Manual Transmission Acura TL III

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How to Troubleshoot Circuits at the ECM

Special Tools Required

1. Digital multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter
2. Backprobe set 07SAZ-001000A (2)

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1. Gently slide the sharp tester probe (A) into the connector from the wire side until it touches the end of the wire terminal.
2. 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.
3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections.

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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 and select lock pin into the locked position. As a result, the interlock 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 return spring pulls back the select lock pin, enabling the interlock to move freely so reverse gear can be selected.

VEHICLE SPEED SPECIFICATION TABLE

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1. Check the No. 18 (15A) fuse in the under-dash 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/tl/iii-2003-2006/remont/auxiliary-emission-control-systems/#fuel-and-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 16.
6. Raise the front of the vehicle, or raise the vehicle on a lift. Make sure it is securely supported and the front wheels turn freely.
7. Start the engine, disable the VSA by pressing the VSA OFF switch, run the engine so the speedometer reads above 12 mph (20 km/h). Can the transmission be shifted into reverse gear? YES - Go to step 8. NO - Intermittent failure, system is OK at this time.
8. Turn the ignition switch OFF.
9. Disconnect the reverse lockout solenoid 2P connector.
10. Turn the ignition switch ON (II).
11. 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. If the connections are OK, repair open in the wire between the No. 18 (15A) fuse in the under-dash fuse/relay box and the reverse lockout solenoid.
12. Turn the ignition switch OFF.
13. Remove the reverse lockout solenoid (see «REVERSE LOCKOUT SOLENOID DISASSEMBLY/REASSEMBLY»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__reverse-lockout-solenoid-disassemblyreassembly) ).
14. Connect the reverse lockout solenoid 2P connector terminal No. 2 to the battery positive terminal, and connect the No. 1 terminal to the battery negative terminal. Check that the reverse lockout solenoid operates. Does the reverse lockout solenoid operate properly? YES - Go to step 15. NO - Replace the reverse lockout solenoid.
15. Reinstall the reverse lockout solenoid, and reconnect the solenoid 2P connector.
16. Turn the ignition switch ON (II).
17. Measure the voltage between ECM connector A22 (2004-2005 models) or E22 (2006 model) and body ground. 2004-2005 models: 2006 model: Is there battery voltage? YES - Check for loose connectors at ECM connector A (31P) (2004-2005 models) or ECM connector E (31P) (2006 model). If necessary, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck (see «HOW TO TROUBLESHOOT CIRCUITS AT THE ECM/PCM»(/acura/tl/iii-2003-2006/remont/auxiliary-emission-control-systems/#fuel-and-emissions-systems__how-to-troubleshoot-circuits-at-the) ). If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Repair open in the wire between reverse lockout solenoid and the ECM (A22) (2004-2005 models) or ECM (E22) (2006 model).

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1. Remove the reverse lockout solenoid (see «REVERSE LOCKOUT SOLENOID DISASSEMBLY/REASSEMBLY»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__reverse-lockout-solenoid-disassemblyreassembly) ).
2. Connect the battery positive terminal to the reverse lockout solenoid 2P connector No. 2 terminal, and connect the battery negative terminal to the No. 1 terminal.
3. Check that the reverse lockout solenoid operates.
4. If the reverse lockout solenoid does not work, replace it.

Reverse Lockout Solenoid Disassembly/Reassembly

Note. Use fender covers to avoid damaging painted surfaces.

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1. Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
2. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the audio presets. Make sure the ignition switch is OFF. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
3. Remove the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
4. Remove the battery base.
5. Carefully remove the shift cable, select cable, and cable bracket together to avoid bending the cables (see step 17 ).
6. Disconnect the reverse lockout solenoid connector.
7. Remove the bolts (A), transmission harness bracket (B), and reverse lockout solenoid assembly (C).
8. Remove the roller (A) and select lock cam (B).
9. Install in the reverse order of removal.
10. Remove the 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 the components 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.
11. Install the reverse lockout solenoid assembly (A) and transmission harness bracket (B).
12. Connect the reverse lockout solenoid connector.
13. Install the cable bracket, select cable, and shift cable (see step 36 ).
14. Install the battery base.
15. Install the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
16. Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion.
17. Install the left rear engine compartment cover and the left side engine compartment cover.
18. Enter the radio and navigation system anti-theft codes, then enter the audio presets, and set the clock.

Transmission Fluid Inspection and Replacement

Note. Use fender covers to avoid damaging painted surfaces.

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1. Park the vehicle on level ground, and turn the ignition switch OFF.
2. Remove the engine under cover (see step 29 ).
3. Remove the oil check bolt (A) and washer (B). Check the condition of the fluid and make sure it is at the proper level (C). If the fluid is dirty, remove the drain plug (D) and washer (E).
4. Install the oil check bolt with a new washer.
5. Install the drain plug with a new washer.
6. Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
7. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the audio presets. Make sure the ignition switch is OFF. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
8. Remove the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
9. Remove the battery base.
10. Remove the oil filler plug (A) and washer (B).
11. Refill the fluid from the oil filler plug hole of the transmission, and until the transmission fluid overflows from the oil check bolt hole (A).
12. After the fluid stops overflowing, install the oil check bolt (B) with a new washer (C). Fluid capacity 2.2 L (2.3 US qt) at fluid change 2.5 L (2.6 US qt) at overhaul Use only Acura Manual Transmission Fluid (MTF). Using engine oil can cause stiffer shifting because it does not contain the proper additives.
13. Install the oil filler plug (A) with a new washer (B).
14. Install the battery base.
15. Install the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
16. Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion.
17. Install the left rear engine compartment cover and the left side engine compartment cover.
18. Enter the radio and navigation system anti-theft codes, then enter the audio presets, and set the clock.

Back-up Light Switch Test

Note. Use fender covers to avoid damaging painted surfaces.

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1. Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
2. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the audio presets. Make sure the ignition switch is OFF. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
3. Remove the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
4. Remove the battery base.
5. Disconnect the back-up light switch (A) 2P connector.
6. 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.
7. 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 it on the transmission housing. Tighten the back-up light switch to the specified torque. NOTE: Do not install the components 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.
8. Install the battery base.
9. Install the air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
10. Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion.
11. Install the left rear engine compartment cover and the left side engine compartment cover.
12. Enter the radio and navigation system anti-theft codes, then enter the audio presets, and set the clock.

Transmission Removal

Special Tools Required

1. Engine support hanger, A and Reds AAR-T-12566
2. Engine hanger balance bar VSB02C000019
3. Front subframe adapter VSB02C000016 (Available through the Acura Tool and Equipment Program 1-888-424-6857)

Note. Use fender covers to avoid damaging painted surfaces.

