Honda Service Bulletin 07-050: CVT Drive Belt Slippage Warranty Extension

Warranty Extension: CVT Drive Belt Slippage

(Supersedes 07-050, dated November 2, 2007, to update the information marked by the black bar)

BACKGROUND

Due to a class action settlement, the warranty extension coverage for CVT drive belt slippage on 2002–05 Civic GXs and HXs with CVT, 2003–05 Civic Hybrids with CVT, and 2002–05 Insights with CVT purchased or leased between April 13, 2002, and November 7, 2006, is 7 years or 105,000 miles, whichever occurs first. Refer to Service Bulletin 06-085 for more information.

On affected vehicles, the CVT (continuously variable transmission) drive belt may slip during acceleration. American Honda is extending the warranty for this potential problem to 7 years or 100,000 miles, whichever comes first. This extended warranty covers only CVT drive belt slippage and CVT start clutch judder below 15 mph (refer to Service Bulletin 07-049). Other CVT complaints are covered by the normal 3-year, 36,000-mile new vehicle limited warranty.

This warranty extension does not apply to vehicles declared a total loss or issued a salvage, branded, or similar title. VIN status inquiry is required to check vehicle eligibility.

CUSTOMER NOTIFICATION

Owners of affected vehicles will receive a notification of this warranty extension. Before work, verify eligibility via VIN status inquiry and ensure the customer has a notification letter.

CORRECTIVE ACTION

Perform the diagnosis outlined in this bulletin. If needed, install a CVT lower valve body kit and update the ECM (Civic Hybrid), or replace the CVT (Civic GX, Civic HX, and Insight).

PARTS INFORMATION

• CVT Lower Valve Body Kit (Civic Hybrid only): P/N 06270-PZC-305, H/C 8610495
• Remanufactured CVT (Civic GX, Civic HX, and Insight): Order via iN, select SERVICE, then Automatic Transmission, then Warranty A/T Order.

REQUIRED MATERIALS

• Honda Genuine CVT Fluid: P/N 08200-9006, H/C 8031437. Approximately 3 to 6 quarts per vehicle are needed.

SOFTWARE INFORMATION (Civic Hybrid Only)

• Use HDS Software Version: 2.009.007 (Brown CD) or later.
• Using an incorrect HDS software version may lead to incorrect vehicle update status.

Updated PGM-FI software program IDs and P/Ns:

WARRANTY CLAIM INFORMATION

Failed Part: P/N 20031-PZC-L01, H/C 8778862

Defect Code: 5SL00

Symptom Code: Q5300

Skill Level: Repair Technician

Out of warranty: Repairs after warranty expiration may be eligible for goodwill consideration. Request consideration from the District Parts and Service Manager or Zone Office.

DIAGNOSIS

Complete diagnosis before attempting CVT repairs.

1. Civic Hybrid and Insight only: Ensure IMA battery level is at least three-quarters charged. If not, charge it by removing the Insight EPS fuse, starting the engine, running at 3,500 rpm until charged, and then reinstalling the EPS fuse.
2. Connect the HDS to the vehicle's DLC, turn the ignition to ON (II), and power on the HDS.
3. Enter VIN (if prompted) and odometer reading at the HDS prompts.
4. Select HONDA SYSTEMS from the SELECT MODE screen.
5. Select A/T from the SYSTEM SELECTION menu.
6. Select SNAPSHOT from the MODE MENU.
7. Set snapshot points: Trigger type: Manual, Recording time: 2 minutes, Trigger point: -60 seconds.
8. Find a flat road for a 2-minute drive with an assistant.
9. Ensure the engine is at normal operating temperature. Select a vehicle speed (40, 50, 60, 70, or 75 mph) from the appropriate chart below for your 2-minute snapshot. Do not exceed posted speed limits.

Civic GX Data

Civic HX Data

Civic Hybrid Data

Insight Data

10. Accelerate to the selected vehicle speed. Have your assistant tap the camera icon on the HDS to trigger the snapshot. Maintain vehicle speed and throttle position during the snapshot. Turn A/C off before capturing.
11. When the snapshot is finished, have your assistant follow prompts to save the data.
12. After returning to the shop, disconnect the HDS and review snapshot data. Open the saved file in the snapshot folder using HDS stand-alone mode.
13. Tap the configuration icon and select parameters to graph: Engine speed (rpm), TP sensor opening (degrees), Driven pulley speed (vehicle speed, mph).
14. Check engine speed (rpm) on the graph under these conditions: More than 60 seconds from snapshot start, and at a steady throttle for 5 seconds or longer.
15. Compare engine speed to the corresponding vehicle speed and throttle position listed in the chart on page 2.
16. If Yes:
    • Civic Hybrid only: Go to REPAIR PROCEDURE A.
    • Civic GX, Civic HX, and Insight: Go to REPAIR PROCEDURE B.
17. If No:
    • Civic Hybrid only: Go to step 23 of REPAIR PROCEDURE A.
    • Civic GX, Civic HX, and Insight: The CVT is OK. Return the vehicle to the customer.

