Acura TSX Wagon Manual Conversion

The Acura TSX Wagon manual conversion involves transforming the automatic transmission model into a manual transmission vehicle using OEM or aftermarket components. This comprehensive guide covers the conversion process, required parts, installation steps, programming considerations, and performance enhancements for the K24 engine platform. Below are key sections for planning, parts sourcing, installation, programming, testing, and troubleshooting.

1. Conversion Overview 2. Required Parts List 3. Tools and Equipment 4. Installation Process 5. ECU Programming 6. Clutch System Setup 7. Drivetrain Modifications 8. Performance Considerations 9. Testing and Calibration 10. Common Issues 11. Maintenance

Conversion Overview

Key components: Manual transmission assembly, clutch system, pedal assembly, shifter mechanism, ECU programming, drive shaft modifications.

Component	Description
Transmission Assembly	6-speed manual transmission from TSX sedan or compatible Honda models
Clutch System	Clutch master cylinder, slave cylinder, clutch line, pressure plate, clutch disc
Pedal Assembly	Manual brake/clutch pedal bracket with clutch pedal
Shifter Mechanism	Shifter assembly, cables, shift knob, boot
ECU and Wiring	Manual transmission ECU or programming for automatic ECU
Drive Shaft	Modified or replacement drive shaft for manual transmission
Flywheel	Lightweight flywheel for improved throttle response
Mounts	Transmission mounts and engine mounts as needed
Hydraulic Lines	Clutch hydraulic lines and reservoir
Sensors	Vehicle speed sensor, reverse light switch, clutch position sensor

Required Parts List

Complete inventory of OEM and aftermarket components needed for successful conversion.

Manual transmission (TSX sedan 6-speed or Accord V6 6-speed)
Clutch kit (pressure plate, disc, release bearing, alignment tool)
Clutch master cylinder and slave cylinder
Manual transmission pedal assembly
Shifter assembly with cables and linkages
Manual transmission ECU or flash programming
Drive shaft (modified or direct replacement)
Transmission fluid (Honda MTF or equivalent)
Various bolts, brackets, and mounting hardware
Wiring harness modifications

WARNING! Ensure all parts are compatible with TSX wagon chassis and K24 engine.

Tools and Equipment

Essential tools for professional conversion installation.

Complete socket set (metric 8mm-19mm)
Transmission jack and engine support bar
Torque wrench (ft-lb and in-lb)
Clutch alignment tool
Bleeding kit for hydraulic system
ECU programming software and interface
Jack stands and hydraulic floor jack
Various pry bars and specialty tools
Wire crimping and soldering equipment

CAUTION! Use proper safety equipment and follow lift procedures.

Installation Process

Step 1: Disconnect battery and drain transmission fluid
Step 2: Remove automatic transmission components
Step 3: Install clutch pedal assembly and master cylinder
Step 4: Mount manual transmission and clutch system
Step 5: Install shifter mechanism and cables
Step 6: Connect hydraulic lines and bleed system
Step 7: Modify drive shaft and install
Step 8: Complete wiring modifications
Step 9: Program ECU and test systems

ECU Programming

Critical programming steps to ensure proper vehicle operation after conversion.

Options: Manual transmission ECU swap, automatic ECU reprogramming, aftermarket ECU solutions.

Programming: Disable automatic transmission codes, configure reverse light operation, adjust shift points (if applicable), calibrate speed sensor, set clutch start safety feature. Install: Ensure proper communication with all vehicle systems, test all electronic functions.

Clutch System Setup

Proper installation and bleeding of hydraulic clutch system.

Bench bleed master cylinder before installation
Install clutch pedal with proper pivot points and return spring
Route hydraulic line from master to slave cylinder
Bleed system completely to remove air bubbles
Adjust clutch pedal free play (10-15mm typical)

Tip: Use pressure bleeder for most efficient bleeding process.

Drivetrain Modifications

Adapting drivetrain components for manual transmission compatibility.

Measure and modify drive shaft length if necessary
Install proper transmission mounts and brackets
Check differential compatibility and gear ratios
Verify axle spline count and CV joint compatibility
Install speed sensor and vehicle speed pulse generator
Connect reverse light switch and neutral safety switch
Modify exhaust routing if clearance issues occur
Check transmission tunnel clearance

WARNING! Ensure proper drive shaft balance and U-joint alignment.

Performance Considerations

Enhancements and modifications for improved driving experience.

Testing and Calibration

Comprehensive testing procedures post-installation.

CAUTION! Perform initial tests in safe, controlled environment.

Common Issues

Symptom	Possible Cause	Corrective Action
Gear grinding	Clutch not disengaging fully	Bleed hydraulic system; adjust pedal free play
Reverse lights not working	Reverse switch wiring	Check reverse switch connection and wiring
Speedometer inaccurate	VSS calibration	Reprogram ECU with correct pulse count
Clutch pedal vibration	Misalignment or worn components	Check clutch alignment; inspect release bearing
Transmission noise	Fluid level or bearing issues	Check fluid level; inspect input shaft bearing

Reset: Clear ECU codes after conversion completion.

Support: Acura technical service bulletins; online conversion forums