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1. Set the wheels in the straight ahead position.
2. Lock the steering wheel.
3. Disconnect the support struts from both sides of the pivot ball (bolted to the hood). Secure the hood (A) in a vertical position. Remove the right side pivot ball, and install it into the lower threaded hole (B), then reattach the support strut. NOTE: Do not attempt to close the hood with the support strut in the vertical position; it will damage the support strut and hood.
4. Remove the left rear engine compartment cover (A) and the left side engine compartment cover (B).
5. Remove the right side engine compartment cover (A) and the right rear engine compartment cover (B).
6. Remove the intake manifold cover (A) and the bulkhead cover (B).
7. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the audio presets. Make sure the ignition switch is OFF. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the battery.
8. Remove the air cleaner housing and resonator chamber (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
9. Remove the battery base.
10. Remove the under-hood fuse/relay box.
11. Remove the strut brace.
12. Disconnect the back-up light switch connector (A) and reverse lockout solenoid connector (B), then remove the harness clips (C).
13. Disconnect the input shaft (mainshaft) speed sensor connector (A) and output shaft (countershaft) speed sensor connector (B).
14. Remove the harness clips (A), then disconnect the vacuum hose (B).
15. Disconnect the starter cable (A), then remove the starter motor (B).
16. Remove the harness bracket.
17. 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.
18. Disconnect the vacuum hose (C).
19. Carefully remove the slave cylinder without bending the clutch line. Do not press the clutch pedal once the slave cylinder has been removed.
20. Remove the front engine mount mounting nuts (A), front engine mount stop (B), and the front engine mount mounting bolt (C).
21. Remove the transmission upper mounting bolts.
22. Remove and plug the return hose (A) from the power steering fluid reservoir (B). Wipe off any spilled fluid at once.
23. Remove the power steering pump outlet line (C) from the power steering pump (D), and remove the hose (E) from its clamp (F).
24. Lift and support the engine with the engine support hanger (A) and the engine hanger balance bar (B). Attach the front arm (C) to the front cylinder head with a spacer (D) and the 10 x 1.25 mm bolt (E). Attach the rear arm (F) to the rear cylinder head with the 8 x 1.25 mm bolt (G).
25. Remove the steering joint cover (A).
26. Make a reference mark (B) across the steering joint and steering gearbox pinion shaft (C). Remove the steering joint bolt (D), and disconnect the steering joint (E) by removing the steering joint toward the steering column. Hold the slider shaft (F) on the column with a piece of wire (G) between the joint yoke (H) on the slider shaft to the joint yoke on the upper shaft (see step 8 on «STEERING COLUMN REMOVAL AND INSTALLATION»(/acura/tl/iii-2003-2006/remont/manual-power-steering/#power-steering-system__steering-column-removal-and-installation) ).
27. Remove the transmission mount bracket (A) and ground cable (B).
28. Raise the vehicle, and make sure it is securely supported.
29. Remove the engine under cover.
30. Drain the transmission fluid. Reinstall the drain plug using a new washer (see «TRANSMISSION FLUID INSPECTION AND REPLACEMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__transmission-fluid-inspection-and-replacement) ).
31. Remove the splash shield.
32. Remove exhaust pipe A.
33. Separate the front stabilizer link (see step 3 on «STABILIZER LINK REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
34. Remove the damper fork (see step 5 on «REMOVAL»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension__removal) ).
35. Separate the knuckle from the lower arm (see step 13 on «KNUCKLE/HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
36. Separate the tie-rod ball joint (see step 11 on «KNUCKLE/HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
37. Remove the left and right driveshaft inboard joints (see step 11 on «DRIVESHAFT REMOVAL»(/acura/tl/iii-2003-2006/remont/axle-shafts/#drivelineaxle) ).
38. Remove the intermediate shaft (see «INTERMEDIATE SHAFT REMOVAL»(/acura/tl/iii-2003-2006/remont/axle-shafts/#drivelineaxle) ).
39. Remove the rear engine mount base bracket bolts.
40. Disconnect the power steering pressure switch connector.
41. Remove the transmission lower mount mounting nuts.
42. Remove the subframe middle mounting bolts.
43. Make the appropriate reference lines (A) at both ends of the subframe (B) that line up with the edge (C) of the stiffeners (D).
44. Support the front suspension subframe with the front subframe adapter and a jack.
45. Remove the front suspension subframe stays (A) and front suspension subframe (B).
46. Remove the front engine mount upper bracket.
47. Remove the transmission lower front mount (A) and the transmission lower rear mount (B).
48. Remove the clutch cover.
49. Place the transmission jack under the transmission, and remove the transmission lower mounting bolts.
50. Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate, then lower the transmission on the transmission jack.
51. Remove the boot (A), release fork (B), and release bearing (C) from the transmission.

Transmission Installation

Special Tools Required

1. Engine support hanger, A and Reds AAR-T-12566
2. Engine hanger balance bar VSB02C000019
3. Front subframe adapter VSB02C000016 (Available through the Acura Tool and Equipment Program 1-888-424-6857

Note. Use fender covers to avoid damaging painted surfaces.

SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ), and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before performing repair or service.

