mainshaft-thrust-clearance-adjustment) ). Install the oil gutter plate (B), the oil guide plate M, and the 72 mm shim into the transmission housing (C).
8. Remove any dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent leakage. NOTE: Do not assemble the housings if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
9. Install the 14 x 20 mm dowel pins (A).
10. Set the tapered cone ring (B) as shown (5-speed model). Place the transmission housing over the clutch housing, being careful to line up the shafts.
11. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.
12. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing. Dimension $1 as installed: 3.3-6.0 mm (0.13-0.24 in.)
13. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the 32 mm sealing cap (D), and install it on the transmission housing. NOTE: Do not install the 32 mm sealing cap if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
14. Install the harness bracket (A) (6-speed model), the transmission hanger A (B), the transmission hanger B (C), and the 8 mm flange bolts, finger-tight.
15. Tighten the 8 mm flange bolts in a crisscross pattern in several steps. 8 x 1.25 mm 27 N.m (2.8 kg m, 20 lbf.ft)
16. Remove any dirt and oil from the change lever cover sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface. NOTE: Do not install the change lever cover if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
17. Install the 8 x 14 mm dowel pins (A), the change lever assembly (B), and the clutch line clip bracket (C).
18. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the interlock bolt (D), and install it on the transmission housing. NOTE: Do not install the interlock bolt if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
19. 2002-2004 models: Install the drain plug (A), the filler plug (B), and the 10 mm flange bolt (C) with new washers.
20. 2005-2006 models: Install the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), the output shaft (countershaft) speed sensor (D), the plain washer (5-speed model) (E), and the new O-ring (F).
21. Install the detent bolts (A), the springs, and the steel balls with new washers.
22. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the back-up light switch (B), and install it on the transmission housing. NOTE: Do not install the back-up light switch if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
23. 2002-2004 models: Install the vehicle speed sensor (VSS) (A) and the O-ring (B).
24. 2005-2006 models: Install the 20 mm bolt (A) and the new 20 mm washer (B).

Scheme 200

Component Location Index

Note. 6-speed model has reverse lockout system. 5-speed model does not have this system.

Scheme 201

System Description

At a vehicle speed of 12 mph (20 km/h) or more, a signal from the ECM activates the reverse lockout solenoid, which pushes the select lock cam B into the locked position. As a result, the select lever cannot rotate to the reverse select position, making it impossible to engage reverse gear. At a vehicle speed of 9 mph (15 km/h) or less, the signal from the ECM is interrupted, which turns off the reverse lockout solenoid. The select lock return spring pulls back the select lock cam B, enabling the select lever to move freely so the reverse gear can be selected.

VEHICLE SPEED

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

1. Check the No. 4 (10A) fuse in the underdash fuse/relay box. Is the fuse OK? YES - Go to step 2. NO - Replace the fuse, and recheck.
2. Start the engine, and check the Malfunction Indicator Lamp (MIL). Does the MIL come on? YES - Troubleshoot the DTC (see «GENERAL TROUBLESHOOTING INFORMATION»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems) ), and recheck. NO - Go to step 3.
3. Turn the ignition switch OFF.
4. Shift into reverse gear. Can the transmission be shifted Into reverse gear? YES - Go to step 5. NO - Repair the transmission, and recheck.
5. Turn the ignition switch ON (II). With the vehicle moving slowly (vehicle speed below 9 mph (15 km/h)), shift the transmission into reverse gear. Can the transmission be shifted into reverse gear? YES - Go to step 6. NO - Go to step 7 .
6. Raise the front wheels, and block the rear wheels. Run the vehicle to a speed above 12 mph (20 km/h). Can the transmission be shifted into reverse gear? YES - Go to step 7. NO - Intermittent failure, system is OK at this time.
7. Turn the ignition switch OFF.
8. Disconnect the reverse lockout solenoid 2P connector.
9. Turn the ignition switch ON (II).
10. Measure the voltage between the reverse lockout solenoid 2P connector terminal No. 2 and body ground. Is there battery voltage? YES - Go to step 11. NO - Check for loose or poor connections at C101 (20P) connector. If the connections are OK, repair open in the wire between No. 4 (10 A) fuse in the underdash fuse/relay box and the reverse lockout solenoid.
11. Turn the ignition switch OFF.
12. Remove the reverse lockout solenoid (see «REVERSE LOCKOUT SOLENOID TEST»(/acura/rsx/i-2001-2004/remont/manual-trans/#manual-transmission) ).
13. Connect the No. 2 terminal of the reverse lockout solenoid 2P connector to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. Make sure the reverse lockout solenoid operates. Does the reverse lockout solenoid operate properly? YES - Go to step 14. NO - Replace the reverse lockout solenoid.
14. Reinstall the reverse lockout solenoid, and reconnect the solenoid 2P connector.
15. Turn the ignition switch ON (II).
16. Measure the voltage between ECM connector B7 terminal (2002-2004 models) or E2 terminal (2005-2006 models) and body ground. 2002-2004 models: 2005-2006 models: Is there battery voltage? YES - Check for loose connectors at ECM connector B (24P) (2002-2004 models) or E (31P) (2005-2006 models). If necessary, update the ECM if it does not have the latest software, or substitute a known-good ECM (see «HOW TO SUBSTITUTE THE ECM/PCM (2002-2004 MODELS)»(/acura/rsx/i-2001-2004/remont/auxiliary-emission-control-systems/#fuel-system-emissions-systems__how-to-substitute-the-ecmpcm-2002-2004) ), then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM (see «ECM/PCM REPLACEMENT»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#pgm-fi-system) ) NO - Repair open in the wire between the reverse lockout solenoid and the ECM (B7) (2002-2004 models) or ECM (E2) (2005-2006 models).

