Front brake HONDA CR-V 1997 RD1-RD3 / 1.G User Guide

Pressure Testing
Changing
NOTE: Keep all foreign particles out of the transmis-
sion.
1. Bring the transmission up to operating temperature
(the radiator fan comes on) by driving the vehicle.
Park the vehicle on level ground. turn the engane
off. then remove the drain Plug.
NOTE: lf a cooler flusher is to be used, see page
14-264 and 14-265.
TRANSMISSIONEND COVER
DRAIN18 x 1.5 mmSEALING WASHEBReplace.49 N.m {5.0 kgt.m, 36 lbf.tl)
Reinstall the drain plug with a new sealing washer,
then refill the transmission with the recommended
fluid to the uDper mark on the dipstick. Always use
Genuine Honda Premium Formula Automatic
Transmission Fluid (ATF) Using a non-Honda ATF
can affect shift quality.
Automatic Transmission Fluid Capacity:
4WD;
2.9 { (3.1 US qt. 2.6 lmp qt) 8t change
5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul
2WD:
2.7 | l2.S US qt,2.1lmp qtl ai change
5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul
2.
a
a
1.
Wlrile testing, be careful of the rotaling wheols.
Mako sure lifts, iacks, and safety stands ar€ placed
properly (see scction 11.
Before testing, be sure the transmission fluid is
filled to the proPer level.
4WD:
Raise the vehicle (see section 11.
2WD:
Raise the front of the vehicle, and make sure it is
securely supported. Set the parking brake, and block
both rear wheels securely.
Allow all four wheels {4WD) or front wheels (2wD}
to rotate freely.
Warm up the engine (the radiator fan comes on),
then stop it and connect the tachometer.
Connect the oil pressure gauges to each inspection
hole securely, and do not allow dust or other foreign
particles to enter the inspection holes.
TOROUE: 18 N'm ll.8 kgf'm, 13 lbf'ft)
5.
A/T PRESSURE HOS€,2210 mm07MAJ - PYiOllA
{4 Requircd}
,4'/"' ,a
W'
A/T PRESSURE HOSEADAPTER07MAJ - PYt0120(il Rcquiledl
6. Measure the following Pressure:. Line Pressure ..........,14-162
. 1st. 1st-hold Clutch Pressure .............'. 14-162
. 2nd,3rd and 4th Clutch Pressure .......... 14-163
7. Install new sealing washers and the sealing bolts in
the inspection holes, and tighten to the specified
toroue.
(cont'd)
A/T OIL PRESSUREGAUGE SET W/PANEL07{06 - 0020400
/4\\-J-- (
+..\.-.\-'-\
A/T LOW PBESSUREGAUGE w/PANEL07406 - 0070300
TOROUE: 18 N'm 11.8 kgf'm, 13 lbf'ft)
14-161
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Transfer
4.
Inspection
@E Mako suro lifts, jacks, and safety standsare placod properly lsoe section t).
1. Raise the front of the vehicle, and make sure it issupported securely.
2. Set the parking brake, and block both rear wheelssecurely.
Shift to E position.
Make a reference mark across the propeller shaftand the transfer assembly flanges.
Separate the propeller shaft from the transferassembly.
8 x 1.25 mm32 N.m 13.3 kgl,m,24 lbf.ftlReplace.
14-164
\
6. Set a dial indicator on the transfer assembly flange.then measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.002 - 0.006 inl
7. lf the measurement is out of standard, remove thetransfer assembly and adjust transfer gear backlash{see page '14-232 thru 14-2491.
8. Check for fluid leaks between the mating faces oftransfer cover A and cover B.
9. lf there is a fluid leak, remove the cover, and reDlacethe O-ring.
'10. Check for fluid leaks between the mating face of thetransfer assembly and transmission.
11. lf there is a fluid l€ak, remove the transf€r assem-bly, and replace the O-ring,
12. Check the transfer oil seal for damage and fluidle8ks.
13, lf oil seal replacement is required. remove the trans-fer assembly, replace the oil seal, and adjust thetotal starting torque (see page 1+232 thtu ]'4-249||.
NOTE: Do not replace the oil seal with the transferassembly on the transmission.
COMPANION FLANGE
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Transfer Assembly
Removal
@ Make sure the lifts, iacks, and safety
stands are placed properly (see section 11.
1. Raise the front of the vehicle, and make sure it is
supported securely.
2. Set the parking brake, and block both rear wheels
securelv.