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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. Place the transmission on the transmission jack, and raise it to the engine level.
4. Install the transmission lower mounting bolts.
5. Install the clutch cover.
6. Install the front engine mount upper bracket.
7. Support the front suspension subframe with the front subframe adapter and a jack.
8. Loosely install the front suspension subframe (A) and front suspension subframe stiffeners (B).
9. Align the reference lines (A) with edge (B) of both rear stiffeners (C), and tighten the rear subframe mounting bolts, then the front bolts, and tighten the stiffener bolts to the specified torque.
10. Install the subframe middle mounting bolts.
11. Install the transmission lower front mount (A) and the transmission lower rear mount (B).
12. Install the transmission lower mount mounting nuts.
13. Install the rear engine lower mount mounting bolts.
14. Connect the power steering pressure switch connector.
15. Install the intermediate shaft (see «INTERMEDIATE SHAFT INSTALLATION»(/acura/tl/iii-2003-2006/remont/axle-shafts/#drivelineaxle) ).
16. Install the left and right driveshaft inboard joints (see «DRIVESHAFT INSTALLATION»(/acura/tl/iii-2003-2006/remont/axle-shafts/#drivelineaxle) ).
17. Install the tie-rod ball joint (see step 18 on «WHEEL BEARING REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
18. Install the knuckle onto the lower arm (see step 18 on «WHEEL BEARING REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
19. Install the damper fork (see step 2 on «INSTALLATION»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
20. Connect the front stabilizer link (see step 4 on «STABILIZER LINK REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).
21. Install exhaust pipe A and the new gaskets (B).
22. Install the splash shield.
23. Install the engine under cover.
24. Lower the vehicle.
25. Install the transmission mount bracket (A) and ground cable (B).
26. Remove the engine support hanger and special tools from the engine.
27. Unlock the steering wheel.
28. Connect the steering joint to the steering gearbox pinion shaft (A) by aligning the reference mark (B), and remove the wire (C) from the joint yoke (D).
29. Install the steering joint cover (E).
30. Install the power steering pump outlet line (A) with a new O-ring (B) to the pump (C), and install the hose (D) in its clamp (E).
31. Connect the return hose (F) to the power steering fluid reservoir (G), then secure the hose with its clamp (H).
32. Install the transmission upper mounting bolts.
33. Install the front engine mount mounting bolt (A), the front engine mount stop (B), and mounting nuts (C).
34. Apply super high temp area grease (P/N 08798-9002) to the end of the pushrod. Install the slave cylinder. Be careful not to bend the clutch line.
35. Connect the vacuum hose (A).
36. Install the cable bracket (B) and cables (C).
37. Apply a light coat of super high temp area grease (P/N 08798-9002) or silicone grease (P/N 08C30-B0234M) to the cable ends, then install new cotter pins (D).
38. Install the harness bracket.
39. Install the starter motor (A), then connect the starter cable (B).
40. Connect the vacuum hose (A), then install the harness clips (B).
41. Connect the input shaft (mainshaft) speed sensor connector (A) and output shaft (countershaft) speed sensor connector (B).
42. Connect the back-up light switch connector (A) and reverse lockout solenoid connector (B), then install the harness clips (C).
43. Install the strut brace.
44. Install the under-hood fuse/relay box.
45. Refill the transmission fluid (see «TRANSMISSION FLUID INSPECTION AND REPLACEMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__transmission-fluid-inspection-and-replacement) ).
46. Install the battery base.
47. Install the resonator chamber and air cleaner housing (see «AIR CLEANER REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/testing-diagnostics/#intake-air-system) ).
48. Install the battery. Clean the battery posts and cable terminals with sandpaper. Connect the positive cable to the battery first, then connect the negative cable, and apply grease to prevent corrosion.
49. Install the bulkhead cover (A) and the intake manifold cover (B).
50. Install the right rear engine compartment cover (A) and the right side engine compartment cover (B).
51. Install the left side engine compartment cover (A) and the left rear engine compartment cover (B).
52. Reinstall the hood support struts to the proper locations on both sides of the hood.
53. Remove the steering wheel (see «STEERING WHEEL REMOVAL»(/acura/tl/iii-2003-2006/remont/manual-power-steering/#power-steering-system__steering-wheel-removal) ).
54. Center the cable reel, and reinstall the steering wheel (see «STEERING WHEEL REMOVAL»(/acura/tl/iii-2003-2006/remont/manual-power-steering/#power-steering-system__steering-wheel-removal) ).
55. Start the engine, then turn the steering wheel from lock-to-lock several times to bleed air from the system.
56. Recheck the fluid level, and refill if necessary.
57. Check the front wheel alignment (see «WHEEL ALIGNMENT»(/acura/tl/iii-2003-2006/remont/wheel-alignment/#front-suspension-and-rear-suspension__wheel-alignment) ).
58. Check the shift lever and clutch operation.
59. Test-drive the vehicle.
60. Enter the radio and navigation system anti-theft codes, then enter the audio presets, and set the clock.

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Note. Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

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1. Remove the strainer cover (A), O-ring (B), strainer set spring (C), and oil pump strainer (D).
2. Remove the transmission harness bracket (A), reverse lockout solenoid (B), and back-up light switch (C).
3. Remove the set screws (A), 22.0 mm spring (B), 26.1 mm spring (C), 27.4 mm springs (D), steel balls (E), oil filler plug (F), washer (G), and clutch line bracket (H).
4. Remove the set screws (A), 22.0 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and O-rings (G).
5. Remove the oil check bolt (A), 6 mm washer (B), drain plug (C), and 14 mm washer (D).
6. Remove the transmission hanger (A), transmission hanger (B), and 8 mm flange bolt (C). Remove the 10 mm flange bolts in a crisscross pattern in several steps.
7. Remove the transmission case cap (A) and 37.7 mm O-ring (B).
8. Expand the 75 mm snap ring (C) on the countershaft ball bearing, and remove it from the groove with snap ring pliers.
9. Remove the transmission housing (D) and 14 x 20 mm dowel pins (E).
10. Remove the oil guide pipe (A), oil guide pipe (B), and magnet (C).
11. Remove the pin (A) and reverse shift lever (B).
12. Remove the 20 mm thrust washers (A), 20 mm thrust needle bearings (B), reverse idler gear shaft assembly (C), 33 mm spring washer (D), and reverse shift fork (E) as an assembly.
13. Remove the pin (A), select return spring (B), shift piece shaft (C), shift piece (D) and interlock (E).
14. Remove the 5 mm spring pin, 3 mm spring pin (A), select arm (B), 14 x 20 x 5 mm dust seal (C), and select lever (D).
15. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).
16. Remove the 64 mm spring washer (E).
17. Remove the oil pump shaft (A) and differential assembly (B).
18. Remove the oil pump plate (A), oil pump inner rotor (B), oil pump outer rotor (C), relief valve spring (D), and steel ball (E).
19. Remove the 82 mm shim (A) from the transmission housing (B).
20. Remove the 8 mm special bolt (A), 8 mm spring washer (B), shift arm (C), change lever (D), and 16 x 23 x 5 mm dust seal (E).

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1. Measure the clearance between the reverse shift lever (A) and reverse shift fork (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2. Standard: 0.05-0.50 mm (0.002-0.020 in.) Service Limit: 0.6 mm (0.024 in.)
2. Measure the width of the reverse shift lever. If the width is not within the standard, replace the reverse shift lever. If the width is within the standard, replace the reverse shift fork. Standard: 6.400-6.650 mm (0.2520-0.2618 in.)
3. Measure the clearance between the reverse shift lever (A) and reverse shift piece (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 4. Standard: 0-0.4 mm (0-0.015 in.) Service Limit: 0.5 mm (0.020 in.)
4. Measure the width of the reverse shift lever. If the width is not within the standard, replace the reverse shift lever. If the width is within the standard, replace the reverse shift piece. Standard: 13.0-13.2 mm (0.51-0.52 in.)

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1. Measure the clearance between the select arm (A) and interlock (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: 0.5 mm (0.020 in.)
2. Measure the width of the select arm. If the width is not within the standard, replace the select arm. If the width is within the standard, replace the interlock. Standard: 12.9-13.0 mm (0.50-0.51 in.)

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1. Measure the clearance between the shift arm (A) and shift piece (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 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 piece. Standard: 13.9-14.0 mm (0.54-0.55 in.)

Scheme 121

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Scheme 123

1. Measure the thrust clearance between the oil pump gears (A) and clutch housing (B) with a straight edge (C) and a feeler gauge (D). Standard (new): 0.03-0.13 mm (0.001-0.005 in.) Service Limit: 0.15 mm (0.006 in.)
2. Measure the side clearance between the outer rotor (A) and clutch housing (B) with a feeler gauge (C). Standard (new): 0.1-0.2 mm (0.004-0.008 in.) Service Limit: 0.22 mm (0.009 in.)
3. Measure the side clearance between the outer rotor (A) and inner rotor (B) with a feeler gauge (C). Standard (new): below 0.14 mm (0.006 in.) Service Limit: 0.2 mm (0.008 in.)
4. If clearance is not within the standard, replace the oil pump outer and inner rotors.

