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Old 04-15-2011, 09:49 AM   #1 (permalink)
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lamebmx
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Hi and thanks in advance.

It does not like to stay in 5th gear, drops out to neutral.

2001 Accent Hatchback. 1.5l 5-speed

The other day it started slipping out of 5th gear on the expressway. Held good for the first 10 to 20 minutes. Afterwards I had to hold it in 5th for it to stay in gear. While holding I noticed it pushed on the shifter when applying throttle, and let up some when I let of the gas.

I inspected the pivots at the transmission. The forward / back bushing was not installed properly by the previous owner. I rigged it up better with a fender washer and cotterpin. It previously had just a pin and the bushing had expanded out. This removed the play from shifting I had previously noticed. It also halfway fixed the popping out of gear. It stays in gear a little longer, and when I put it back into 5th it stays there for a while most of the time.

I have not inspected the lubricant level yet.

Any advice where to check next?
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Old 04-15-2011, 10:18 AM   #2 (permalink)
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I would take the center consol out and make sure the shifter assembly is bolted down tight mine had worked loose and the shift lever would move back and forth.
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Old 04-15-2011, 10:55 AM   #3 (permalink)
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QUOTE (carlherrnstein @ Apr 15 2011, 10:18 AM)
Quote:
I would take the center consol out and make sure the shifter assembly is bolted down tight mine had worked loose and the shift lever would move back and forth.
I will check on this one over the weekend.

Anyone else have suggestions. I work with computers for a living and try to avoid them over the weekends
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Old 04-18-2011, 06:30 AM   #4 (permalink)
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Okay, I got the center console apart over the weekend, good reminder why I love these cars. so easy to work on.

So the pivots are not binding there. The assembly was not sliding around. It was all the way slid back. I figured sliding it as far forward as it would allow should help, putting it a little more into 5th.

the shifting itself feels better. but it still popped out of 5th gear on me.

i was not able to check the transmission lube, as the remainder of my time went to replacing the starter. i am still open to some ideas to check out.
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Old 04-20-2011, 06:30 AM   #5 (permalink)
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Adding some notes:

Found this regarding a Suzuki TSB

================================================== =========

AS23-06

NOTICE
Unintended disengagement of 5th gear under acceleration on a 2002 or 2003 Aerio equipped with
manual transmission.

CORRECTION
A 5th gear spring set with a modified 5th gear shift yoke spring has been made available for 2002 and
2003 Aerio (RH420) vehicles equipped with manual transmission. Note that this set is not applicable to
2004 and later model year Aerio (RH423) as the 5th/reverse gear shift yoke and related parts on these
vehicles has been changed.

PARTS INFORMATION
A 5th gear spring set may be ordered according to your normal parts ordering procedure. The 5th gear
spring set includes a spring, washer and plug.

REPAIR PROCEDURE
1. Turn the ignition switch OFF, set the parking brake
and place the shift lever in 5th gear position.
2. Raise the hood and locate the plug for the 5th gear
spring which is mounted on the top of the transaxle.
The 5th gear spring plug is the closest of the three
plugs to the front of the vehicle.
3. Remove the 5th gear plug and spring.
4. Install the new 5th gear spring into the opening.
Install the plug and washer. Tighten the plug to the
specification.

================================================== =============

The peoples description is very similar to mine. Other things mentioned was 5th gear syncro. That seems unlikly as its more to guide the gear in correctly. And of course fluid level.
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Old 04-20-2011, 07:19 AM   #6 (permalink)
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If the TSB steps don't solve the problem. The next cause would be a bad synchronizer on the fifth gear. If you are driving and hold the shifter in fifth and it tries to kick out hard, it would be the synchro. That all being if the Hyundai tranns have synchros which is the norm in the industry except some Hino trucks.
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Old 04-23-2011, 07:41 PM   #7 (permalink)
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QUOTE (titaniumskull @ Apr 20 2011, 07:19 AM)
Quote:
If the TSB steps don't solve the problem. The next cause would be a bad synchronizer on the fifth gear. If you are driving and hold the shifter in fifth and it tries to kick out hard, it would be the synchro. That all being if the Hyundai tranns have synchros which is the norm in the industry except some Hino trucks.
Not a synchro issue... synchro is used only to brake the gear speed to match the shaft speed so hub can slide across and couple gear to shaft.

What holds the hub in place is a set of keys that aid in holding the hub to the gear.. so possible set of keys and springs may solve the issue.

Also be aware of shift fork fit to the groove in the hub.. sloppy fit, and shifter throw will not be able to fully engage the hub to the gear.. do not use shifter as a handrest during driving, as pressure applied to shifter will put that load on the fork and drag the fork in the hub groovem now you have a wide groove in the hub and a real skinny fork finger...
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Old 04-23-2011, 08:11 PM   #8 (permalink)
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True to a degree, I work on tranis up to 15 speed, Commercial vehicles. when a driver grinds gears the synchro gets rounded out teeth and then has less hold. I have at least two transmissions a year with this problem, usually 4th and 5th gears when they up shift and down shift without letting the splitter fully shift.

My S-10 pickup borgwarner 6th gear did the same, I was the blame for that one.

Each brand of trani has its own unique features, I spend most of my time with Eaton/Fuller and BorgWarners. I am sure that Asian Boxes have their own unique mechanical features and designs to trap a gear. I am mostly familiar the fore mentioned transmissions.

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Old 04-24-2011, 12:30 AM   #9 (permalink)
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Thanks for the info. I have to drive with my hand on 5th gear. I understand there is slight pressure applied, like leaving your foot on the brakes or clutch. The last poster description make me think the previous owner may have been using it as a hardest and created the issue.

OS the spring and keys accessible without cranny removal? Due to work anything that's more than like 3 hours isn't happening, ill have to get a used tranny the rebuild this one. It also has a sound like a bad bearing at idle that for goes away when I push in the clutch. And I don't notice it with a gear engaged.
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Old 04-24-2011, 11:05 AM   #10 (permalink)
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Bearing noise that goes away when the clutch is depressed usually means a dry throwout bearing. The life expectancy in that case I can not say. When you press on the clutch, you are pressing the throwout bearing against the clutch fingers, the rattle goes away since there is less lateral play in the bearing.

It is possible the previous owner spent time riding the clutch at stop lights to hold the car in position. You are in a catch 22 spot. Not knowing how the previous driver used the clutch and shifted gears leaves you in the dark as to the overall condition of everything from linkages to the clutch itself.

How I can diagnose a semi trucks tanni and clutch is quite different than a car, Then again I have an open view port to see the clutch and bearing as well as lube points and I can pull the top cover off the tranni to access the shifter rails . In reality I have an easier job even though the tranni is a lot bigger, I dont have to work in a constrictive space as with a car. sbr711 and others on the forum have had their experience with the Hyundai tranns and you should still follow the tips on the external parts inspections before condemning the situation. refer to the following link and or an aftermarket manual.

http://www.hmaservice.com/ has the info needed.

A Haynes manual is done more in laymans terms and has step by step instructions in diagnosing and repair if needed.
Even though I am a commercial Veh tech I still buy the Haynes manual for every car or truck I buy for myself or my daughter. The book is available at most car parts stores and can be ordered if needed. They cost around $20 and is a great tool for DIY repairs. It will provide step by step instructions and reference photos.
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