Acura TL Manual Transmission Rebuild

The Acura TL manual transmission rebuild process involves disassembling, inspecting, replacing worn components, and reassembling the 5-speed or 6-speed manual gearbox found in various TL model years. This comprehensive guide covers safety precautions, required tools, step-by-step rebuild procedures, common issues, and troubleshooting for optimal performance restoration.

1. Rebuild Overview 2. Required Tools & Parts 3. Safety Precautions 4. Transmission Removal 5. Disassembly Process 6. Component Inspection 7. Replacement Parts 8. Reassembly Steps 9. Reinstallation 10. Testing & Break-in 11. Troubleshooting

Rebuild Overview

Key components: Gear sets, synchronizers, shift forks, bearings, seals, and clutch assembly.

Component	Function
Gear sets	Transmit power at different ratios
Synchronizers	Match gear speeds for smooth shifting
Shift forks	Engage/disengage gears
Bearings	Reduce friction between moving parts
Seals	Prevent fluid leaks
Clutch assembly	Transfer engine power to transmission
Input shaft	Receives power from clutch
Output shaft	Delivers power to driveshaft
Shift linkage	Connects shifter to transmission
Drain/fill plugs	For fluid changes

Required Tools & Parts

Gather all necessary equipment before starting rebuild process.

Basic hand tools: Socket set, wrenches, screwdrivers, pry bars
Specialty tools: Transmission jack, bearing puller, seal driver, torque wrench
Cleaning supplies: Parts cleaner, shop towels, brake cleaner
Replacement parts: Synchronizer kit, bearing kit, seals, gaskets, fluid

WARNING! Use proper transmission jack; transmission is heavy and awkward to handle.

Safety Precautions

Always prioritize safety during transmission rebuild.

Work on level surface with adequate lighting
Wear safety glasses and gloves
Use jack stands - never work under vehicle supported only by jack
Disconnect battery before starting
Allow exhaust system to cool before working

CAUTION! Transmission fluid may be hot; wear protective gear when draining.

Transmission Removal

Vehicle Preparation: Park on level surface, engage parking brake, disconnect battery
Drain Fluid: Remove fill plug first, then drain plug
Disconnect Components: Shift linkage, clutch hydraulic line, sensors, driveshaft
Support Transmission: Position transmission jack securely
Remove Mounts: Transmission mount, crossmember if necessary
Lower Transmission: Slowly lower while checking for any remaining connections

Disassembly Process

Methodical disassembly ensures proper reassembly. Work on clean bench with adequate space.

Steps: Remove bellhousing, extension housing, shift mechanism cover. Extract snap rings carefully. Remove gear sets in order, noting orientation. Document component positions with photos.

Clean all parts thoroughly in parts cleaner. Organize components in order of removal. Label bearings and races for proper reassembly.

Component Inspection

Thorough inspection identifies worn or damaged parts requiring replacement.

Gears: Check for chipped teeth, excessive wear, blueing from heat
Synchronizers: Inspect brass rings for wear, damaged teeth
Bearings: Check for roughness, noise, play
Shift forks: Look for bending, wear at contact points
Seals: Replace all seals regardless of condition
Case: Check for cracks, damaged threads, warping

Tip: Use micrometer to measure critical tolerances per factory specifications.

Replacement Parts

Common replacement components for Acura TL manual transmission rebuild.

Part	Common Issues	Replacement Frequency
3rd gear synchro	Worn brass rings cause grinding	High mileage vehicles
Input shaft bearing	Noise in neutral	Every rebuild
Output shaft seal	Fluid leaks	Every rebuild
Shift fork pads	Worn causing difficult shifting	As needed
Drain/fill plug washers	Leaks at plugs	Every service

Reassembly Steps

Reverse of disassembly with new components. Use assembly lube on all moving parts.

Install new bearings using proper drivers
Assemble gear sets with new synchronizers
Install shift forks and rails
Set proper end play with selective shims
Install extension housing and shift mechanism
Replace all seals with new units
Torque all fasteners to specification

WARNING! Do not force components; they should assemble smoothly with proper alignment.

Reinstallation

Careful reinstallation ensures proper operation and prevents damage.

Lift transmission into position with jack. Align input shaft with clutch disc. Install bellhousing bolts hand-tight first. Reconnect shift linkage, sensors, and hydraulic lines. Install crossmember and mounts. Fill with specified manual transmission fluid.

Testing & Break-in

Proper testing and break-in procedure extends transmission life.

Start vehicle, depress clutch, check for unusual noises. Test shift through all gears with vehicle stationary. Road test: gentle acceleration, smooth shifts. Avoid hard launches and aggressive shifting for first 500 miles. Check for leaks after initial drive.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Grinding shifts	Worn synchronizers	Replace synchronizer assembly
Difficulty engaging gear	Clutch issues, bent shift fork	Inspect clutch hydraulic system, replace shift fork
Transmission noise	Worn bearings, low fluid	Replace bearings, check fluid level
Leaking fluid	Damaged seals, overfilled	Replace seals, correct fluid level
Jumping out of gear	Worn detents, shift forks	Replace shift mechanism components

Professional Service: Consult certified Acura technician for complex issues.

Technical Support: Acura dealership or transmission specialist for specific model year variations.