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Extremely Notchy Gearbox Fix (2->3 and 4->5)

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114K views 225 replies 60 participants last post by  Cdn17Sport6MT  
#1 · (Edited)
Hey guys! As some of you may know I've been having the problem with the extremely notchy shifter from 2 to 3 and 4 to 5. I began to accept it as a normal feeling even though it felt like the car was not engaging into the gears as smoothly as the test drive unit. So I brought it into my dealer for it's first oil change and lo and behold theres a TSB fix for early production manual 2.0 mazda3s regarding the shifter. Took it for a spirited drive after my oil change and noticed I don't have to move the shifter like a chess piece and actually shift it like my previous manual cars (miata, mini, bmw).

Below is what it said on my invoice:
Customer reports transmission feels notchy when shifting. Inspected for TSB. Found 05-14-01 for similar concern. Adjust shifter cable as per TSB for smoother engagement of gears
Not sure if it's the same number (05-14-01) for you USA folks but try to mention this to your dealer if you have the rough / notchy shifter and get it fixed! Also let us know if it did fix your problem or not

Have fun zoom zooming!!! :Racing 1:
@Soler25 posted the TSB on page three. First post.
 
#44 ·
How to access shifter assembly - see steps #1-6, courtesy of JBR.

I've noticed some problems getting into 1st gear--not enough to bother going to the dealer for, but this sounds like an easy enough DIY fix that I'll have to attempt it.
 
#59 ·
There's a gap between the boot and shifter. I fixed the gap with a couple washers under the top of the boot. For a better shift and no modifications, take a look at the james barone racing shift knobs.
 
#68 · (Edited)
I have a December 2013 manufacture date, and also seem to have this problem, though it could also be related to TSB 05-008/14. Will try this fix first.

***Performed adjustment as specified, but noted no significant change in the position of the linkage adjuster (2 threads showing before and after). Will update after I have a chance to drive it a bit if it made any differences.
 
#70 ·
Just a suggestion to you all with this issue ...if you haven't been to the dealer, make sure you go and get the issue written up by your service advisor/writer and get a copy for your documentation. Just in case you fall out of warranty by time thy get a fix or solution for it. Always cover your ass. I know they have coverage intervals like 12/12, 3/36 and then the powertrain.
 
#71 ·
Any chance the problem carried over to the 15's? Mine does this pretty badly between 2&3 and 4&5. Also fights me going into first gear a few times a day. Looks like I'll be spending my weekend at the dealership... hooray.
 
#76 ·
I'm going to venture and say yes because my 2015 (late 2014 build date; I'll check which month later today) is notchy getting into 3rd and 5th gear at less than 600 miles on it. It could be related to the 05-008-14 TSB as well.
 
#72 ·
Hey guys! As some of you may know I've been having the problem with the extremely notchy shifter from 2 to 3 and 4 to 5. I began to accept it as a normal feeling even though it felt like the car was not engaging into the gears as smoothly as the test drive unit. So I brought it into my dealer for it's first oil change and lo and behold theres a TSB fix for early production manual 2.0 mazda3s regarding the shifter. Took it for a spirited drive after my oil change and noticed I don't have to move the shifter like a chess piece and actually shift it like my previous manual cars (miata, mini, bmw).

Below is what it said on my invoice:


Not sure if it's the same number (05-14-01) for you USA folks but try to mention this to your dealer if you have the rough / notchy shifter and get it fixed! Also let us know if it did fix your problem or not

Have fun zoom zooming!!! :Racing 1:
@Soler25 posted the TSB on page three. First post.
By chance do you know of a link to find the TSB? I have looked on like 25+ sites and I've found nothing about the manual transmission problem.
 
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#75 ·
I have only experienced the difficulty of getting back in to 1st gear from nuetral. I find that if I let up on the clutch a couple inches it will go in. It's only happened probably less than 10 times and I have just over 14k on her. I will have the dealer take a look at it when she goes in for her next oil change & tire rotation at 15k.
 
#77 ·
Has anyone figured out a alternate fix to this other than the TSB? I have a 2015 sGT that's suffering pretty bad from this and I've done the TSB probably 4 or 5 times now. The TSB temporarily makes it a little better but then it gets worse again in about 2 weeks.

I don't want to change shift knobs as I like the OEM one and I don't really care for my dealer as they don't really do anything to fix issues like these.
 
#84 ·
So my dealer didn't know what I was talking about, and said there is no adjustment, of course it might of not helped that I thought it was under the hood. After taking a better look at the picture I discovered it was right next to the shifter, makes more sense seeing that other picture with it torn apart lol. I brought it home and did it myself, it wasn't hard, I did almost break it because I didn't know how it adjusted, finally figured it out, and seems to be a little better, but I don't feel it's like how it was when I test drove it.. oh well.
 