3 Drain the automatic transmission fluid (ATF).
Reinstall the drain plug with a new sealing washer'
DRAIN PLUG'18 x'1.5 rnm49 N.m 15.0 kgf.m, 36 lbl.ftl
4. Remove the guard bar and the splash shield.
GUARD 8AR
14-165
5.Disconnect the primary heated oxygen sensor
{Primary HO2S) connector.
Remove exhaust pipe A.
SELF-LOCKINGNUTBeplace.
7.
SEI-F.LOCKINGNUTReplace.
NUTReplace
Remove the shift cable cover.
Remove the snap pin and control pin, then separate
the shift cable from the control lever. Do not bend
the shift cable excessively.
(cont'd)
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Front DriveshaftsIntermediate Shaft
Installation {cont'd}
Install the damper fork over the driveshaft and ontothe lower arm. Install the damper in the damperfork so the aligning tab is aligned with the slot inthe damper fork.
FLANGE BOLT10 x 1.25 mm€ N.m {4.i1kst.n,32 lbf.ftl ALtcNtNG TAB
12x 1.25 mm64 N.m {6.5 kgf.m, 47 lbf.ftlReplace.
7. Loosely install the flange bolts and the new self-locking nut.
8. Apply oil to the seating surface of the new spindle nut.
FRONT WHEELi WHEEL NUT 12 x 1.5 mm108 N.m (11.0 kgf.m,80lbf.ftl
SPINDLE NUT24 x 1.5 mm245 N.m{25.0 ksf.m, 181 lbf.ft)NOTE: Atter tightening. use a drift tostake the spindle nut shoulder against the driveshaft.
9. Install a new spindle nut, then tighten the nut.10. Clean the mating surfaces of the brake disc and thewheel. then install the front wheel with the wheelnuts,
1'1. Tighten the flange bolts and the new setf-lockingnut with the vehicle's weight on the damper.12. Refill the transmission with recommended fluid (see
section 13 or 14).
13. Check the front wheel alignment. and adjust if nec-essary (see section 18).
16-18
1.
Removal
Drain the transmission oil or fluid (see section 13 or14).
Remove the left driveshaft (see page 16-3).
Remove the three dowel bolts.
Remove the intermediate shaft from the differential.Hold the intermediate shaft horizontal until it is clear ofthe differentialto prevent damage to the differential oilseal.
INTERMEDIATE SHAFT
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Front Toe Inspection/Adjustment
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment (caster,
camber, toe, and turning angle). Follow the equipment
manufacturer's instructions,
3.
1.Check the tire pressure.
Center the steering wheel spokes.
Check the toe with the wheels pointed straight
ahead.
Front toe-in: 0 i 3 mm {0 t 1/8 inl
- lf adjustment is required, go on to step 4.
- lf no adjustment is required, remove alignment
equipment.
Loosen the tie-rod locknuts, and turn both tie-rods
in the same direction until the front wheels are
pointing straight ahead.
5.Turn both tie-rods equally until the toe reading on
the wheel alignment computer is correct.
After adjusting, tighten the tie-rod locknuts and
reposition the tie-rod boots if they are twisted or
displaced.
sir N m (5.5 kgJ.m, 'O lbf.ft)
Rear Toe Inspection/Adjustment
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment (caster,
camber. toe, and turning angle). Follow the equipment
manufacturer's instructions.
Release parking brake to avoid an incorrect mea-
surement.
Check the toe.
Ro8r toe-in: 2 :1 mm {lN l/16:t 1/16 in,
- lf adjustment is required, go to step 2.
- lf no adiustment is required. remove alignment
equrpmenr.
Before adjustment, note the locations of adjusting
bolts on the right and left compensator arms.
Loosen the adjusting bolts, and slide the compen-
sator arm in or out. as shown, to adiust the toe.
1.
FLANGE BOLT'10 x 1.5 mm
COMPENSATOR ARM
Example: After the rear toe inspection, the wheel is 2
mm (0.08 in) out of the specification.- Move the arm so the adjusting bolt moves 2 mm
{0.08 in) inward from the position recorded before the
adjustment.- The distance the adjusting bolt is moved should be
equal to the amount out-of-specification.
5. Tighten the adjusting bolts.
6a N.m 16.5 kgf.m, 47 lbf'ftl
18-5
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Knuckle/Hub Replacement
Note these items during replacement:
. Replace the selt-locking nuts after removal.