Shift Fork Clearance Inspection

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

Scheme 124

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Scheme 128

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.) 1st/2nd, 3rd/4th, 5th/6th: Reverse
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. Standard: 1st/2nd, 3rd/4th, 5th/6th: 7.4-7.6 mm (0.29-0.30 in.) Reverse: 6.2-6.4 mm (0.24-0.25 in.)
3. Measure the clearance between each shift fork (A) and shift piece (B). If the clearance exceeds the service limit, go to step 4. Standard: 0.2-0.6 mm (0.008-0.024 in.) Service Limit: 0.7 mm (0.028 in.)
4. Measure the width of the shift piece. If the width is not within the standard, replace the shift piece. If the width is within the standard, replace the shift fork. Standard: 12.8-13.0 mm (0.50-0.51 in.)

Shift Fork Disassembly/Reassembly

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

Scheme 129

Mainshaft Assembly Clearance Inspection

Note. If replacement is required, always replace the synchro sleeve and hub as a set.

Scheme 130

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Scheme 140

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 gear (C) and 3rd gear (D) 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: 0.06-0.19 mm (0.002-0.007 in.) Service Limit: 0.3 mm (0.01 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 and sleeve. Standard: 23.89-23.97 mm (0.941-0.944 in.) Service Limit: 23.8 mm (0.94 in.)
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: 0.06-0.19 mm (0.002-0.007 in.) Service Limit: 0.3 mm (0.01 in.)
5. Measure distance (1) on the 4th gear side 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: 22.53-22.58 mm (0.887-0.889 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 and sleeve. Standard: 22.39-22.47 mm (0.881-0.885 in.) Service Limit: 22.3 mm (0.88 in.)
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: 0.06-0.19 mm (0.002-0.007 in.) Service Limit: 0.3 mm (0.01 in.)
8. Measure distance (2) on the 5th gear side 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: 22.53-22.58 mm (0.887-0.889 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/6th synchro hub and sleeve. Standard: 22.39-22.47 mm (0.881 --0.885 in.) Service Limit: 22.3 mm (0.88 in.)
10. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 11. Standard: 0.06-0.19 mm (0.002-0.007 in.) Service Limit: 0.3 mm (0.01 in.)
11. Measure the thickness of the distance collar. If the thickness is less than the standard, replace the distance collar. If the thickness is within the standard, go to step 12. Standard: 22.03-22.08 mm (0.867-0.869 in.)
12. 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 and sleeve. Standard: 21.89-21.97 mm (0.862-0.865 in.) Service Limit: 21.8 mm (0.86 in.)

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Scheme 144

1. Support 6th gear (A) on the steel blocks, and press the mainshaft out of the ball bearing (B). Use of a jaw-type puller can damage the gear teeth.
2. Support 5th gear (A) on the steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.
3. Support 3rd gear (A) on the 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.
4. Support the angular ball bearing on the steel blocks, and press out the mainshaft.

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Scheme 146

1. Inspect the oil passage, gear, and bearing surfaces for wear and damage, then measure the mainshaft at points A, B, C, D, E, and F. If any part of the mainshaft is less than the service limit, replace it. Standard: A: Ball bearing surface (transmission housing side): 30.987-31.000 mm (1.2200-1.2205 in.) B: 6th gear distance collar surface: 32.987-33.000 mm (1.2987-1.2992 in.) C: 4th/5th gear distance collar surface: 35.987-36.000 mm (1.4168-1.4173 in.) D: Needle bearing surface: 41.984-42.000 mm (1.6529-1.6535 in.) E: Ball bearing surface (clutch housing side): 28.002-28.015 mm (1.1024-1.1030 in.) F: Pilot bearing surface: 19.967-19.980 mm (0.7861-0.7866 in.) Service Limit: A: 30.93 mm (1.218 in.) B: 32.93 mm (1.296 in.) C: 35.93 mm (1.415 in.) D: 41.93 mm (1.651 in.) E: 27.95 mm (1.100 in.) F: 19.91 mm (0.784 in.)
2. Inspect the runout by supporting both ends of the mainshaft. Then rotate the 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.)

Scheme 147

Special Tools Required

1. Driver, 40 mm I.D. 07746-0030100
2. Driver, 30 mm I.D. 07946-MB00000

Note. Refer to the Exploded View as needed during this procedure.

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1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs.
2. Install the new angular ball bearing (A) using the special tool and a press. Note the direction of installation.
3. Install the needle bearing (A) and 3rd gear (B) on the mainshaft (C).
4. 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 outer synchro ring fingers (B) with the grooves 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).
9. Install the double cone synchro assembly (B) by aligning the outer synchro ring fingers (C) with the grooves in 3rd/4th synchro hub (D).
10. Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes in 4th gear (C).
11. Install the needle bearings, distance collar, 5th gear, synchro ring, and synchro spring.
12. Install the 5th/6th synchro hub (A) by aligning the outer synchro ring fingers (B) with the grooves in 5th/6th synchro hub (C).
13. Install the 5th/6th synchro hub (A) using the special tool.
14. Install the 5th/6th synchro sleeve.
15. Install the synchro spring and synchro ring.
16. Install the distance collar, needle bearing, and 6th gear.
17. Install the new angular ball bearing (A) using the special tool. Note the direction of installation.

Countershaft Assembly Clearance Inspection

Note. Before inspection, make sure the 20 mm special bolt is tightened to the specified torque.

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Scheme 165

1. Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 2. Standard: 0.04-0.17 mm (0.002-0.007 in.) Service Limit: 0.28 mm (0.011 in.)
2. Measure the distance of the countershaft reverse gear. If the distance is less than the standard, replace the countershaft reverse gear. If the distance 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. If the thickness within the service limit, replace the 1st/2nd synchro hub and sleeve. Standard: 22.91-22.99 mm (0.902-0.905 in.) Service Limit: 22.86 mm (0.900 in.)
4. Measure 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: 0.04-0.17 mm (0.002-0.007 in.) Service Limit: 0.28 mm (0.011 in.)
5. Measure the thickness of the distance collar. If the thickness is less than the standard, replace the distance collar. If the thickness is within the standard, go to step 6. Standard: 23.03-23.08 mm (0.907-0.909 in.)
6. 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 and sleeve. Standard: 22.91-22.99 mm (0.902-0.905 in.) Service Limit: 22.86 mm (0.900 in.)

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Scheme 173

1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the 20 mm special bolt (left-hand threads).
3. Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing.
4. Remove the 35 mm shim and 6th gear.
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 4th and 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 2nd and 3rd gear.
7. Remove the distance collar and needle bearing.
8. Remove the triple cone synchro assembly (A) and synchro spring (B).
9. Remove the 1st/2nd synchro sleeve.
10. Remove the 1st/2nd synchro hub (A).
11. Remove the synchro spring (A) and the triple cone synchro assembly (B).
12. Remove 1st gear (A), needle bearing (B), and countershaft reverse gear (C).

