Acura TSX Manual Transmission Rebuild

The Acura TSX manual transmission rebuild guide covers the complete process for rebuilding the 6-speed manual transmission found in 2004-2008 Acura TSX models. This comprehensive guide includes disassembly, inspection, replacement of worn components, reassembly procedures, and proper lubrication specifications for optimal performance and longevity.

Tools and Equipment Required

Essential tools for Acura TSX manual transmission rebuild: transmission jack, socket set, torque wrench, bearing puller, snap ring pliers, dial indicator, micrometer, and specialty Honda tools.

Transmission Removal Procedure

Step-by-step process for removing transmission from vehicle.

1. Disconnect battery: Remove negative terminal for safety.
2. Drain transmission fluid: Remove drain plug, collect fluid properly.
3. Remove shift linkage: Disconnect shifter cables from transmission.
4. Disconnect clutch hydraulic line: Use flare nut wrench for brake line.
5. Remove driveshaft: Mark alignment before removal.
6. Support engine: Use engine support bar or jack with wood block.
7. Remove transmission mounts: Support transmission with jack.
8. Lower transmission: Carefully lower and remove from vehicle.

WARNING! Transmission weighs approximately 85 lbs; use proper lifting equipment and technique to prevent injury.

Disassembly Process

Systematic disassembly of transmission components.

1. Clean exterior: Thoroughly clean transmission case before disassembly.
2. Remove bellhousing: Unbolt and separate from main case.
3. Remove shift mechanism: Disassemble shift forks and rails.
4. Remove input/output shafts: Carefully extract complete shaft assemblies.
5. Disassemble differential: Remove ring gear and pinion assembly.
6. Remove synchronizers: Note orientation and order of components.
7. Extract bearings: Use proper bearing puller tools.
8. Clean all components: Use parts cleaning solvent and compressed air.

CAUTION! Document component positions and orientations; take photos during disassembly for reference during reassembly.

Component Inspection

• Gears: Check for chipped teeth, excessive wear, pitting.
• Synchronizers: Inspect brass rings for wear, damaged teeth.
• Bearings: Check for roughness, noise, axial/radial play.
• Shafts: Measure runout, check splines for wear.
• Shift forks: Inspect for bending, wear at contact points.
• Case: Check for cracks, damaged threads, bearing bore wear.
• Seals: Replace all seals regardless of condition.
• Differential: Check backlash, bearing preload.

Replacement Parts List

Common replacement components for TSX transmission rebuild.

Reassembly Instructions

Proper reassembly sequence for transmission components.

1. Install new bearings: Use proper bearing driver tools.
2. Assemble input/output shafts: Install gears, synchronizers in correct order.
3. Set gear endplay: Measure and adjust with selective shims.
4. Install shift mechanism: Align shift forks properly.
5. Assemble differential: Set ring gear backlash and bearing preload.
6. Install shafts in case: Ensure proper meshing of gears.
7. Install bellhousing: Torque bolts to specification.
8. Final inspection: Verify all components move freely.

Tip: Use assembly lubricant on all bearings and synchronizers during reassembly.

Lubrication and Fluids

Proper lubrication specifications for rebuilt transmission.

1. Transmission fluid: Honda MTF only - 2.2 quarts required.
2. Bearing lubrication: Use high-temperature bearing grease.
3. Synchronizer lubrication: Light coating of transmission fluid.
4. Seal lubrication: Use petroleum jelly on lip seals.
5. Shift mechanism: Light coating of grease on moving parts.

WARNING! Do not use conventional gear oil; only Honda Manual Transmission Fluid is approved for this transmission.

Reinstallation

Installing rebuilt transmission back into vehicle.

1. Position transmission: Use transmission jack for alignment.
2. Install clutch components: Align clutch disc properly.
3. Connect driveshaft: Align marks made during removal.
4. Install shift linkage: Adjust for proper shift feel.
5. Connect clutch hydraulic line: Bleed system properly.
6. Fill with fluid: Add Honda MTF through fill plug.
7. Reconnect battery: Final electrical connections.

CAUTION! Ensure transmission is properly supported during installation to prevent damage to input shaft and clutch components.

Testing and Break-in

Proper testing procedure and break-in period.

Initial testing: Check for leaks, verify all gears engage smoothly. Break-in period: Avoid hard acceleration and high RPM shifts for first 500 miles. Fluid check: Verify fluid level after first heat cycle. Final inspection: Check for unusual noises, proper shift operation.

Common Issues

Frequently encountered problems with TSX manual transmissions.

Troubleshooting

Professional Service: For complex issues, consult certified Acura transmission specialist.

Technical Support: Acura Technical Service Bulletin database for updated repair procedures.