Campaign - A/T, CVT Start Clutch Warranty Extension: Overview

07-049

February 5, 2008

Applies To:
2001-05 Civic GX With CVT - ALL
2001-05 Civic HX With CVT - ALL
2003-05 Civic Hybrid With CVT - ALL
2001-05 Insight With CVT - ALL

Warranty Extension: CVT Start Clutch Judder
(Supersedes 07-049, dated August 24, 2007)

Updated information is shown with asterisks.

BACKGROUND

*NOTE:
Because of a class action settlement, the warranty extension coverage for CVT start clutch judder on 2002-05 Civic GXs and HXs with CVT, 2003-05 Civic Hybrids with CVT, and 2002-05 Insights with CVT purchased or leased between April 13, 2002, and November 7, 2006, is 7 years or 105,000 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.*

On affected vehicles, a momentary judder may be felt after accelerating from a stop, but only up to about 15 mph. The most likely cause of the judder is a worn start clutch in the CVT (continuously variable transmission). To increase customer confidence, American Honda is extending the warranty for this potential problem to 7 years or 100,000 miles, whichever comes first. This extended warranty covers only CVT start clutch judder below 15 mph and CVT drive belt slippage (see Service Bulletin 07-050, Warranty Extension: CVT Drive Belt Slippage). Any other customer complaints with the CVT are covered by the normal 3-year, 36,000-mile new vehicle limited warranty.

This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry.

CUSTOMER NOTIFICATION

All owners of affected vehicles were sent a notification of this warranty extension. An example of the customer notification is shown in this service bulletin.

Before beginning work on a vehicle, verify its eligibility by doing a VIN status inquiry and by making sure the customer has a notification letter.

CORRECTIVE ACTION

Do the diagnosis in this service bulletin. Then, only if needed, burnish the start clutch or replace it.





PARTS INFORMATION





REQUIRED SPECIAL TOOLS





REQUIRED MATERIALS





WARRANTY CLAIM INFORMATION

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.

DIAGNOSIS

NOTE:
You must complete the diagnosis before attempting any CVT repairs.

1. Check the CVT fluid level; add fluid if needed.

2. Check the engine and transmission mounts for damage. Replace any damaged mounts.

NOTE:
Engine and transmission mounts are not covered by the CVT extended warranty.

3. Remove the flywheel inspection cover, and inspect the flywheel for excessive grease on its surface. If you find excessive grease, replace the flywheel.

NOTE:
The flywheel is not covered by the CVT extended warranty.

4. Civic Hybrid and Insight only: Make sure the IMA battery level gauge shows at least three-quarters charged. If you need to increase the IMA charge, do this:

^ Insight only: Remove the EPS (electronic power steering) fuse from the under-hood fuse/relay box.

^ Start the engine, and run it at 3,500 rpm until the battery level gauge shows at least three-quarters charged.

^ Insight only: Reinstall the EPS fuse.

5. With the engine fully warmed up, test-drive the vehicle by accelerating from a stop several times.

^ If you feel a judder below 15 mph, go to step 6.

^ If you do not feel a judder below 15 mph, ask the customer additional questions to figure out what is wrong, then troubleshoot as needed.

6. Disconnect the EGR valve.

7. Do another test-drive, accelerating from a stop several times.

^ If you feel a judder below 15 mph, reconnect the EGR valve, then go to REPAIR PROCEDURE.

^ If you do not feel a judder below 15 mph, reconnect the EGR valve, then troubleshoot the EGR system.

NOTE:
EGR system troubleshooting is not covered by the CVT extended warranty.





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