. The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.
. Torque the castle nuts to the lower torque specifications, then tighten them only far enough to align the slots with each
pin hole. Do not align the nuts by loosening.
o Use only genuine Honda wheel weights for aluminum wheels. Non'genuine wheel weights may corrode and damage
the aluminum wheels.
. Onthealuminum wheels, remove the center cap from the inside of the wheel after removing the wheel.
. Before installing the brake disc, clean the mating surfaces of the front hub and brake disc.
. Before installing the wheel. clean the mating surfaces ofthe brake disc and wheel.
. Wipe off the grease before tightening the nuts at the balljoints.
CALIPER MOUNTING BOLT12 x 1.25 mm108 N.m (11.0 kgtm.80 lbt.ftl
LOWER BALL JOINTInspect for faultymovement and wear,Replacement, page'18 15
CASTLE NUT10 x 1.25 mm39 - 47 N.m (i1.0 - 4.8 kgf.m, 29 - 35 lbf.ftl
COTTER PINReplace.
WHEEL BEARINGBeplace.Replacement, page 18-13
CIRCLIPSPLASH GUARD
SCREW5x0.8mm4.9 N.m {0.5 kgf.m,3.6lbf.ft)
SET RING
FRONT HUBCheck for damage and
Replacement,page 18 10
BALL JOINT BOOTCheck for deteriorationano oamage.SPINOLE NUT24 x 1.5 mm245 N.m {25.0 kgI.m, 181 lbtft}Replace.. Before installing the spindle nut, applyengine oil to the seating surface of the nut.. After tightening, use a drift to stake thespindle nut shoulder against the spindle.
COTTER PINReplace.
CASTLE NUT12x 1.25 fim49 - 59 N.m 15.0 - 6.0 kgt.m. 36 - € lbf.ft)
BRAKE DISCCheck for wear andrust.Replacement, page 18-10Inspection, section 19.
WHEEL NUT12 x 1.5 mm108 N.m{11.0 kgt m,80 tbf.ftl
6 mm BRAKE DISC RETAINING SCREW9.8 N.m (1.0 kgtm, 7.2 lbtftl(cont'd )
18-9
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Front Suspension
Knuckle/Hub Replacement (cont'dl
1.Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is
secu.ely supported.
Remove the wheel nuts and wheel.
SPINDLE NUT24 x 1,5 mm245 N.m (25.0 kgf.m, 181 lbtft)Replace.
Raise the locking tab on the spindle nut, then remove
the nut.
Remove the brake hose mounting bolts.
BRAKE HOSE MOUNTING BOLT8 x 1.25 mm22 N.m {2.2 kgt m, 16 lbtft)
CALIPER MOUNTING BOLTS12 x 1.25 mm108 N.m (11.0 kgl.m, 80 lbl.ft)
Remove the caliper mounting bolts, and hang the
caliper assembly to ona side. To prevent damagg to
the caliper assembly or brake hose, use a shortpiece of wire to hang the caliper from the undercar-
riage.
18-10
7. Remove the 6 mm brake disc retaining screws,
6 mm BRAKE DISCRETAINING SCREWS9.8 N.m(1.0 kgl.m,7.2 lbf.ftl
8.
8 x 1.25 mm BOLTS
Screw two 8 x 1.25 mm bolts into the disc to push it
awav from the hub. Turn each bolt two turns at a
time to prevent cocking the disc excessively,
Remove the brake disc from the knuckle.
Check the front hub for damage and cracks.
11. Remove the wheel sensor from the knuckle (for
vehicles with ABS). Do not disconnect the wheel
sensor connector.
9.8 N.m(1.0 kgf.m,7.2 tbttrl
MOUNTINGBOLTS9.8 N.mlr.0 kgf.m, ?.2lbf.ftl
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Front Suspension
31.
Knuckle/Hub Replacement (cont'dl
Wash the knuckle and hub thoroughly in high flash
point solvent before reassembly,
Press a new wheel bearing into the knuckle using
the old b6aring, a plate. the special tool, and a
press. Place the wheel bearing on the knuckle with
the pack seal side facing (metal color) toward the
inside. Be careful not to damage the sleeve of the
Dack seal.
DOUBLE LIP SEALIBLACK COLORI
SUPPORT BASE0?965 - SD90t00
33. Install the circlip securely in the knuckle groove.
35. lnstall the hub on the knuckle using the specialtools
shown and a hydraulic press. Be careful not to dis-
tort the splash guard.
