Washer HONDA CR-V 1997 RD1-RD3 / 1.G Owner's Guide

Disassembly
1.
2.
Securely clamp the countershaft assembly in a
bench vise with wood blocks.
SPRIiIG WASHEF
BETICHvtsE
W(X)D BLOCKS
Raise the locknut tab from the groove in the coun-
tershaft, then remove the locknut and the spring
washer.
Remove the ball bearing using a press as shown.
CHISEL
4. Remove the Jriction damper from the spacer using a
press and a socket.
Support lst gear on steel blocks, and press the
countershaft out of 3rd gear.
PRESS
t
5.
PRESS
I
3RD GEAR
1ST GEAR
FRICTION DAMPERInspect lor wear and damage.
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8. Install sth gear using the special tools and a press.
PRESS
I
DRIVER, 40 mm l.D.
07715 - 0030300
ATTACHMENT,30 mm LD.077,16 - 0030300
LInstall the needle bearing using the special tools
and a press, then installthe bearing outer race
PRESS
I
DRIVER. 40 mm l.D.077{6 - 0030100
ATTACHMENT,30 mm l.D.07746 - 0030300
NEEDLEBEASING
10. Install the ball bearing using the special tools and a
press.
PRESS
I
DRIVER. 40 mm LD.07746 - 0030100
ATTACHMENT,30 mm LD.077a6 - 0030300
11.Securely clamp the countershaft assembly in
bench vise with wood blocks.
LOCKNUTReplace.
Install the spring washer.
Install the new locknut to the correct torque, then
stake the locknut tab into the groove.
Torque: 127 + 0 + 127 N.m 113 - 0 +13 kgf.m,
94+0-94|bf.ft)
12.
wooD slocKs
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O TRANSFER HOUSING
@ O-RING Replace.
O DAMPER HUB
G) NEEDLE BEARING
G) TRANSFER DRIVEN GEAR
G) TRANSFER SHAFT
O TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING
€) TRANSFER SHAFT COLLAR
@ THRUST SHIM, 25 mm selective part
6D TRANSFER DRIVE GEAR (HYPOID GEAR)
@ CONICAL SPRING WASHER RePlace
GD TRANSFER SHAFT LOCKNUT.22 x 1.25 mm Left-hand threads, replace'
E) TAPERED ROLLER BEARING
@ TAPERED ROLLER BEARING OUTER RACE
@ THRUST sHlM. 68 mm selective part
O o.RlNG Replace.
@ TRANSFER COVER A
GD TRANSFER COVER B
@ O-RING Replace.
€) TRANSFER DRIVEN GEAR SHAFT (HYPOID GEAR}
@ THRUST SHIM, 35 mm Selective Part
@ TAPERED ROLLER BEARING
@ TRANSFEB SPACEB RepIace.
@ TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING OUTER RACE
@) TAPERED ROLLER BEARING
@ olL SEAL Replace.
@ COMPANION FLANGE
@ O-RING Replace.
@ BACK-UP RING
@ coNtcAL SPRING WASHEB Replace.
(o TRANSFER DRIVEN GEAR SHAFT LOCKNUT,22 x 1.25 mm Replace.
TOROUE SPECIFICATIONS
Boh/Nut No.Torque ValueSizeRemarks
6A
8C
22L
22H
12 N.m (1.2 kgf.m.8.7 lbf.ft)
24 N.m {2.4 kgf.m, 17 lbf'ft)
118 N.m (12.0 kgf.m, 86.8 lbf'ftl
132 - 216 N.m (13.5 - 22.0 kgf'm,
97.6 - 159 lbf.ft)
6x1.0mm
8 x 1.25 mm
22 x 1 ,25 mm
22 x 1 .25 mm
Transfer shaft locknut:
Lett-hand threads
Transfer driven gear shaft locknut
Tightening torque: dePending on
Total Starting Torque vaiue
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Transfer Assembly
Disassembly (cont'd)
Secure the transfer housing in a bench vise withsoft jaws.
COMPANION FLANGEHOLDER07RAA -
Install the special tool on the companion flange,then loosen the transfer driven gear shaft locknut.
Remove the transfer driven gear shaft locknut, coni-cal spring washer, back-up ring, O-ring, and com-psnion flange.
7.