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Scheme 175

1. Inspect the oil passage, gear, and bearing surfaces for wear and damage, then measure the countershaft at points A, B, C, and D. If any part of the countershaft is less than the service limit, replace it. Standard: A Ball bearing surface (transmission housing side): 30.002-30.015 mm (1.1812-1.1817 in.) B Distance collar surface: 42.975-42.991 mm (1.6919-1.6926 in.) C Countershaft reverse gear surface: 45.934-45.950 mm (1.8084-1.8091 in.) D Needle bearing surface (clutch housing side): 43.974-43.990 mm (1.7313-1.7319 in.) Service Limit: A: 29.95 mm (1.179 in.) B: 42.92 mm (1.690 in.) C: 45.88 mm (1.806 in.) D: 43.92 mm (1.729 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 176

Special Tools Required

1. Driver, 56 x 62 mm 070AD-PYZA100
2. Driver, 40 mm I.D. 07746-0030100

Note. Refer to the Exploded View as needed during this procedure.

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1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the countershaft reverse gear (A), needle bearing (B), and 1st gear (C) onto the countershaft (D).
3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 1st gear (C), then install the synchro spring (D).
4. Install the 1st/2nd synchro hub (A) by aligning the outer synchro ring fingers (B) with the grooves in the 1st/2nd synchro hub (C).
5. Install the 1st/2nd synchro sleeve.
6. Install the synchro spring (A).
7. Install the triple cone synchro assembly (B) by aligning the outer synchro ring fingers (C) with the grooves in the 1st/2nd synchro hub (D).
8. Install the distance collar and needle bearing.
9. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).
10. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the special tool and a press (C).
11. Install 4th gear (A) using the special tool and a press (B).
12. Install 5th gear (A) using the special tool and a press (B).
13. Install 6th gear (A) using the special tool and a press (B).
14. Install the 35 mm shim (A) and the old ball bearing (B) using the special tool and a press (C).
15. 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.)
16. If the clearance is more than the standard, select a new shim from the following table. 35 mm Shim 35 MM SHIM - SPECIFICATION TABLE Part Number Thickness A 23981-PPP-000 0.87 mm (0.034 in.) AA 23981-PPP-900 0.91 mm (0.036 in.) B 23982-PPP-000 0.95 mm (0.037 in.) AB 23982-PPP-900 0.99 mm (0.039 in.) C 23983-PPP-000 1.03 mm (0.041 in.) AC 23983-PPP-900 1.07 mm (0.042 in.) D 23984-PPP-000 1.11 mm (0.044 in.) AD 23984-PPP-900 1.15 mm (0.045 in.) E 23985-PPP-000 1.19 mm (0.047 in.) AE 23985-PPP-900 1.23 mm (0.048 in.) F 23986-PPP-000 1.27 mm (0.050 in.) AF 23986-PPP-900 1.31 mm (0.052 in.) G 23987-PPP-000 1.35 mm (0.053 in.) AG 23987-PPP-900 1.39 mm (0.055 in.) H 23988-PPP-000 1.43 mm (0.056 in.) AH 23988-PPP-900 1.47 mm (0.058 in.) J 23989-PPP-000 1.51 mm (0.059 in.) AJ 23989-PPP-900 1.55 mm (0.061 in.) K 23990-PPP-000 1.59 mm (0.063 in.) AK 23990-PPP-900 1.63 mm (0.064 in.) L 23991-PPP-000 1.67 mm (0.066 in.) AL 23991-PPP-900 1.71 mm (0.067 in.) M 23992-PPP-000 1.75 mm (0.069 in.) AM 23992-PPP-900 1.79 mm (0.070 in.) N 23993-PPP-000 1.83 mm (0.072 in.) AN 23993-PPP-900 1.87 mm (0.074 in.) P 23994-PPP-000 1.91 mm (0.075 in.) AP 23994-PPP-900 1.95 mm (0.077 in.) Q 23995-PPP-000 1.99 mm (0.078 in.)
17. Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the old ball bearing.
18. If a new 35 mm shim was selected in step 16, install the shim, and recheck the clearance.
19. Install 6th gear (A) using the special tool and a press (B).
20. Install the 35 mm shim (A) and new bearing (B) using the special tool and a press (C).
21. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
22. Tighten the new 20 mm special bolt (B) (left-hand threads).

Reverse Idler Gear Shaft Assembly Disassembly/Reassembly

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

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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 synchro hub slots (E) because it will damage the spring ring. NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set.

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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 hub (E) with transmission fluid, and place its synchro ring on it. Rotate the synchro ring, making sure that 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 synchro cone. Synchro Ring-to-Gear Clearance Standard: 5th gear: 0.70-1.49 mm (0.028-0.059 in.) 6th gear: 0.73-1.44 mm (0.029-0.057 in.) Service Limit: 0.4 mm (0.016 in.) Double Cone Synchro-to-Gear Clearance Standard: (1): Outer Synchro Ring (B) to Synchro Cone (C) 0.70-1.19 mm (0.028-0.047 in.) (2): Synchro Cone (C) to Gear (A) 0.50-1.04 mm (0.020-0.041 in.) (3): Outer Synchro Ring (B) to Gear (A) 0.95-1.68 mm (0.037-0.066 in.) Service Limit: (1): 0.3 mm (0.012 in.) (2): 0.3 mm (0.012 in.) (3): 0.6 mm (0.024 in.) Triple Cone Synchro-to-Gear Clearance Standard: (1): Outer Synchro Ring (B) to Synchro Cone (C) 1st gear: 0.70-1.19 mm (0.028-0.047 in.) 2nd gear: 0.70-1.19 mm (0.028-0.047 in.) (2): Synchro Cone (C) to Gear (A) 1st gear: 0.45-1.14 mm (0.018-0.045 in.) 2nd gear: 0.60-1.88 mm (0.024-0.074 in.) (3): Outer Synchro Ring (B) to Gear (A) 1st gear: 1.12-1.68 mm (0.044-0.066 in.) 2nd gear: 0.87-1.82 mm (0.034-0.072 in.) Service Limit: (1): 0.3 mm (0.012 in.) (2): 0.3 mm (0.012 in.) (3): 0.6 mm (0.024 in.)

Mainshaft Oil Seal Replacement

Special Tools Required

1. Attachment, 42 x 47 mm 07746-0010300
2. Driver 07749-0010000

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1. Remove the mainshaft assembly.
2. Remove the oil seal from the clutch housing. Be careful when removing the seal so the clutch housing is not damaged.
3. Drive in the new oil seal from the transmission side using the special tools.

Countershaft Bearing Replacement

Special Tools Required

1. Adjustable bearing puller, 45-75 mm 07YAC-0010100
2. Attachment, 72 x 75 mm 07746-0010600
3. Driver 07749-0010000
4. Slide hammer, commercially available

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1. Remove the bearing set plate (A) from the clutch housing (B).
2. Remove the needle bearing (A) from the clutch housing (B) using the special tool and a commercially available 3/8"--16 slide hammer (C).
3. Install the new needle bearing (A) using the special tools.
4. Install the bearing set plate (A) with bolts (B).