Scheme 209

1. Remove the reverse lockout solenoid (see «REVERSE LOCKOUT SOLENOID TEST»(/acura/rsx/i-2001-2004/remont/manual-trans/#manual-transmission) ).
2. Connect battery positive terminal to the No. 2 terminal of the reverse lockout solenoid 2P connector, and connect the battery negative terminal to the No. 1 terminal.
3. Make sure the reverse lockout solenoid operates. If the reverse lockout solenoid does not work, replace it.

Scheme 210

Scheme 211

Scheme 212

1. Make sure you have the anti-theft codes for the radio, then write down the customer's radio station presets. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
2. Remove the intake manifold cover (see step 6 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
3. Remove the air cleaner housing (see step 7 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
4. Remove the intake air duct (see step 8 on «ENGINE REMOVAL»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
5. Remove the battery base (see step 5 ).
6. Disconnect the transmission ground cable (see step 6 ).
7. Disconnect the back-up light switch connector, the vehicle speed sensor (VSS) connector, the reverse lockout solenoid connector, and the output shaft speed sensor connector (see step 7 ).
8. Carefully remove the shift cable, select cable, and cable bracket together to avoid bending the cables (see step 8 ).
9. Remove the bolts (A) and reverse lockout solenoid (B).
10. Remove the roller (A), the select lock return spring (C), and the select lock cam B.
11. Install in the reverse order of removal.
12. Remove any dirt and oil from the sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface. NOTE: Do not install reverse locknut solenoid if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.
13. Install the reverse lockout solenoid.
14. Install the cable bracket, select cable, and shift cable (see step 26 ).
15. Connect the back-up light switch connector, the vehicle speed sensor (VSS) connector, the reverse lockout solenoid connector, and the output shaft (countershaft) speed sensor connector (see step 28 ).
16. Connect the transmission ground cable (see step 29 ).
17. Install the battery base (see step 30 ).
18. Install the intake air duct (see step 42 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
19. Install the air cleaner housing (see step 43 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
20. Install the intake manifold cover (see step 45 on «ENGINE INSTALLATION»(/acura/rsx/i-2001-2004/remont/mechanical/#engine-removal-and-installation) ).
21. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them apply grease to prevent corrosion. Connect the positive cable to the battery first, then connect the negative cable.
22. Enter the audio anti-theft codes, then enter the customer's audio station presets, and set the clock.
23. 2002-2004 models: Do the ECM idle learn procedure (see «ECM/PCM IDLE LEARN PROCEDURE»(/acura/rsx/i-2001-2004/remont/testing-diagnostics/#idle-control-system) ).
24. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(/acura/rsx/i-2001-2004/remont/windows/#power-windows__resetting-the-power-window-control-unit) ).

