remove clutch HONDA CR-V 1999 RD1-RD3 / 1.G User Guide

Release Bearing
4. Torque the mounting bolts in a crisscross pattern as
shown. Tighten the bolts in several steps to prevent
warping the diaphragm spring.
8 x 1.25 mm25 N.m (2.6 kgf.m, 19lbfft)
Remove the special tools.
Check the diaphragm spring fingers for height (see
page 12-7]'.
5.
6.
Removal/lnspection
1. Remove the release fork boot from the clutch hous-
Ing.
RELEASEBEABING
RELEASEFORKBOOT
\
RELEASE FORK
Remove the release fork and release bearing from
the clutch housing.
Check the release bearing for play by spinning it by
ha nd.
NOTE: The release bearing is packed with grease.
Do not wash it in solvent.
lf there is excessive play, replace the release bear-
ing with a new one.
12-11
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Transmission AssemblY
Removal
@FMak. sw. iack" and safety stands are placed propel-
ly, and hoist brackets are attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the batterY.
2. Remove the intake air duct and air cleaner houslng
(see section 5).
3. Remove the slave cylinder and clutch hose bracket'
NOTE:
. Do not operate the clutch pedal once lhe slave
cvlinder has been removed.
. Take care not to bend the clutch line.
4. Disconnect the
ground cable.
starter cables and transmission
TRANSMISSIONGROUND CABLE
Disconnect the back-up light switch connector and
wire harness clamP.
(cont'd)
13-7
WIRE HARNESS CLAMP
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Transmission Assembly
Removal (cont'dl
6. Remove the cotter pins,
washers, plastic washers.
cable from the levers.
then remove the steel
shift cable, and select
1.
8.
Remove the cable bracket from the clutch housing.
Disconnect the vehicle speed sensor (VSS) connec-tor.
-------------.2
13-8
9. Remove the
bolts.
four upper transmission mou nting
10.
11.
Drain transmission fluid (see page '13-3).
Remove the guard bar and the splash shield.
MOUNNNG BOLTS
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Transmission Assembly
Removal (cont'd)
20. Remove the intermediate shaft.
21.Tie plastic bags over the both ends of the intermedi-
ate shaft. Coat all precision finished surfaces withclean engine oil.
Remove the rear engine stiffene. and clutch hous-Ing cover.
13-10
23. Remove the right front mounvbracket.
RIGHT FRONTMOUNT/BRACKET
Place a jack under the transmission, raise it just
enough to take it off of the mounts, then remove
the transmission mount bracket and transmission
mount.
TRANSMISSION MOUNT
MOUNT BRACKET
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25. Remove the transmission mounting bolts and the
rear engine mounting bolts.
REAR ENGINE MOUNTING BOLTSReplace.
TRANSMISSION
Pull the transmission away from the engine until it
clears the mainshaft, then lower it on the transmis-
sion jack.
NOTE: Take care not to bend the clutch line.
Remove the starter motor and hose clamp from the
transmission housing.
STARTERMOTOR
28. Remove the release tork boot. release bearing, and
release fork from the clutch housing
RELEASEBEANING
13-1 1
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7. Remove the set ball screws, washers, springs, steel
balls. and back-uP light switch.
STEEL BALLD. 5/16 in
8. Remove the flange bolt. drain plug, and filler plug
DRAIN PLUG
WASHERReplace.
LIGHT SWITCH
FILLER PLUG
WASHERReplace.
FLANGE BOLT
9. Remove the transmission housing mounting bolts
in a crisscross pauern in several steps.
10. Remove the 32 mm sealing bolt
Expand the snap ring on the countershaft ball bear-
ing, and remove it from the groove using a pair of
snap ring plier.
Separate the transmission housing from the clutch
housing.
Remove the dowel pins, and wipe it clean of the
sealant.
'I t.
(cont'd)
13-15
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20.
2't.
19. Remove the reverse lock cam.
lf necessary, check the clearance of the reverse shift
holder (see page 13-20).
Remove the reverse shift holder.
HOLOER
22. '97 - 99 models: Remove the reverse gear shaft and
the reverse idler gear.'00 model: Remove the reverse gear shaft, reverse
idler gear, thrust washer and the coller.
13-17
23. Remove the mainshaft and countershaft assemblies
with the shift forks from the clutch housing.
