A/T - Judder/Harsh Shift
Model Applicable To File Under Bulletin No.
'83 - '84 ALL 85-025
ACCORD with automatic TRANS
Issue Date
and up to trans number
PRELUDE AS-1080604 MAY 3, '85
Broken 2nd Gear Thrust Washer on Mainshaft
PROBLEM Judder and/or very harsh shifting from low to 2nd and from 3rd to 2nd.
PROBABLE CAUSE The thrust washer for 2nd gear broke because of excessive 2nd gear clearance.
CORRECTIVE ACTION
1. Replace all the parts listed under PARTS INFORMATION according to the procedures in the appropriate Honda Service Manual. Also replace any other damaged parts.
ADJUSTMENT OF CLEARANCE ON MAINSHAFT 2ND GEAR:
2. Adjust the mainshaft 2nd gear clearance to 0.50-0.10 mm as shown on the back of this page.
Thrust Washer:
PARTS INFORMATION
CAUTION: The new type thrust washer for the mainshaft 2nd gear has chamfered edges on its cutouts; the old type does not. Do not use the old type thrust washer.
Part
Qty H/C Exception
Mainshaft 1 1511765 On '83 Prelude, use 1463124
(ex '83 Prelude)
Thrust bearing (42 x 58 x 2 mm) 1 1352236
Needle bearing (36 x 41 x 18.3mm) 1 1352269
2nd Gear 1 1463165
Thrust bearing (36 x 52 x 2 mm) 1 1409291
2nd gear thrust washer(36.5x51x?mm) 1 --- Select thickness from chart on back.
2nd/4th clutch assembly 1 1857499 On '83 Accord, use 1900315
(ex '83 Accord)
Thrust washer (26 x 53 x 3 mm) 1 1351824
4th gear collar 1 1351907
Thrust bearing (39 x 54 x 2 mm) 1 1352277
Needle bearing (32 x 38 x 20 mm) 2 0896837
4th Gear 1 1334184 On '84 Accord
(ex '84 Accord) - use 1564863 for KA (49 ST)
- use 1564871 for KL (CAL) & KH (ALL ALT)
Thrust bearing (32 x 44 x 2 mm) 1 0896928
Thrust washer (26 x 45 x 3 mm) 1 1351832
Snap ring (26 mm) 1 0896670
Sealing rings (32 mm) 3 1333988 Only 2 required on '83 Prelude
(ex '83 Prelude)
Torque converter housing gasket 1 1333723
End cover gasket 1 1333731
O-ring (31.2 x 1.9 mm) 3 0897058
O-ring (19.8 x 1.9 mm) 2 0897074
WARRANTY CLAIM INFORMATION
Operation number: 218132 - Includes trans R & R, cleaning, throttle cable adjustment, and road test.
Flat rate time: Accord - 5.2 hours, Prelude - 5.6 hours. Failed part H/C: 135183
Defect code: 031
Contention code: C99
ADJUSTMENT OF CLEARANCE ON MAINSHAFT 2ND GEAR:
Adjustment of Clearance on Mainshaft 2nd Gear
NOTE: This supersedes the 2nd gear clearance adjustment procedure in the Service Manual.
1 . Clamp the mainshaft holder tool in a vise. Then assemble the mainshaft, insert it in the holder, and
torque its locknut (left-hand thread) to about 35 N-m (25 lb-ft).
2. With a grease pencil or felt-tip pen, mark a few teeth opposite each other on 2nd and 3rd gears so you'll be able to measure clearance at exactly the same place on 2nd gear every time.
3. Push 2nd gear all the way into the clutch and line up the teeth you marked, then measure the clearance between 2nd gear and 3rd gear as shown. Write it down.
MEASUREMENT:
4. Pull 2nd gear all the way out and keep the marked teeth lined up, then measure the clearance between 2nd and 3rd gear again. Write that measurement down.
5. To figure out 2nd gear clearance, subtract your second measurement from the first one. The difference (actual clearance) should be no less than 0.05 mm and no more than 0.10 mm. Change the specification for Mainshaft 2nd Gear Clearance in your Service Manual to 0.05-0.10 mm.
6. lf the clearance is outside that range, disassemble the mainshaft and measure the thickness of the 2nd gear thrust washer. Figure out how much thinner (to increase clearance) or thicker (to decrease clearance) the washer must be, then select an appropriate replacement from the following list.
Thickness H/C P/N
3.00 mm 1476761 90410-PC9-000
3.05 mm 1476779 90411-PC9-000
3.10 mm 1476787 90412-PC9-000
3.15 mm 1476795 90413-PC9-000
3.20 mm 1476803 90414-PC9-000
3.25 mm 1476811 90415-PC9-000
3.30 mm 1476829 90416-PC9-000
3.35 mm 1589209 90418-PC9-000
3.40 mm 1589217 90419-PC9-000
3.50 mm 1904184 90441-PC9-010
3.55 mm 1904200 90442-PC9-010
3.60 mm 1904226 90443-PC9-010
3.65 mm 1904242 90444-PC9-010
3.70 mm 1904267 90445-PC9-010
3.75 mm 1904283 90446-PC9-010
3.80 mm 1904309 90447-PC9-010
3.85 mm 1904325 90448-PC9-010
3.90 mm 1904341 90449-PC9-010
7. Reassemble the shaft and check the clearance again.