A/T - Shift Lever Hard To Move
07-037June 19, 2007
Applies To:
2003-05 Civic Hybrid With CVT - ALL
Shift Lever Is Hard to Move
SYMPTOM
The shift lever is hard to move.
PROBABLE CAUSE
Corrosion in the joint between the shift cable and the control lever causes the joint to bind. The corrosion is most often caused by road salt.
CORRECTIVE ACTION
Replace the shift cable and control lever with revised parts.
PARTS INFORMATION
Control Wire and Lever Set
(includes shift cable and control lever):
P/N 04401-S5B-305, H/C 8619108
Lock Washer (6 mm):
P/N 90433-639-000, H/C 0560433
Hex Bolt (6 mm):
P/N 90001-PA9-000, H/C 0896209
REQUIRED MATERIALS
Super High-Temp Urea Grease
(one container repairs about 25 vehicles):
P/N 08798-9002, H/C 3720984
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 2141A6
Flat Rate Time: 1.2 hours
Failed Part: P/N 54315-55B-952 H/C 7105034
Defect Code: 00701
Symptom Code: 03101
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Park the vehicle on a lift.
2. Remove the center panel and the center console:
^ Refer to page 20-54 of the 2003-2005 Civic Hybrid Service Manual, or
^ Online, enter keyword CENTER CON, and select Center Console Removal/Installation from the list.
3. Move the shift lever to N.
4. Remove the shift cable end locknut, then separate the cable end from the shift lever assembly.
5. Rotate the socket holder on the shift cable a quarter turn so the tab is in the opening of the shift lever bracket base. Slide the holder out to remove the shift cable from the bracket base.
6. Raise the vehicle on the lift.
7. Remove the bolts and nuts securing the shift cable brackets.
8. Remove the grommet, and pull the shift cable out.
9. Lower the vehicle.
10. Remove the air cleaner housing and the intake air duct.
11. Remove the air cleaner housing bracket.
12. Remove the spring clip and the washers.
13. Loosen the locknut on the shift cable, then separate the cable from the shift cable bracket and control lever.
NOTE:
You will not reuse the spring clip and the washers.
14. Make marks across the transmission range switch and the transmission at both bolts using a felt-tip pen.
15. Remove the transmission range switch bolts, then lift up the switch to remove it, but do not disconnect the clip or the connector.
16. Remove the bolt, then remove the control lever.
17. Install the new control lever with the new lock washer and bolt.
18. Raise the vehicle.
19. Insert the new shift cable through the grommet hole, then install the cable brackets.
20. Install the grommet into the grommet hole.
21. Lower the vehicle.
22. Align the socket with the shift cable bracket, and install the new shift cable.
23. Tighten the locknut.
24. Apply super high-temp urea grease to the shift cable end and the pin on the new control lever.
25. Install the shift cable end to the control lever with the new control lever pin and spring clip.
26. Reinstall the transmission range switch, align the marks you made in step 14, and torque the bolts to 12 N.m (8.7 ft-lb).
27. Turn the ignition switch to ON (II), and make sure the N indicator comes on. If the indicator does not come on, push the shift cable until it stops, then release it. Pull the shift cable back two steps so that the shift cable position is in N. Do not hold the shift cable guide to adjust the shift cable.
28. Turn the ignition switch to LOCK (0).
29. Make sure the shift lever is in N.
30. Insert a 6 mm (0.24 in.) pin through the positioning hole on the shift lever bracket base and into the positioning hole on the shift lever assembly. This secures the shift lever in N.
31. Align the socket holder on the shift cable with the slot in the cable bracket base, then slide the holder into the base.
32. Install the shift cable end over the mounting stud, and align the square hole with the square fitting at the bottom of the stud. Rotate the holder a quarter turn to secure the shift cable. Do not install the cable by twisting the shift cable guide. Make sure the shift cable end is properly installed on the mounting stud.
33. Install and torque the locknut.
34. Remove the 6 mm (0.24 in.) pin installed in step 30.
35. Move the shift lever to each position, and make sure the gear position indicator indicates the correct shift lever position.
36. Install the air cleaner housing bracket, and torque the bolts to 12 N~m (8.7 ft-lb).
37. Install the air cleaner housing and the intake air duct.
38. Raise the vehicle on the lift, and make sure no objects or people are near the front wheels.
39. Start the engine, and check the shift lever indicator and transmission operation in all gears.
NOTE:
Make sure to apply the brake before shifting between P, N, and D.
40. Reinstall the center console, the console panel, and all the related parts.
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