NOTE; Before removing the mainshaft and counter-
shaft assemblies, tape the mainshaft spline to pro-
tect it.
ASSEMBLY
Tape the main'
shaft splines.
WASHER
SPRING WASHER
24. Remove the differential asssmbly.
COUNTEBSHAFT
HOUSING
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Differential
Bearing Outer Race Replacement
Note these items:
. The bearing outer race and tapered roller bearingshould be replaced as a set.. lnspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
'1. Remove the oil seals from the transmission housingand clutch housing (see page j3-43).
2. Drive the bearing outer race and thrust shim out ofthe transmission housing, or remove the bearingouter race and 75 mm shim from the clutch housingby heating the clutch housing to about 212"F(100"C) with a heat gun. Do not reuse the thrustshim if the outer race was driven out.
TRANSMISSIONHOUSING:
ATTACHMENT52x55mm07746 - 0010400
THRUST SHIM
BEARINGOUTER RACE
CLUTCHHOUSING:
13-40
4, lnstallthe oil seal (see page 13-43).
3. Install the thrust shim or 75 mm shim and the bear-ing outer race in the transmission housing andclutch housing using the special tools.
Note these items during bearing replacement:. Install the bearing outer race squarely.. Check that there is no clearance between thebearing outer race, thrust shim or 75 mm shimand housing.
TRANSMISSIONHOUSING:
HANDI-E07749 - 00 xxto
ATTACHMENT,62x68mm077ir6 - 0010500
BEARINGOUIER RACETHRUST SHIM
CLUTCHHOUSING:HANDLE07749 - 001tXX)o
ATTACHMENT.72xt5mm07745 - 00106{x)
OUTER RACE
75 mm SHIM
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Tapered Roller Bearing Preload Adiustment
lf any oJ the items listed below were replaced, the tapered
roller bearing preload must be adjusted.
. Transmission housing
. Clutch housing
. Differential carrier
o Tapered roller bearing and bearing outer race
. Thrust shim
. 75 mm sham
1. Remove the bearing outer race and thrust shim
from the transmission housing (see page 13-40)'
NOTE:
. Do not reuse the thrust shim if the bearing outer
race was driven out.
. Let the transmission cool to room temperature il
the bearing outer race was removed by heating
the clutch housing.
2. Do not use more than one thrust shim to adjust the
tapered bearing preload. First try the same size
thrust shim that was removed. There are no shims
used on the clutch housing side
SHIMTHRUST
/A
After installing the thrust shim, install the bearing
outer race in the transmission housing (see page
13-40).
With the mainshaft and countershaft removed,
install the differential assembly, and torque the
clutch housing and transmission housing.
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
TOBOUE; 8 x 1.25 mm: 27 N'm(2.8 kgf'm, 20 lbt'ftl
Rotate the differential assembly in both directions
to seat the tapered roller bearings.
Measure the tapered roller bearing preload at nor-
mal room temperature. Measure the starting torque
of the differential assembly in both directions with
the special tool and a torque wrench.
STANDAFD: 1.4 - 2.5 N'm
{1/r - 26 kgf'cm, 12 - 23 lbf in)
(cont'd)
4.
5.
07HAJ - PK4020'1
13-41
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Oil Seal Replacement
Transmission Housing:
1. Remove the oil seal from the transmission housing
2.lnstall the new oil seal into the transmission hous-
ing using the special tools.
NOTE: Install oil seal up to i0.5 mm (10.02 jn) from
transmission housing end surface.
TRANSMISSIONHOUSING
PRESS
fHANOLE
.--.'/'01119 - @1OCIO0
DRIVER ATTACHMENT- PG4()r00
PILOT,28 x 30 mm07JAO - PH80400
OIL SEALReplace.
OIL SEAL
Clutch Housing:
1. Remove the oil seal from the clutch housing.
HANDLE
lnstall the new oil seal into the clutch housing using
the special tools.
NOTE: Install oil seal up to t0.5 mm (t0.02 in) from
transmission housing end surface
CLUTCHHOUSING
PRESS
I
07749 - tx)l(xxto
DRIVER ATTACHMENTOTJAD - PHM1Ol
PILOT, 28 x 30 mm07JAD - PH8oaU)
Replace.
13-43
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