Scheme 213

Scheme 214

Scheme 215

1. Place the differential assembly on V-blocks (A), and install both axles.
2. Measure the backlash of both pinion gears (B) with a dial indicator (C). If the backlash is not within the standard, replace the differential carrier. Standard (New): 0.05-0.15 mm (0.002-0.006 in.)

Scheme 216

1. Remove the bolts (left-hand threads) in a crisscross pattern in several steps, then remove the final driven gear (A) from the differential carrier (B).
2. Install the final driven gear with the chamfer on the inside diameter facing the carrier. Tighten the bolts in a crisscross pattern in several steps.

Carrier Bearing Replacement

Special Tools Required

Driver, 40 mm I.D. 07746-0030100

Scheme 217

Scheme 218

1. Check the carrier bearings for wear and rough rotation. If they rotate smoothly and their rollers show no signs of wear, the bearings are OK.
2. Remove the carrier bearing (A) with a commercially-available bearing puller (B).
3. Install the new bearings (A) with the special tool and a press. Press on each bearing until it bottoms. There should be no clearance between the bearings and the carrier. NOTE: Place the seal part of the bearing (B) towards the outside of the differential, then install it.

Oil Seal Replacement

Special Tools Required

1. Driver 07749-0010000
2. Oil seal driver attachment 07NAD-P20A100

Scheme 219

Scheme 220

Scheme 221

Scheme 222

1. Remove the differential assembly.
2. Remove the oil seal (A) from the transmission housing (B).
3. Remove the oil seal (A) from the clutch housing (B).
4. Install the new oil seal in the transmission housing with the special tools.
5. Install the new oil seal in the clutch housing with the special tools.

Differential Thrust Clearance Adjustment

Special Tools Required

Driver, 40 mm I.D. 07746-0030100

Scheme 223

Scheme 224

Scheme 225

Scheme 226

1. If you removed the 80 mm shim from the transmission housing, reinstall the same sized shim.
2. Install the differential assembly into the clutch housing.
3. Install the transmission housing onto the clutch housing, then tighten the 8 mm flange bolts in a crisscross pattern in several steps (see step 15 ). 8 x 1.25 mm 27 N.m (2.8 kgf.m, 20 lbf.ft)
4. Use the special tool to bottom the differential assembly in the clutch housing.
5. Measure the clearance between the 80 mm shim and the bearing outer race in the transmission housing. Standard: 0-0.10 mm (0-0.0039 in.)
6. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 5 is within the standard, go to step 9 . 80 mm Shim THICKNESS Part Number Thickness A 41441-PL3-B00 1.0 mm (0.0394 in.) B 41442-PL3-B00 1.1 mm (0.0433 in.) C 41443-PL3-B00 1.2 mm (0.0472 in.) D 41444-PL3-B00 1.3 mm (0.0512 in.) E 41445-PL3-B00 1.4 mm (0.0551 in.) F 41446-PL3-B00 1.5 mm (0.0591 in.) G 41447-PL3-B00 1.6 mm (0.0630 in.) H 41448-PL3-B00 1.7 mm (0.0669 in.) J 41449-PL3-B00 1.8 mm (0.0709 in.) K 41450-PL3-B00 1.05 mm (0.0413 in.) L 41451-PL3-B00 1.15 mm (0.0453 in.) M 41452-PL3-B00 1.25 mm (0.0492 in.) N 41453-PL3-B00 1.35 mm (0.0531 in.) P 41454-PL3-B00 1.45 mm (0.0571 in.) Q 41455-PL3-B00 1.55 mm (0.0610 in.) R 41456-PL3-B00 1.65 mm (0.0650 in.) S 41457-PL3-B00 1.75 mm (0.0689 in.)
7. Remove the bolts and the transmission housing.
8. Replace the thrust shim selected in step 6 , then recheck the clearance.
9. Reinstall the transmission.

See also:
• PASSENGER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION
• ENGINE REMOVAL
• DRIVESHAFT REMOVAL
• WHEEL ALIGNMENT
• ECM/PCM IDLE LEARN PROCEDURE
• RESETTING THE POWER WINDOW CONTROL UNIT
• GENERAL TROUBLESHOOTING INFORMATION
• HOW TO SUBSTITUTE THE ECM/PCM (2002-2004 MODELS)
• ECM/PCM REPLACEMENT
• TRANSMISSION FLUID INSPECTION AND REPLACEMENT
• MAINSHAFT THRUST CLEARANCE ADJUSTMENT