2003 Acura TL Manual Transmission Swap

The 2003 Acura TL manual transmission swap involves converting an automatic transmission Acura TL to a manual transmission configuration. This comprehensive guide covers the process, required parts, tools, installation steps, and important considerations for a successful transmission conversion. Below are key sections for preparation, parts list, installation procedure, wiring modifications, and troubleshooting.

1. Required Parts and Tools 2. Pre-Installation Preparation 3. Removal of Automatic Transmission 4. Manual Transmission Installation 5. Clutch System Components 6. Pedal Assembly Installation 7. Wiring and ECU Modifications 8. Driveshaft and Axle Considerations 9. Final Assembly and Testing 10. Common Issues and Solutions

Required Parts and Tools

Essential components for complete manual transmission conversion: Manual transmission assembly, clutch kit, flywheel, pedal assembly, shifter mechanism, and related hardware.

ComponentDescription
Manual TransmissionJ-series compatible 6-speed manual transmission
Clutch KitComplete clutch disc, pressure plate, throwout bearing
FlywheelManual transmission specific flywheel
Pedal AssemblyClutch and brake pedal set from manual TL
Shifter AssemblyComplete shifter mechanism with cables
Master CylinderClutch master cylinder and lines
Slave CylinderClutch slave cylinder
Transmission MountManual transmission specific mount
ECUManual transmission compatible ECU
DriveshaftManual transmission specific driveshaft

Pre-Installation Preparation

Proper preparation ensures smooth installation process and prevents damage to components.

  1. Vehicle Preparation: Park on level surface, engage parking brake, disconnect battery.
  2. Drain Fluids: Drain transmission fluid and engine oil as necessary.
  3. Remove Components: Remove exhaust system, heat shields, and driveshaft access.
  4. Safety Equipment: Use jack stands, transmission jack, and proper safety gear.

WARNING! Vehicle must be securely supported on jack stands. Transmission is heavy; use proper lifting equipment.

Removal of Automatic Transmission

Carefully remove automatic transmission to prepare for manual transmission installation.

  1. Disconnect Components: Remove shift cable, cooler lines, electrical connectors.
  2. Support Engine: Use engine support bar to secure engine during removal.
  3. Remove Driveshaft: Unbolt and remove driveshaft from differential.
  4. Lower Transmission: Use transmission jack to lower and remove automatic transmission.
  5. Remove Flexplate: Remove automatic transmission flexplate from crankshaft.

CAUTION! Label all electrical connectors and bolts for proper reassembly.

Manual Transmission Installation

Clutch System Components

Complete clutch system installation including flywheel, clutch disc, pressure plate, and hydraulic components.

Installation Steps: Install flywheel with proper torque sequence, align clutch disc using alignment tool, install pressure plate with even torque, install throwout bearing, and connect hydraulic lines.

Flywheel: Torque to 76 ft-lbs in star pattern. Clutch: Torque pressure plate bolts to 19 ft-lbs. Hydraulics: Bleed clutch system thoroughly. Adjustment: Ensure proper clutch pedal free play.

Pedal Assembly Installation

Manual pedal assembly replacement including clutch pedal installation and brake pedal modification.

  1. Remove automatic pedal assembly from driver footwell.
  2. Install manual pedal assembly with clutch pedal bracket.
  3. Connect clutch master cylinder pushrod to clutch pedal.
  4. Adjust brake pedal height to match clutch pedal.
  5. Install clutch pedal position switch and wiring.

Tip: Test pedal operation before finalizing installation.

Wiring and ECU Modifications

Essential electrical modifications for proper manual transmission operation and computer compatibility.

  1. ECU Replacement: Swap automatic ECU for manual transmission compatible ECU.
  2. Neutral Safety Switch: Bypass or modify automatic transmission safety features.
  3. Reverse Lights: Connect manual transmission reverse light switch.
  4. Speed Sensor: Ensure proper vehicle speed sensor operation.
  5. Clutch Switch: Install clutch pedal position switch for starting interlock.

WARNING! Proper ECU programming is critical for engine operation and emissions compliance.

Driveshaft and Axle Considerations

Manual transmission requires specific driveshaft and may require axle modifications.

Final Assembly and Testing

Complete reassembly and thorough testing of manual transmission conversion.

  1. Install remaining components: Exhaust, heat shields, underbody panels.
  2. Fill fluids: Transmission fluid, engine oil, coolant as needed.
  3. Bleed systems: Clutch hydraulic system, brake system if disturbed.
  4. Initial testing: Check clutch operation, gear selection, no-load operation.
  5. Road testing: Test all gears, clutch engagement, and transmission operation.

CAUTION! Perform initial testing with wheels off ground to verify proper operation.

Common Issues and Solutions

SymptomPossible CauseCorrective Action
Hard shiftingClutch adjustment/fluidAdjust clutch pedal free play; bleed hydraulic system; check fluid level.
Gear grindSynchronizer/fluidUse proper Honda MTF; check synchronizer wear; verify clutch disengagement.
Clutch slipAdjustment/wearAdjust clutch pedal; inspect clutch disc wear; check hydraulic pressure.
No reverse lightsWiring/switchCheck reverse light switch connection; verify wiring continuity.
VibrationDriveshaft/mountsCheck driveshaft balance; verify transmission mount condition and installation.

Professional Assistance: Recommended for complex electrical and programming tasks.

Resources: Acura service manuals and transmission specialists for technical support.

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