TRANSFER DRIVENGEAR SHAFT LOCKNUTReolace,
13-48
9. Remove the transfer driven gear shaft, then removethe transfer spacer from the transfer driven gearshaft.
TRANSFER ORIVENGEAR SHAFT
Remove the oil seal and the tapered roller bearingfrom the transfer housing,
OIL SEALReplace.
TAPEREO ROLIIRAEARING
TRANSFER HOUSING
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Transter Gear Backlash Inspection and Transfer Gear
Tooth Contaqt Inspection
2. lnstall the 35 mm thrust shim on the transfer driven
gear shaft, then install the tapered roller bearing
using the special tools and a press.
NOTE: Use old lransfer spacer for bearing installa-
tion, then discard it.
TRANSFER DRIVENG€AR SHAFT
Install the bearing outer race, then the tapered bear-
ing on the companion flange side ot the transfer
housing.
3.
OIL SEAL DRIVERATTACHMENT07JAD - PH80101DRIVER077/tg - 001qt00
Replace.TAPERED ROLLERBEARING
Install the new oil seal on the transfer housing
using the special tools.
5. Install the transfer driven gear shaft in the transfer
housing. Do not install the transfer spacer on the
transfer driven gear shaft in this step.
TRANSFERHOUSING
Installthe companion flange. conical spring washer,
and locknut on the transfer driven gear shaft. Do
not install the O-ring and the back-up ring on the
transfer gear shaft in this step.
6,
COMPANIONFLANGE
CONICAL SPRING
direction.
(cont'd)
13-53
TRANSFER HOUSING
WASHER
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Transfer Assembly
Reassembly (cont'd)
7.Secure the transfer housing in a bench vise with
soft jaws, then install the special tool on the com-
panion flange. To prevent damage to the transfer
housing, always use soft jaws or equivalent materi-
als between the transfer housing and the vise.
COMPANION FLANGEHOLDER07RAB - 0020000
WRENCH
8. Tighten the locknut while measuring the starting
torque so the starting torque is within 0.98 - 1.39
N.m {10.0 - 14.2 kgf.cm. 8.68 - 12.3 lbf.in).
NOTE:
. Coat the threads of the locknut, and the shaft
with MTF before installing the locknut.
. Do not stake the locknut in this step.
STARTING TOROUE:
0.98 - 1.39 N.m(10.0 - 14.2 kgf.cm, 8.68 - 12.3 lbf.in)
9.Install the transfer shaft assembly in the transfer
housing, then install the tapered roller bearing,
transfer shaft collar,25 mm thrust shim, transfer
drive gear, conical spring washer, and locknut on
the transfer shaft.
NOTE:
. Coat the threads of the locknut, and the shaft
with MTF before installing the locknut.
. Do not stake the locknut in this step.
TRANSFER SHAFTASSEMBLY
TRANSFER
THRUST SHIM.25 mmSelective part
COLLAR
TRANSFER DRIVEGEAR
CONICAL SPRINGWASHERReplace.Replace.
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20. Remove the parts on the transfer shaft, and remove
the transfer shatt from the transfer housinq.
TRANSFER SHAFT
TRANSFER HOUSING
TAPERED ROLLERBEARING
TRANSFER SHAFTCOLLAR
TMNSFER DRIVEGEAR
THRUST SHIM, 25 mmSelective part
CONICAL SPRINGWASHERReplace.
LOCKNUTReplace.
Transter Driven Gear Shaft Starting Torque Inspection
and Adlustment
21. Secure the transfer housing in a bench vise with
soft iaws.
Install the special tool on the companion flang€,
then remove the transfer driven gear shaft locknut
and the conical spring washer.
COMPANION FLANGE HOLDER
22.
BACK.UP
Remove the transter driven gear shaft and the com-
panion flange.
Install the new transfer spacer on the transfer dri-
ven gear shaft, then install them in the transfer
housing.
TRANSFER DRIVENGEAR SHAFTTRANSFER SPACERInstall in this direction.TRANSFER
25.Install the companion flange, O-ring, back-up ring,
conical spring washer and locknut on the transfer
driven gear shaft.
NOTE:
. Coat the threads of the locknut, O-ring and trans-
fer shaft with MTF before installing the locknut.
. Install the conical spring washer in the direction
shown.
TRANSFER HOUSING
O.RING
COMPANIONFLANGECONICAL SPRINGWASHERReplace.
LOCKNUTReplace.
(cont'd)
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Transfer Assembly
Reassembly (cont'dl
26. Secure the transfer housing in a bench vise with
soft jaws.