Mainshaft Thrust Clearance Adjustment

Special Tools Required

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

Note. Carry out the measurement at normal room temperature. Clean all the parts thoroughly before installation.

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1. Remove the 82 mm shim (A) from the transmission housing (B).
2. Install the ball bearing (A), 3rd/4th synchro hub (B), 4th/5th gear distance collar (C), 5th/6th synchro hub (D), distance collar (E), and angular ball bearing (F) on the mainshaft (G), then install the assembled mainshaft in the transmission housing (H). NOTE: The angular ball bearing is directional. If installed the wrong way, the measurements will not be accurate.
3. Measure distance (1) between the end of the transmission housing and ball bearing with a straight edge and depth gauge. Measure at three locations, and average the reading.
4. Measure distance (2) the depth of the clutch housing with a straight edge and depth gauge. Measure at three locations, and average the reading. Shim Selection Formula
5. Select the proper 82 mm shim from the chart. Follow the example below, and use the measurements you made in steps 3 and 4. (Basic Formula) (2) - (1)- (0.85 + 0.14)= shim thickness (maximum) (2) - (1) -(0.85 + 0.21)= shim thickness (minimum) Subtract distance (2) (step 4) from distance (1) (step 3). 0.85 mm (0.033 in.): Spring washer, a dimension in the installation. 0.14 mm (0.006 in.): Minimum thrust clearance. 0.21 mm (0.008 in.): Maximum thrust clearance. (For example) 21.04 - 17.97 - (0.85 + 0.14) = 2.08 mm (0.082 in.) 21.04 - 17.97 - (0.85 + 0.21) = 2.01 mm (0.079 in.) Take the middle value 2.04 mm (0.080 in.) of the minimum value and the maximum value, and select the 0.93 mm (0.037 in.) and 1.11 mm (0.044 in.) shims. NOTE: Enable to select the two sizes of 82 mm shim. 82 mm Shim 82 MM SHIM - SPECIFICATION TABLE Part Number Thickness A 23931-PR8-F00 0.60 mm (0.024 in.) B 23932-PR8-F00 0.63 mm (0.025 in.) C 23933-PR8-F00 0.66 mm (0.026 in.) D 23934-PR8-F00 0.69 mm (0.027 in.) E 23935-PR8-F00 0.72 mm (0.028 in.) F 23936-PR8-F00 0.75 mm (0.030 in.) G 23937-PR8-F00 0.78 mm (0.031 in.) H 23938-PR8-F00 0.81 mm (0.032 in.) I 23939-PR8-F00 0.84 mm (0.033 in.) J 23940-PR8-F00 0.87 mm (0.034 in.) K 23941-PR8-F00 0.90 mm (0.035 in.) L 23942-PR8-F00 0.93 mm (0.037 in.) M 23943-PR8-F00 0.96 mm (0.038 in.) N 23944-PR8-F00 0.99 mm (0.039 in.) O 23945-PR8-F00 1.02 mm (0.040 in.) P 23946-PR8-F00 1.05 mm (0.041 in.) Q 23947-PR8-F00 1.08 mm (0.043 in.) R 23948-PR8-F00 1.11 mm (0.044 in.) S 23949-PR8-F00 1.14 mm (0.045 in.) T 23950-PR8-F00 1.17 mm (0.046 in.) U 23951-PR8-F00 1.20 mm (0.047 in.) V 23952-RAT-000 1.23 mm (0.048 in.) W 23953-RAT-000 1.26 mm (0.050 in.) X 23954-RAT-000 1.29 mm (0.051 in.) Y 23955-RAT-000 1.32 mm (0.052 in.) Z 23956-RAT-000 1.35 mm (0.053 in.) AA 23957-RAT-000 1.38 mm (0.054 in.) AB 23958-RAT-000 1.41 mm (0.056 in.) AC 23959-RAT-000 1.44 mm (0.057 in.)
6. Install the selected 82 mm shim (A) in the transmission housing (B).
7. Thoroughly clean the spring washer before installing it on the clutch housing. Note the installation direction of the spring washer (see «EXPLODED VIEW - CLUTCH HOUSING»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission) ).
8. Install the mainshaft in the clutch housing.
9. Place the transmission housing over the mainshaft and onto the clutch housing.
10. Tighten the clutch and transmission housings with several 10 mm bolts. NOTE: It is not necessary to use sealing agent between the housings.
11. Lightly tap on the mainshaft with a plastic hammer.
12. Attach the special tools 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 toward the transmission. Align the mainshaft holder lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
13. Fully seat the mainshaft by tapping on its end with a plastic hammer.
14. Thread in the mainshaft holder bolt until it just contacts the wide surface of the mainshaft base.
15. Zero a dial gauge (A) on the end of the mainshaft.
16. 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 end play. 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.
17. If the reading is within the standard, the clearance is correct. If the reading is not within the standard, recheck the shim thickness. Standard: 0.14-0.21 mm (0.006-0.008 in.)

Transmission Reassembly

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

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Scheme 230

Scheme 231

1. Press the new dust seal (A) into the transmission housing surface, then install the change lever (B), shift arm (C), 8 mm spring washer (D), and 8 mm special bolt (E).
2. Select the proper size 82 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment (see «MAINSHAFT THRUST CLEARANCE ADJUSTMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__mainshaft-thrust-clearance-adjustment) ). Install it into the transmission housing (B).
3. Install the steel ball (A), relief valve spring (B), oil pump outer rotor (C), oil pump inner rotor (D), and oil pump plate (E).
4. Install the differential assembly (A) and oil pump shaft (B).
5. Install the 64 mm spring washer (A). Note the installation direction of the 64 mm spring washer.
6. Apply tape to the mainshaft splines (B) to protect the seal. Install the mainshaft and countershaft (C) into the shift forks (D) as an assembly.
7. Press the new dust seal (A) into the clutch housing surface, then install the select lever (B), select arm (C), new 5 mm spring pin (D), and new 3 mm spring pin (E).
8. Set the select return spring (A), pin (B), and interlock (C) as shown.
9. Install the shift piece (A) and shift piece shaft (B).
10. Install the 33 mm spring washer (A). Note the installation direction of the spring washer.
11. Install the 20 mm thrust needle bearings (B), 20 mm thrust washers (C), reverse idler gear shaft assembly (D), and reverse shift fork (E) as an assembly.
12. Slide the reverse idler gear shaft assembly (A) on the rib (B) of clutch housing, then install it into the hole (C) of the clutch housing.
13. Install the reverse shift lever (A), and pin (B).
14. Install the oil guide pipe (A), oil guide pipe (B), and magnet (C).
15. 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 oil leakage. NOTE: Do not install the components 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.
16. Install the 14 x 20 mm dowel pins (A).
17. Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).
18. Lower the transmission housing the rest of the way as you expand the 75 mm snap ring (E). Release the snap ring so it seats in the groove of the countershaft bearing.
19. Make sure the 75 mm snap ring is securely seated in the groove of the countershaft bearing. Dimension (1) as installed: 9.91 - 11.52 mm (0.390-0.454 in.)
20. Install the new 37.7 mm O-ring (F) and transmission case cap (G). NOTE: Check the operation of the change lever.
21. Install the transmission hanger (A), transmission hanger (B), 8 mm flange bolt (C), and the 10 mm flange bolts, finger-tight.
22. Tighten the 10 mm flange bolts in a crisscross pattern in several steps.
23. Install the oil check bolt (A), new 6 mm washer (B), drain plug (C), and new 14 mm washer (D).
24. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the set screws (A), then install the set screws, 22.0 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and new O-rings (G). NOTE: Do not install the components 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.
25. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the set screws (A), then install the set screws, 22.0 mm spring (B), 26.1 mm spring (C), 27.4 mm springs (D), steel balls (E), oil filler plug (F), washer (G), and clutch line bracket (H). NOTE: Do not install the components 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.
26. Remove any dirt or oil from the reverse lockout solenoid sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface. NOTE: Do not install the components 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.
27. Install the transmission harness bracket (A) and the reverse lockout solenoid (B).
28. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the back-up light switch (C), and install the switch in the transmission housing. NOTE: Do not install the components 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.
29. Install the strainer cover (A), new O-ring (B), strainer set spring (C), and oil pump strainer (D).
30. Adjust the differential carrier bearing preload (see «CARRIER BEARING PRELOAD ADJUSTMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__carrier-bearing-preload-adjustment) ).

