Okay TL gurus, I hope you can help me out here…
I have scoured the forums and called local mechanics to try and understand my problem, but am having a hard time putting all the pieces together to make an informed decision moving forward.
Thank you in advance for any help.
I have an 04 TL 6 speed with 85,000 miles on it. I am the third owner and it is on the original clutch, however it shows no signs of slipping. Leading up to Friday (my freakin’ birthday), the car had driven as it always had, showing no signs of gradual deterioration. The only thing I had ever noticed up to this point was periodic clutch smell (after spirited driving) and a click when I would engage the clutch, but neither of them seemed concerning…other than my apparent periodic misuse of the clutch.
I was getting onto a highway and taking 2nd out pretty far (who doesn’t) and was blocked from getting to third. I was able to get it into gear after I came down to speed and able to shift to each gear as long as I’m being very conservative. What I mean by conservative is, as long as I am going slow enough such that the gear I try to go into will not cause the engine to exceed about 2,000 RPM I can go into that gear no problem. For instance, the car goes about 40MPH in 4th gear at about 2,000 RPM so, at 35-40 MPH I can put the car in any gear above 4th, but not any gear lower (hope that makes sense).
After talking to a local mechanic (and from what I have read here), one possibility could be the hydraulic system. I replaced the master cylinder (it didn’t appear to be leaking but, for $60 what the hell) and bled all the fluid following a kickass guide on the forum (thanks JJH), making sure to limit the slave cylinder while bleeding. It made no difference at all.
The last thing I am comfortable doing DIY (that I know of) is replacing the slave cylinder, as I do not have the tools, experience or resources to replace a clutch or transmission. However, I would like to limit random replacements (and lining a mechanics pocket) without being as informed as possible.
It appears from the forums to either be the hydraulic system or pressure plate, unless there are other adjustments to be made. One of the mechanics I spoke to (I cannot speak to his credibility) said it sounded like the transmission synchronizers, although it seems odd to me these would all behave the same way?
Here is some additional information on how the car behaves to help in thinking it out:
If the car is running and moving:

• If I short shift (stay below 3000 RPM or so) it drives and shifts perfectly fine into every gear, or at least as it always has for me.

If the car is running and stopped or off:

• I can shift into every gear perfectly fine EXCEPT 5th. I cannot get the car into fifth if sitting idle, regardless of if the car is on or off.

In addition to any suggestions/possible fixes, if anybody knows of a good mechanic for our cars in the Cincinnati area, please let me know.

 

If you did any kind of research in these forums, you'd find practically ALL the 6MT owners here cured these types of ills by replacing their transmission fluid with the GM Synchromesh Friction Modified, GM Part # 12377916. I had issues shifting into 3rd gear after I bought the car new 9 years ago. The GM fluid is like a magic fix. Try it BEFORE you do anything else.

Start by calling Chevy dealers in your area and give the parts dept(s) that part #. If they don't have it in stock, they can probably tell you who does. It's also available on-line.
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Although not exactly the most popular post, I figured I would share my findings for anyone with similar issues in the future.
Several months ago, after trying the synchromesh band aid and replacing the hydraulic system, I took the car to Acura for their diagnosis as the issue was still occurring. Their opinion, and that of other local mechanics was the synchros or other transmission components were at fault. Given the cost, I decided to hold off and drive it until the thing finally gave up. I was driving a couple of weeks ago and the pedal went completely dead and I decided it was time to face the music.
I took it to Cottman Transmission and their diagnosis was the clutch was likely the culprit. I asked him about their comfort level with the self adjusting clutch (and required specialty tool) and he says "It's just an ordinary clutch Mike, this is what we do...". Given the service manual almost explicitly states the clutch is not ordinary, I decided to pass on them, take it to the dealer and pay for the peace of mind.
Despite having said it was the transmission ~6 months ago, this time they said it was the clutch. They replaced the clutch and it drives like a dream...just hope I didn't add too much wear to the transmission driving it with a bad clutch.