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2004 Element EX-S AWD 6MT = “Zippy”
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Yes, the cost is certainly getting worse, for sure...
Availability may be the next problem...

Even though my project vehicle modification is still in the "To Be Completed" column, I ended up modifying Zippy's previously replaced interlock...
(aside: Why do I save junk? This is why!) I just couldn't get another factory piece, and the mod was pretty easy...
Pic below pretty clearly shows material removal as I was working down through it...

207792
 

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2004 Element EX-S AWD 6MT = “Zippy”
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453 Posts
Semi-Related to the 6MT:

I swapped out wheels and tires recently... (with BC Racing coilovers :geek:)

I went from:
stock EX wheels 225/70r16 Nokian (+2% in diameter over stock)

I went to:
stock SC wheels 235/50r18 Toyo (-1.5% in diameter under stock)

I am finding that I am using 6th gear quite a bit more than I used to... Just another point of data for anyone interested...

Cheers,
Brad

207846
 

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Kind of off topic but my search hasn’t led me to anything fruitful.

I have an 03 awd auto, are there any swaps I can do to keep both awd and auto but have either 5 or 6 speed transmission? My biggest concern would be ECU issues which I think may be a problem if I were to go with an 07 auto trans from an element.

Thanks
 

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2004 Element EX-S AWD 6MT = “Zippy”
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453 Posts
I agree that swapping a newer 5-forward-gear automatic transmission with and older ECU (that also controls the 4-forward-gear automatic transmission) would be problematic.

I do not know of anything else that is possible in your situation for an automatic transmission swap...
(but I'm the kind of guy that prefers a box of gears and a third pedal... 🤷‍♂️ )

Brad
 

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Honda Element 6 speed Manual Transmission Conversion

Part numbers supplied are from a 2006 Acura TSX 6MT
The identical parts could be obtained from a 2006 Civic Si 6MT, but the part numbers will be slightly different.

I recommend both of these manuals:
Helms Honda Element Manual
Helms Acura TSX Manual

- Shifter mechanism parts -
Reverse shift piece 24240-PNS-000
Shift arm interlock 24430-PNS-000 (or modify the old one)

5-6 gearshift fork 24201-RAS-000 NOTE: In at least one CRV and possibly in some later model Elements the Reverse shift piece may be welded to the Element's 5-Reverse shift fork, instead of being attached by a pin. In this case see step 3 below.

These parts are optional. The function of these parts hasn't been determined; however the transmission functions well without them. They may be necessary for reverse safety interlock.
  • MBS arm 24412-PNS-000
  • MBS arm spring 24413-PNS-000
  • - added by MikeQBF.
}

- Main shaft parts -
Mainshaft 6th gear 23590-RAS-A00
Needle Bearing (35 x 41 x 24) 91103-RAS-003
Collar (28 x 35 x 24) 23916-PNS-000
5-6 Synchronizer Sleeve Set 23626-PNS-315

- Countershaft parts -
Special bolt 90011-PPP-000
Countershaft 6th gear 23491-RAS-000

Procedure
Note: This is the procedure that I followed. This worked for me, however if there are mistakes or omissions I cannot be held responsible. There are several variations that will also work. Without proper experience it is possible to destroy the transmission if it is not reassembled correctly. It is important to inspect all parts and if there are any worn parts they should be replaced. Please use caution and common sense.

1. Following procedure in the Element Manual, remove the transmission. Note it is not necessary to remove the outboard joints of the driveshafts from the wheel hub. They can remain in place. Just remove the inboard joints from the transmission and intermediate shaft. Do remove the intermediate shaft.

2. Follow procedure in the Element Manual for disassembly of the transmission. Stop after the shifter and gearsets have been removed. Discard the reverse cam lock.

3. Drive out the pin connecting the reverse shift fork and the 5th gear shift fork. Discard the pin. Remove and discard the reverse shift fork. Replace with the new 6 speed reverse shift fork. In at least one CRV and possibly some later model Elements the reverse shift fork may be welded to the 5th gear shift fork (rather than attached by a connecting pin). In this case you must order the TSX 5-6 gearshift fork 24201-RAS-000. Use this shift fork as a replacement for the stock 5th gear shift fork.

4. Follow the procedure in the Element Manual for disassembly of the mainshaft. Remove the taper cone ring and associated distance collar, and discard. Remove 5th gear synchronizer, discard and stop. Follow the procedure in the Acura TSX manual for reassembly of the mainshaft. Press the new 5-6 synchronizer hub onto the mainshaft. Place the new collar and needle bearing on the mainshaft. Place the new mainshaft 6th gear over the needle bearing. Replace the ball bearing as directed.

5. Follow the procedure in the Element Manual for disassembly of the countershaft. The appropriate way to do this is to use a bearing puller and hydraulic press, but some people cheat. Other people find a local tranny shop may help with this step. Remove the special bolt (note - reverse threads). Remove the bearing, the shim, and the distance collar, then stop. Discard the special bolt and distance collar. Follow the procedure in the Acura TSX manual for reassembly of the mainshaft. Press the countershaft 6th gear onto the countershaft. Complete reassembly of the countershaft as directed.

6. Replace the shift arm interlock with the new interlock. Alternatively, the slot in the old shift arm interlock can be elongated by about 6mm (the width of the reverse select lever).

7. Follow procedure in the Element Manual for reassembly of the transmission. Do not re-install the reverse lock cam. Note: Be sure to install the speed sensor spacer (It is not a washer) in the correct order - Bolt, sensor, spacer, transmission.

8. Following procedure in the Element Manual, install the transmission.

9. Drive.
 

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It’s already been done without switching the tranny I saw a YouTube video where all they did was added the extra 6th gear in the current tranny just gotta know what ur doing
 

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It’s already been done without switching the tranny I saw a YouTube video where all they did was added the extra 6th gear in the current tranny just gotta know what ur doing
Wasn’t that for a five speed to a six speed? Also was that a manual or an auto?

I have a four speed auto and I want either a five or a six speed auto.

I generally prefer manual transmissions but because of how I sit in the Element and the location of the shifter, a manual doesn’t look comfortable at all. Add to that that I am frequently in traffic and a manual becomes a chore.
 
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