M/T - Clicking Noise Driving in 2nd Gear

03-009

June 10, 2003

Applies To:
2001-03 Civic DX, LX, HX, EX with M/T - ALL
2003 Civic Hybrid - From VIN JHMES95..3S000001 thru JHMES95..3S018631

Clicking Noise While Driving in 2nd

(Supersedes 03-009, dated April 1, 2003)

Updated information is shown with asterisks.

SYMPTOM

* While driving in 2nd gear, a clicking noise occurs when turning right (DX, LX, HX, and EX) or when turning left (Civic Hybrid).*

PROBABLE CAUSE

The reverse idler gear is contacting the 1st/2nd hub sleeve set.

CORRECTIVE ACTION

Replace the reverse idler gear, the 1st/2nd synchro hub/sleeve set, and the reverse gear holder.

REQUIRED MATERIALS

Honda Manual Transmission Fluid (1.7 quarts required):
P/N 08798-9016, H/C 4928271

Liquid Gasket:
P/N 08718-0001, H/C 2963817





PARTS INFORMATION

WARRANTY CLAIM INFORMATION

In warranty:
The normal warranty applies.

Operation Number: 213110

Flat Rate Time: 4.0 hours

Failed Part: P/N 24230-PLW-000
H/C 6568653

Defect Code: 042

Contention Code: B07

Template ID: 03-009A (DX, LX, EX)
03-009B (HX)
03-009C (Hybrid)

Skill Level: Repair Technician

Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.

REPAIR PROCEDURE





1. * Remove the transmission. See page 13-4 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-18. Then remove the housing. See page 13-16 of the 2001-2003 Civic Service Manual; for the Hybrid, see page 13-32.*





2. * Remove the reverse idler shaft and the reverse idler gear; discard the gear. See page 13-17 (13-32 for Hybrid) of the service manual.*





3. Remove and discard the shift fork.





4. Apply vinyl tape to the mainshaft splines to protect the seal, then remove the mainshaft and shift forks as an assembly from the clutch housing.





5. Disassemble the countershaft assembly; see page 13-32 (13-45 for Hybrid) of the service manual.





6. Replace the 1st/2nd synchro hub/sleeve, and reassemble the countershaft; see page 13-34 (13-48 for Hybrid) of the service manual.





7. Check the countershaft clearance; see page 13-30 (13-44 for Hybrid) of the service manual.





8. Reassemble the transmission; see page 13-43 (13-59 for Hybrid) of the service manual.





9. Install the new shift fork holder. Check the reverse shift fork clearance; see page 13-19 (13-34 for Hybrid) of the service manual.

10. Reinstall the transmission; see page 13-9 (13-23 for Hybrid) of the service manual.

11. Fill the transmission with MTF.

12. * Test-drive the car; make several right turns (left turns for Hybrid), and check that the clicking noise is gone.*





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