2001 Rubicon transmission issue

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2001 Rubicon transmission issue

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2001 Rubicon transmission issue - 5/19/2008 10:11:41 AM

rubi_nubi

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I picked up a '01 Rubicon with a transmission issue. When I got it, the "_",D1,D2 and ESP were all flashing constantly as soon as you turned on the key. It would run and shift through all the gears, but not move. It acted as if it were in a high gear - the engine wouldn't wind up and it seemed like it was trying to move. Also noted a slight burning smell. We cleared the "_",D1,D2 and ESP flashing and it also had code for the angle sensor, which we cleared. Still acts the same. We pulled the motor with the intention of looking into the subtransmission. Any ideas? Thanks.

Post #: 1

RE: 2001 Rubicon transmission issue - 5/19/2008 3:24:30 PM

J_Fred

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Defintately sounds like the hondamatic hydrostat. Tale-tale signs are not being able to move in gear. Could also be the seperate oil pump, as this will also cause some issues, such as the burning smell. But more than likely, the hydrostat is gone.

Maybe ATV Mechanic/Dynamo or Honda Mechanic can fill you in, they are much more knowledgeable than I at this.

Fixing the Hondamatic basically means replacing it. You can clean it a bit, and maybe if your an expert replace some parts, but for the most part it's about a $1000.00 kick in the pocket book, maybe $1500 depending on how much of a blood sucker your Honda dealership/parts department is. Check www.hidyhondapowersports.com, they have the best Rubicon prices for your year model, maybe your dealership can get close to that, but most dealerships sell the Hondamatic for about $1300-1600. And they are out to take your money not be your friend. (nothing wrong with that, it's business)

Good thing about the 01-04 Rubicons, everything on them is relatively cheap to replace compared to other comparable quads (foremans, Sportsmans, AC 500's, Suzuki Vinsons, King Quad, etc...) Partly because you find a lot of them being parted out on ebay because they suffer from transmission problems and are deemed unworthy of fixing.

Not trying to scare you or anything, it could be something simple, but that really sounds like the Hondamatic, if it were the subtransmission, the quad would have power but either make a grinding/popping noise or would more than likely have trouble shiftin into gear (or sometimes into nuetral).

< Message edited by J_Fred -- 5/19/2008 3:36:27 PM >

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Post #: 2

RE: 2001 Rubicon transmission issue - 5/20/2008 8:54:46 AM

rubi_nubi

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Joined: 5/19/2008
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Thanks for the info. Hopefully one of those guys will respond. I pulled the oil reservoir and front cover last night and I can see that the clutch has seen a bit of heat. The large gear on the Hondamatic will not turn but I haven't taken the rear cover off to decouple it from the subtransmission yet.

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Post #: 3

RE: 2001 Rubicon transmission issue - 5/20/2008 3:45:01 PM

J_Fred

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From: Meeks, GA
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sounds like you've got farther than I have, PM Dynamo, Honda Mechanic or ATV Mechanic (might have to search for those names specifically though). they would be able to help more than I.

good luck,
Josh

_____________________________

"I don't get stuck, I just lose traction and stop moving."
----------
2001 Polaris 500 H.O.
K&N, 27x12 Vamp rear /American EDL fronts
----------
Gone -- AC 500m
28x12 Mudzillas, Snorked, G*rillas all around
----------
SOLD
2001 Honda Rubicon - Lift, 27x12 Vamps, snorkels, the works.
----------
www.myspace.com/joshfrederick

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Post #: 4

RE: 2001 Rubicon transmission issue - 5/20/2008 5:03:46 PM

Jordan Petry

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From: Lawrence, Kansas
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quote:

ORIGINAL: J_Fred

sounds like you've got farther than I have, PM Dynamo, Honda Mechanic or ATV Mechanic (might have to search for those names specifically though). they would be able to help more than I.

good luck,
Josh

Dynamo = ATVtech... Dynamo no longer posts, ATVtech posts though... Give him or Honda Mechanic a PM and I would be willing to be they will help.

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Post #: 5

RE: 2001 Rubicon transmission issue - 5/20/2008 5:23:18 PM

toodeep

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my first guess is the oil pump went out and starved the trany of oil (causing it to lock up). the 01 were notorious for there oil pumps but the new one's are updated. probably looking at replacing both but i have been wrong before, just make sure you check the pump out

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RE: 2001 Rubicon transmission issue - 5/20/2008 5:49:34 PM

ATVtech

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Couldn't quite tell from your first post, but did the machine move at all before you pulled the engine? Reason I ask is that I have seen a few Rubicons throw oil pump chains which causes a zero oil pressure condition which in turn causes the machine to stop moving. Completely. Now that you have the front crankcase cover off, is the oil pump chain still on the oil pump sprocket?

This condition will not cause any trouble codes to show up however.

Also, '01 Rubicons were notorious for oil pump problems, specifically the pressure relief valve sticking open and causing a low oil pressure condition. This usually caused all sorts of grinding/ratcheting noises, but if the oil pressure was low enough, it could also cause the machine to barely move.

It's really too bad you already pulled the engine. The first step to troubleshooting a Rubicon transmission problem is to perform an oil pressure check. Only takes a few seconds.

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Post #: 7

RE: 2001 Rubicon transmission issue - 5/20/2008 6:11:05 PM

ATVtech

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Here is the location of the oil pump drive chain.

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Post #: 8

RE: 2001 Rubicon transmission issue - 5/20/2008 7:35:03 PM

J_Fred

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From: Meeks, GA
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And he truly lives up to his signature... glad you stepped in Tech.