Scheme 232

Scheme 233

Scheme 234

Scheme 235

1. Remove the rear center console (see «CENTER CONSOLE PANEL REMOVAL/ INSTALLATION»(/acura/tl/iii-2003-2006/remont/gauges-instrument-panels/#consoles__center-console-panel-removal-installation) ).
2. Remove the center console panel (see «CENTER CONSOLE PANEL REMOVAL/ INSTALLATION»(/acura/tl/iii-2003-2006/remont/gauges-instrument-panels/#consoles__center-console-panel-removal-installation) ).
3. Remove the shift lever bracket (A) and center console duct (B).
4. Remove the harness clips (A).
5. Remove the cotter pin (B), washer (C), and clamp (D).
6. Remove the shift cable clip (E).
7. Remove the select cable and shift cable (F) as shown.
8. Remove the shift lever housing.
9. Install the shift lever housing in the reverse order of removal.
10. Install the center console panel (see «CENTER CONSOLE PANEL REMOVAL/ INSTALLATION»(/acura/tl/iii-2003-2006/remont/gauges-instrument-panels/#consoles__center-console-panel-removal-installation) ).
11. Install the rear center console (see «CENTER CONSOLE PANEL REMOVAL/ INSTALLATION»(/acura/tl/iii-2003-2006/remont/gauges-instrument-panels/#consoles__center-console-panel-removal-installation) ).

Scheme 236

Operational Check

Note. The helical type limited slip differential (LSD) distributes optimum power between the two driving axles according to the difference in torque as demanded by the driving wheels. Under no circumstances should the engine be started with either wheel raised off the ground, such as when adjusting wheel balance or when transporting the vehicle in the event of an accident.

1. Set the parking brake, and block the rear wheels.
2. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
3. With the ignition switch turned OFF, shift the transmission into 1st gear.
4. Rotate either front wheel by hand, and check that the other wheel rotates in the opposite direction.
5. If the opposite front wheel does not rotate, or if you cannot spin the front wheels at all, the limited slip differential is faulty and should be replaced.

Scheme 237

1. Set the parking brake, and block the rear wheels.
2. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
3. Remove the front wheels.
4. With the ignition switch turned OFF, shift the transmission into neutral.
5. Measure the rotating torque with a beam-type torque wrench in the direction shown. Rotate the torque wrench more than two complete turns, and take the maximum reading.
6. Shift the transmission into 1st gear, and measure the rotating torque again.
7. Calculate the rotating torque. Service Limit: Measurement from step 5/Measurement from step 4 GREATER THEN EQUAL TO 2.5 For example: 7.8 N.m (0.8 kgf.m)/2.9 N.m (0.3 kgf.m)=2.67>2.5
8. Repeat steps 3 through 6 for the other wheel.
9. Replace the limited slip differential assembly if the rotating torque is lower than the service limit.

Differential Carrier, Final Driven Gear Replacement

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

Scheme 238

1. Remove the bolts in a crisscross pattern in several steps, then remove the final driven gear (A) from the differential carrier (B). NOTE: Inspect the final driven gear surface for wear and damage.
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 Tool Required

Installer, 46 mm I.D. 07PAF-0030100

Scheme 239

Scheme 240

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 with the special tool and a press. Press on each bearing until it bottoms out. There should be no clearance between the bearings and the carrier.

Oil Seal Replacement

Special Tools Required

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

Scheme 241

Scheme 242

Scheme 243

Scheme 244

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.

Bearing Outer Race Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 78 x 80 mm 07NAD-PX40100

Note. The bearing outer race and tapered roller bearing should be replaced as a set. Inspect and adjust the tapered roller bearing preload whenever the tapered roller bearing is replaced.

Scheme 245

Scheme 246

Scheme 247

1. Remove the oil seals from the transmission housing and clutch housing (see «OIL SEAL REPLACEMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__oil-seal-replacement) ).
2. Remove the bearing outer race, spacer, and 81 mm thrust shim from the transmission housing, and the bearing outer race and spacer from the clutch housing by heating the housing to about 212°F (100°C) with a heat gun. Do not reuse the thrust shim if the outer race was driven out.
3. Install the 81 mm thrust shim (A), spacer (B), and bearing outer race (C) into the transmission housing (D) using the special tools.
4. Install the spacer (A) and bearing outer race (B) into the clutch housing (C) using the special tools.
5. Install the oil seals into the transmission housing and clutch housing (see «OIL SEAL REPLACEMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__oil-seal-replacement) ).

Carrier Bearing Preload Adjustment

Special Tools Required

1. Attachment, 78 x 80 mm 07NAD-PX40100
2. Preload inspection tool 07XAJ-SOKA100
3. Driver 07749-0010000

If any of the items listed below were replaced, the carrier bearing preload must be adjusted.