#85 ·
Just noticed this when I was searching around for more info ,

TSB: 05-001/15

MULTI-MODEL (6 SPEED SKYACTIV M/T) ? HARD TO SHIFT INTO 3RD, 4TH, 5TH AND/OR 6TH GEAR

This bulletin supersedes the previous bulletins 05-008/14 issued on 07/14/14 and 11/26/14. The PART(S) INFORMATION has been revised.

APPLICABLE MODEL(S)/VINS

2012-2013 Mazda3 (SKYACTIV 6 M/T)

2014-15 Mazda3 (6 M/T) with VINs lower than JM1BM228314 (produced before August 8, 2014)

2013-2015 CX-5 (6 M/T) with VINs lower than JM3KE517027 (produced before August 8, 2014)

2014-2015 Mazda6 (6 M/T) with VINs lower than JM1GJ203425 (produced before August 8, 2014)
 
#86 · (Edited)
I spoke with my dealer and they acknowledged the issue. I was instructed to drive a bit more to see what happens. I'm just passing my first 1k km and it's supposedly still in the break-in period, whatever that might mean.

I'm not a mechanic, just a moderatelly advanced human being aware that car is not a black box. Therefore, I would really appreciate someone explaining this to me. I adjusted shifter cables couple of times now and everytime it is fine for a day or two and then becomes bad as it was in the first place. What is causing this slack in it and why it happens all over again after the adjustment? There must be some dimensional tolerances somewhere to cause this. And it's sooo finicky, we're talking about half a mil here...

Could shifter base be the root of the issues? I'm planning to install solid bushings, so I'm wondering if this could help.

Can shifter adjustment explanation fit the fact that this is happenning irregurarly? Or can this just be explained by different moments (RPM range) of the gear engagement?

What about the RMM? Can excessive movement of the engine/transmission assembly relative to the "fixed" shifter base cause someting to misalign overtime?

I'm really brainstorming here because this thing is ruining my experience with the first new car I've ever had. I would never expect this from Mazda and I'm really pissed off/sad because I don't have any hope this will ever be properly resolved.
 
#88 ·
I'm really brainstorming here because this thing is ruining my experience with the first new car I've ever had. I would never expect this from Mazda and I'm really pissed off/sad because I don't have any hope this will ever be properly resolved.
I'm in the same boat as you. I simply have been too busy at work to call Mazda and create a storm. I have over 6,000 miles on mine and it has gotten worse over time. I would still recommend calling Mazda if you haven't already. As soon as my schedule allows, I'll be making a very upset-customer phone call.
 
#87 ·
@mbarisic

after my adjustment, gears 3 to 6 are fine. 1 and 2 are not as notchy but more than the other gears. so i just dont rush (shift slower) my shifts from 1 to 2. shifting from 1 to 2, at higher revs, seems to be smoother. ive just accepted that this mazda transmission doesnt like to be rushed. also i have 60k miles on my car, and the manual hasnt loosen up after the adjustment. so maybe your 3 needs to be looked at again, maybe by a different dealer.
 
#89 · (Edited)
I had my dealer do the fix at 9K (shifting was great when I bought the car, but got progressively rougher starting at about 4K). After the fix, the notchyness was noticeably worse. I think they skipped the final step in the service bulletin: test drive the car.

In my case the notchyness feels almost like I'm not disengaging the clutch fully -- as if the pedal is an inch or two from bottoming out.

Working the clutch also used to cause a little squeak under the car. (Somewhere in these forums someone posted an audio file of a clutch squeak that sounded identical to mine -- he turned out needing a new master cylinder.) My squeak went away after a few thousand miles, but now I'm noticing a subtle vibration while re-engaging the clutch pedal. I don't recall noticing this when I purchased the car. The clutch was perfectly smooth, as was the shifting.

Wondering if anyone here could help me out by checking to see if they feel a similar vibration in their clutch pedal. I'm putting together my list of symptoms for when I next revisit the dealer about the service bulletin. These are small-ish things that the dealer might dismiss, so I want to be sure I'm on firm footing.

Best way to feel the vibration is while shifting upward, under load (with acceleration). I feel it most from 2 to 3 and 3 to 4. While releasing the pedal, there's a spot about halfway to 2/3 up where it feels like my foot is sitting on a small electric motor. I.e., it's a fast, high-frequency vibration. It may be normal, and I wouldn't think anything of it (probably wouldn't even notice it) except that I was hyper-aware of how smooth all facets of shifting were when I first got the car.

Maybe it's related to the service bulletin problem? Or maybe my clutch will blow one of these days? Regardless, I want to take of it before the warranty expires.