REPAIR PROCEDURE A (Civic Hybrid)

1. Remove the air cleaner housing and intake air duct.
2. Disconnect the CVT solenoid harness connector. Clean the area around the connector to prevent debris entry (refer to illustration in step 6).
3. Raise the vehicle on a lift.
4. Remove the under-cover. [Description of under-cover removal: The under-cover is secured by multiple bolts.]
5. Drain the CVT fluid by removing the drain plug. Reinstall the plug with a new sealing washer, torquing to 49 N·m (36 lb-ft).
6. Remove the CVT oil pan. [Description of oil pan removal and components: The oil pan is secured by bolts. Components to be replaced or serviced include the oil pan gasket, magnets, lower valve body, solenoid harness connector, lower valve body feed pipes, and strainer/O-ring. The oil pan bolts, solenoid harness connector bolt, and feed pipes are also shown.]
7. Remove the CVT strainer. It will not be reused.
8. Remove the CVT lower valve body (refer to illustration in step 6): Remove the eight valve body bolts. While holding the valve body, remove the solenoid harness connector bolt. Remove the valve body and its two feed pipes from the CVT case.
9. Clean mating surfaces of the oil pan and CVT case using a scraper.
10. Thoroughly clean the oil pan and replace the pan magnets.
11. Install two new feed pipes onto the new lower valve body.
12. Insert the new valve body's solenoid harness connector into the CVT case and torque the connector bolt to 12 N·m (8.7 lb-ft).
13. Install the new lower valve body, torquing its mounting bolts to 12 N·m (8.7 lb-ft).
14. Install a new strainer and O-ring on the lower valve body. Torque strainer bolts to 12 N·m (8.7 lb-ft).
15. Reinstall the oil pan: Attach dowel pins and a new gasket. Install the oil pan, torquing bolts to 12 N·m (8.7 lb-ft). A transmission jack may be needed.
16. Replace the external in-line CVT oil filter.
17. Reinstall the under-cover.
18. Connect the CVT solenoid harness connector.
19. Reinstall the intake air duct and air cleaner housing.
20. Refill the CVT with 3.1 quarts of Honda Genuine CVT Fluid.
21. Ensure the vehicle is on level ground. Start the engine, warm it to operating temperature, then shut it off. Check CVT fluid level within 90 seconds; it should be between the upper and lower HOT marks. Add fluid if needed.
22. Calibrate the start clutch using the service manual procedures (driving method or SCS method for 2003 Civic Hybrids). Refer to the 2003-2005 Civic Hybrid Service Manual or online resources.
23. Update the ECM with HDS and Software Version 2.009.007 (Brown CD) or later.

REPAIR PROCEDURE B (Civic GX, HX, Insight)

Replace the CVT with a remanufactured unit. Refer to Section 14 of the service manual or online resources (keyword TRANS).

Note:

• Use Honda Genuine CVT Fluid, not ATF-Z1, when refilling.
• Use the CVT (ATF) filter included with the remanufactured CVT.
• Follow all service manual instructions, including start clutch pressure control system calibration, engine idle learn procedure, and road test.

Example of Customer Letter

Warranty Extension: Transmission Judder or Slippage

Dear Civic GX, Civic HX, Civic Hybrid, or Insight Owner:

This letter notifies you of a warranty extension for two potential problems in your vehicle's continuously variable transmission (CVT).

Warranty extension details

Some vehicles may experience hesitation or judder when starting from a stop, or hesitation/slipping during acceleration. To ensure adequate warranty coverage, the CVT is now covered for judder or slippage for 7 years or 100,000 miles, whichever comes first.

If your vehicle exhibits these symptoms and is within the extended warranty limits, take it to any Honda dealer for inspection and free repair. This extension covers only CVT judder or slippage; other CVT issues are covered by the standard 3-year, 36,000-mile warranty.

Dealers will order parts and schedule appointments. Plan for at least a full day for the vehicle at the dealership.

Note: The last page of this notification contains updated CVT information for your owner's manual.

What to do if you feel this notice is in error

If your vehicle information is incorrect, fill out and return the enclosed Information Change Card to update records.

Reimbursement

If you previously paid for CVT repair for judder or slippage, you may be eligible for reimbursement. Refer to the attached Instructions for Reimbursement.

If you have questions

For questions or assistance contacting a Honda dealer, call Honda Automobile Customer Service at (800) 999-1009.

Sincerely,

American Honda Motor Co., Inc.
Honda Automobile Division