1. Transmission housing
2. Clutch housing
3. Differential carrier
4. Spacer
5. Carrier bearing and outer race

Scheme 248

Scheme 249

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Scheme 251

Scheme 252

1. Remove the oil seals from the transmission housing and clutch housing (see «OIL SEAL REPLACEMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__oil-seal-replacement) ).
2. If you replaced the carrier bearing on the transmission housing side of the carrier, remove and discard the bearing outer race, Heat up the transmission housing to about 212 °F (100 °C) with a heat gun (A), then remove the bearing outer race (B), spacer (C), and 81 mm thrust shim (D). Do not heat the housing in excess of 212 °F (100 °C).
3. If you replaced the carrier bearing on the clutch housing side of the carrier, remove and discard the bearing outer race, heat up the clutch housing to about 212 °F (100 °C) with a heat gun (A), then remove the bearing outer race (B) and spacer (C). Do not heat the housing in excess of 212°F (100°C).
4. Install the 81 mm thrust shim (A), spacer (B), and bearing outer race (C) in the transmission housing by using the special tools. (Use a new bearing outer race if you replaced the bearing.) There should be no space between the bearing outer race, spacer, and housing.
5. If you removed the bearing outer race from the clutch housing, use the special tools to install a new bearing outer race (A) and spacer (B). There should be no space between the bearing outer race, spacer, and housing.
6. With the mainshaft and countershaft removed, install the differential assembly, and bolt the transmission and clutch housing together, and tighten the bolts to 44 N.m (4.5 kgf-m, 33 lbf-ft). NOTE: It is not necessary to use sealing agent between the housings for this adjustment.
7. Rotate the differential assembly in both directions to seat the tapered roller bearings.
8. At normal room temperature, measure the starting torque of the differential assembly by rotating it in both directions with the special tool and a torque wrench (A).
9. If the carrier bearing preload is not within the standard, select a 81 mm thrust shim that will provide the correct preload: Compare the bearing preload you got on the first try with the specified preload of 3.43-4.51 N.m (35-46 kgf-cm, 30-40 lbf-in.). If the preload you measure was less than specified, subtract it from the specified preload. If the preload you measure was more than specified, subtract the specified preload from the preload you measure. For example, with a 2.50 mm (0.098 in.) thrust shim: (1) specified 4.51 N.m (46 kgf-cm, 40 lbf-in.) -you got less 2.55 N.m (26 kgf-cm, 23 lbf-in.)/1.96 N.m (20 kgf-cm, 17 lbf-in.) less (2) you got more 5.29 N.m (54 kgf-cm, 47 lbf-in.) -specified 4.51 N.m (46 kgf-cm, 40 lbf-in.)/0.78 N.m (8 kgf-cm, 7 lbf-in.) more NOTE: Each shim size up or down from standard makes about 0.3-0.4 N.m (3-4 kgf-cm, 2.6-3.5 lbf-in.) difference in preload. In example (1), your preload was 1.96 N.m (20 kgf-cm, 17 lbf-in.) less than standard, so you need a thrust shim five sizes thicker than standard (try the 2.65 mm (0.104 in.) 81 mm thrust shim, and recheck). In example (2) , your preload was 0.78 N.m (8 kgf-cm, 7 lbf-in.) more than standard, so you need a thrust shim two sizes thinner (try the 2.44 mm (0.096 in.) 81 mm thrust shim, and recheck). 81 mm Thrust Shim 81 MM THRUST SHIM - SPECIFICATION TABLE Part Number Thickness A 41438-PYZ-000 2.05 mm (0.081 in.) B 41439-PYZ-000 2.08 mm (0.082 in.) C 41440-PYZ-000 2.11 mm (0.083 in.) D 41441-PYZ-000 2.14 mm (0.084 in.) E 41442-PYZ-000 2.17 mm (0.085 in.) F 41443-PYZ-000 2.20 mm (0.087 in.) G 41444-PYZ-000 2.23 mm (0.088 in.) H 41445-PYZ-000 2.26 mm (0.089 in.) J 41446-PYZ-000 2.29 mm (0.090 in.) K 41447-PYZ-000 2.32 mm (0.091 in.) L 41448-PYZ-000 2.35 mm (0.093 in.) M 41449-PYZ-000 2.38 mm (0.094 in.) N 41450-PYZ-000 2.41 mm (0.095 in.) P 41451-PYZ-000 2.44 mm (0.096 in.) Q 41452-PYZ-000 2.47 mm (0.097 in.) R 41453-PYZ-000 2.50 mm (0.098 in.) S 41454-PYZ-000 2.53 mm (0.100 in.) T 41455-PYZ-000 2.56 mm (0.101 in.) U 41456-PYZ-000 2.59 mm (0.102 in.) V 41457-PYZ-000 2.62 mm (0.103 in.) W 41458-PYZ-000 2.65 mm (0.104 in.) X 41459-PYZ-000 2.68 mm (0.106 in.) Y 41460-PYZ-000 2.71 mm (0.107 in.) Z 41461-PYZ-000 2.74 mm (0.108 in.) AA 41462-PYZ-000 2.77 mm (0.109 in.) AB 41463-PYZ-000 2.80 mm (0.110 in.) AC 41464-PYZ-000 2.83 mm (0.111 in.) AD 41465-PYZ-000 2.86 mm (0.113 in.) AE 41466-PYZ-000 2.89 mm (0.114 in.) AF 41467-PYZ-000 2.92 mm (0.115 in.) AG 41468-PYZ-000 2.95 mm (0.116 in.) AH 41469-PYZ-000 2.98 mm (0.117 in.) AJ 41470-PYZ-000 3.01 mm (0.119 in.) AK 41471-PYZ-000 3.04 mm (0.120 in.) AL 41472-PYZ-000 3.07 mm (0.121 in.) AM 41473-PYZ-000 3.10 mm (0.122 in.) AN 41474-PYZ-000 3.13 mm (0.123 in.) AP 41475-PYZ-000 3.16 mm (0.124 in.)
10. Once the carrier bearing preload is correct, disassemble the transmission housing, and install new oil seals in the differential (see «OIL SEAL REPLACEMENT»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__oil-seal-replacement) ).
11. Reassemble the transmission (see «TRANSMISSION REASSEMBLY»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__transmission-reassembly) ).
12. Reinstall the transmission (see «TRANSMISSION INSTALLATION»(/acura/tl/iii-2003-2006/remont/manual-trans/#manual-transmission__transmission-installation) ).

See also:
• GENERAL TROUBLESHOOTING INFORMATION
• HOW TO TROUBLESHOOT CIRCUITS AT THE ECM/PCM
• AIR CLEANER REMOVAL/INSTALLATION
• STEERING COLUMN REMOVAL AND INSTALLATION
• STABILIZER LINK REPLACEMENT
• REMOVAL
• DRIVESHAFT REMOVAL
• COMPONENT LOCATION INDEX
• STEERING WHEEL REMOVAL
• WHEEL ALIGNMENT
• CENTER CONSOLE PANEL REMOVAL/ INSTALLATION
• REVERSE LOCKOUT SOLENOID DISASSEMBLY/REASSEMBLY
• TRANSMISSION FLUID INSPECTION AND REPLACEMENT
• EXPLODED VIEW - CLUTCH HOUSING
• MAINSHAFT THRUST CLEARANCE ADJUSTMENT
• CARRIER BEARING PRELOAD ADJUSTMENT
• OIL SEAL REPLACEMENT
• TRANSMISSION REASSEMBLY
• TRANSMISSION INSTALLATION