ORIVER077irg - 0010000
SPLASH GUARO
lnstall the knuckle in the reverse order of removal,
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
r Torque a\ mount
g hardv{are to ths speci{ied
torque values,
o Torque the castle nuts to the lower torque speci
fications, then tighten them only iat enough to
align the slots with each pin hole. Do not align
the castle nut by loosening.
a lnstall new cotter pins on the castle nuts or hex
nut after torquing.
. Avoid twisting the sensor wires when installing
the wheel sensor.
. Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the spindle nut, apply a small
amount of engine oil to the seating surface oJ the
nut. After tightening, use a drift to stake the spin-
dle nut shoulder against the driveshaft.
. Before installing the wheel. clean the mating sur-
face of the brake disc and the inside of the wheel.
. Check the front wheel alignment, and adjust it if
necessary {see page 18-4).
scREws5 N.m 10.5 kgl m, 4 lbl'tt)
CIRCLIP
34. Install the splash guard and tight€n the screws.
18-14
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'1.
Lower Ball Joint Replacement
Remove the knuckle (see page 18-10).
Remove the boot by prying the set ring off.
Check the boot for deterioration and damage. and
replace it if necessary.
lnstall the special tools on the ball joint, and tighten
the castle nut.
BAII JOINT BEMOVER BASE07JAF - SH2oe00
Position the special tools over the ball joint as
shown. then set the assembly in a vise. Press the
ball joint out of the knuckle.
Place the ball joint in position by hand.
Install the special tools over the ball joint as shown,
then press the balljoint in.
BAII JOINT INSTAL1IR BASE
7.
8AI.I JOINT REMOVEN/INSTALLER
BALL JOINT HOUSING SURFACE
18-15
8. Install the ball joint boot and set ring using the spe-
cial tool {see page 18-16}.
Install the knuckle in the reverse order of removal.
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
. Torque all mounting hardware to the specified
toroue values.
a Torque the castle nuts to the lower torque speci-
fications, then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. Install new cotter pins on the castle nuts after
IOrqurng.
Avoid twisting the sensor wires when installing
the wheel sensor.
Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
Before installing the wheel. clean the mating sur-
face of the brake disc and the inside of the wheel.
Check the front wheel alignment, and adjust it if
necessary (see page 18-4).
o
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Front Damper
Reassembly
1. Install the damper unit on a spring compressor.
STRUT SPflNG COMPBESSOR:lcomm.rcillly .vrilrble)BRANICKC T/N MST.sEOAor Mod.l 7200or oquivtla
SPRING LOWER SEAT
Assemble the damper in reverse order of removal
except the damper mounting washer and self lock-
ing nut. Align the bottom of the damper spring and
the spring lower seat as shown.
Position the damper mounting base on the damper
unit as shown.
Compress the damper spring,
Install the damper mounting rubber, damper mount-
ing washer, and a new 10 mm self-locking nut.
SELF-LOCKING NUT10 x 1.25 mmZt N.m 13.0 kgf.m, 22 lbf.ft)Replace.
Hold the damper shaft, and tighten the
locking nut.
DAMPERMOUNfING WASHER
18-18
10 mm self-
1.
lnstallation
Loosely install the
aligning tab facing
two flange nuts.
damper on the frame with
inside, then loosely install
FLANGE NUT
the
tne
-__---a-"- 10 x 1.25 mmg*- 59 N.m {5.0 kgt m, 43 tbf.ftl
| -,./.46- --...
./ -4 A-
DAMPERASSEMBLY
ALIGNINGTAB
2, Install the damper fork over the driveshaft and onto
the lower arm. Install the front damper in the
damper fork so the aligning tab is aligned with the
slot in the damDer fork,
3. Loosely install the damper pinch bolt on the top of
the damper fork.
4. Looselv install the damper fork bolt and a new self-
locking nut on the bottom of the damper fork.
5. Raise the knuckle with a floor iack until the vehicle just
lifts off the safetv stand.
The lloor iack must b€ socurely posi-
tioned or personal iniury may result.
6. Tighten the damper pinch bolt.
7. Tighten the damper fork bolt and self-locking nut.
8. Tighten the flange nuts on top of the damper.
9. Install the brake hose mounts with the brake hose
mounting bolts.
10. Installthe front wheel.
10 x 1.25 mmil3 l+m
{4.4 kgf'm,
Replace.
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