_____________________________

"I don't get stuck, I just lose traction and stop moving."
----------
2001 Polaris 500 H.O.
K&N, 27x12 Vamp rear /American EDL fronts
----------
Gone -- AC 500m
28x12 Mudzillas, Snorked, G*rillas all around
----------
SOLD
2001 Honda Rubicon - Lift, 27x12 Vamps, snorkels, the works.
----------
www.myspace.com/joshfrederick

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Post #: 9

RE: 2001 Rubicon transmission issue - 5/20/2008 8:33:03 PM

rubi_nubi

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Joined: 5/19/2008
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I will check the oil pump chain but I would imagine the engine would be making quite a racket if the oil pump wasn't running at all. I would have had trouble with the oil pressure test as I am not sure I could get to 5k rpm. It acted as if I was tring to move with all the brakes on no matter which gear I was in, even neutral. It would roll freely in neutral. I did pull it in gear and got all the tires to turn but it took a lot of effort. When I tried pulling it in low it was even harder but I was able to turn all the wheels. This indicates to me that the subtransmission is working.

< Message edited by rubi_nubi -- 5/20/2008 8:36:39 PM >

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Post #: 10

RE: 2001 Rubicon transmission issue - 5/27/2008 8:54:17 PM

rubi_nubi

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I pulled the rear cover and decoupled the subtransmission and the hondamatic turns very hard (with a pry bar). I guess my hondamatic is toast. Does anyone service these? I am also having trouble finding a puller for the centrifugal clutch. It describes it as a Puller, 40 x 1.5 mm 07ZMC-HN20100 and I have't been able to find it. I found one thread that suggested they used a two jaw puller but I am worried about damaging it. Has anyone found a puller or used a two/three jaw puller successfully?

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Post #: 11

RE: 2001 Rubicon transmission issue - 5/28/2008 5:57:22 AM

Honda Mechanic

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I would only use the Honda centrifugal clutch puller to remove the clutch , if you bend/break the drum/clutch plate or it slips and breaks a piece out of the crankcase (where the clutch cover seals) then you'll be out a couple more hundred bucks or much more..

No one I know of services the Hondamatic mainly because you can't buy/get parts for one..

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Post #: 12

RE: 2001 Rubicon transmission issue - 5/28/2008 9:12:34 AM

J_Fred

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quote:

ORIGINAL: Honda Mechanic

I would only use the Honda centrifugal clutch puller to remove the clutch , if you bend/break the drum/clutch plate or it slips and breaks a piece out of the crankcase (where the clutch cover seals) then you'll be out a couple more hundred bucks or much more..

No one I know of services the Hondamatic mainly because you can't buy/get parts for one..

The only shop around here that deals Honda says you have to buy the whole Hondamatic if it goes bad, and they usually do. But hey, if I could sell Hondamatics for $1600 a pop, I would probably just replace it too, haha. Too bad you and ATVTech dont live near me, could have saved my buddies and me a lot of trouble with our Rubi's, haha.

_____________________________

"I don't get stuck, I just lose traction and stop moving."
----------
2001 Polaris 500 H.O.
K&N, 27x12 Vamp rear /American EDL fronts
----------
Gone -- AC 500m
28x12 Mudzillas, Snorked, G*rillas all around
----------
SOLD
2001 Honda Rubicon - Lift, 27x12 Vamps, snorkels, the works.
----------
www.myspace.com/joshfrederick

(in reply to Honda Mechanic)

Post #: 13

RE: 2001 Rubicon transmission issue - 8/10/2008 9:07:12 PM

rubi_nubi

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I pulled the hondamatic and it was seized up. I figured I had nothing to loose so I disassembled the hondamatic and found a relief valve (or check valve) came out and was ground up. So I replaced the hondamatic with a used one I got from a friend that I believe was miss-diagnosed (wasn't shifting). I also replaced the oil pump with a new one.

No it moves but it has a loud ratcheting sound and jerky movement when I am in low gear ratios. It gets better with a lighter load like in low range. It goes away completely in high ratios 4th and 5th gear (ratio). It seems to shift fine in all modes.

All the research indicates the ratcheting results from low oil pressure. Now I haven't had a chance to check it yet but I would think the new oil pump would have taken care of this.

I am baffled by the fact that it only makes the noise in the lower ratios when from what I have read the hydraulic motor is locked to the shaft.

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Post #: 14

RE: 2001 Rubicon transmission issue - 8/17/2008 6:38:41 PM

rubi_nubi

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ttt

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RE: 2001 Rubicon transmission issue - 8/17/2008 7:40:49 PM

fourtraxforlife

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try doing an oil pressure test.

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Post #: 16

RE: 2001 Rubicon transmission issue - 8/17/2008 8:05:49 PM

rubi_nubi

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I did the oil pressure test and it was around 60 psi at idle and 140 psi at high rpms. I didn't have a tach so I couldn't check per the spec but I am pretty sure it met spec.

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Post #: 17

RE: 2001 Rubicon transmission issue - 8/18/2008 5:54:58 AM

Honda Mechanic

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That oil pressure sounds good... We've dis-assembled a few Hondamatic pumps and it's a shame that you can't get parts for them because a transmission or hydraulic shop could re-build them .. And it sounds like you may need a new one ..

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Post #: 18

RE: 2001 Rubicon transmission issue - 8/18/2008 7:24:38 PM

Jake450s

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quote:

ORIGINAL: J_Fred
Check www.hidyhondapowersports.com, they have the best Rubicon prices for your year model, maybe your dealership can get close to that, but most dealerships sell the Hondamatic for about $1300-1600.

Servicehonda can save another hundred bucks. Mrcycles can save seventy. Maybe a lot more, but I'm assuming that Hindy has room to lower their sixty dollar shipping charge if you asked them to.

It's only ten percent, but a hundred bucks is a hundred bucks. They're all the same part, the online dealer is most likely never going to see it anyway, it'll be drop shipped to your door with their name on it.

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Post #: 19