COMPANION FLANGE HOLDER07RAB - 002tD00
27. Install the special tool on the companion flange.
then tighten the transfer driven gear shaft locknut
while measuring the starting torque of the transfer
driven gear shaft.
STARTING TOROUE:
0.98 - 1.39 N.m
{10.0 - 1i1.2 kgf.cm, 8.68 - 12.3 lbf in}
TIGHTENING TOROUE:
132 - 216 N.m
(13.5 - 22.0 kgf.m, 97.6 - 159 lbf.ft)
NOTE:
. Rotate the companion flange several times to
seat the tapered roller bearing, then measure the
startrng torque.
. lf the starting torque exceeds 1.39 N.m (14.2
kgf.cm, 12.3 lbf.in), .eplace the transfer spacer
and reassemble the parts. Do not adjust the
torque with the locknut loose.
. lf the tightening torque exceeds 216 N.m (22.0
kgf.m, 159 lbf'ft), replace the transfer spacer and
reassemble the parts.
. Write down the measurement of the starting
torque: it is used to measure the total starting
torque.
28. Stake the locknut into the transfer driven oear shaft
using a 3.5 mm punch.
0.7 - 1.2 mm(0.03 - 0.05 inl
Point to bestaked.
Install the transfer shaft assemblv in the transfer
housing, then install the tapered roller bearing,
transfer shaft collar, 25 mm thrust shim, transfer
drive gear, conical spring washer, and transfer shaft
locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut and transfer shaft
with MTF before installing the locknut.
. lnstall the conical spring washer in the direction
snown.
TMNSFER SHAFTASSEMBLY
TRANSFER HOUSING
TAPERED ROLLERBEARING
TRANSFER SHAFTCOLLAR
TRANSFER DRIVEGEAR
PUNCH3.0-3.5 mm10.12 - 0.1a inl
THRUST SHIM, 25 mmSelective part
CONICAL SPRINGWASHEBReplace.
LOCKNUTReplace.
29.
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Mainshaft Thrust Clearance
Adjustment
l. Remove the 78 mm shim
the transmission housing.
4.
and oil guide plate from
Install the 3rd/4th synchro hub, spacer collar, sth
synchro hub, spacer, and ball bearing on the main-
shaft. then install the above assembly in the trans-
mission housing.
lnstallthe washer on the mainshaft.
Measure distance @ between the end of the trans-
mission housing and washer,
NOTE:
. Use a straight edge and vernier caliper.
. Measure at three locations and average the read-
Ing.
END otTRANSMISSION
MAINSHAFT
WASHER
3RD/4TH SYNCHRO HUB
SPACER COLLAR
sTH SYNCHRO HUB
SPACER
78 mm SHIM
13-64
BALL BEARING
5, Measure distance @ between the end of the clutch
housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and avorage the read-
Ings.
END ot CLUTCH HOUSING
BEARING
Select the proper 78 mm shim from the chan by
using the formula below.
Shim S€lection Formula:
From the measurements you made in steps 4 and 5:-1. Add distance @ (step 5) to distance @ (step 4).
-2. From this number. subtract 0.93 (which is the
midpoint of the flex range of the clutch housing
bearing spring washer).
-3. Take this number and compare it to the avail-
able shim sizes in the chart.
(For example)
A: 2.39 2.61
+ Bi O.22 - 0.93
= 2.61= 1.68
Try the 1.68 mm (0.0661 in) shim.
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78 mm SHIM
Part NumborThickness
23941 - P16 - 0001.20 mm (0.0472 in)
23942-P16-0001.23 mm (0.0484 in)
c23943-P16-000'1.26 mm (0.0496 in)
u23944-Pt6-0001.29 mm (0.0508 in)
23945-P16-0001.32 mm (0.0520n)
F23946- P16 - 0001.35 mm (0.0531n)
G23947-P16-0001.38 mm {0.0543n)
H23948-P16-0001.41 mm (0.0555n)
23949-P16-0001.44 mm (0.0567 in)
23950-P16-0001.47 mm (0.0579 in)
K23951 - P16 - 0001.50 mm {0.0591 in}
L23952-Pl6-0001.53 mm (0.0602 in)
M23953-P16-0001.56 mm (0.0614 in)
N23954-P16-0001.59 mm (0.0626 in)
o23955-P15-0001.62 mm (0.0638 in)
23956 - P16 - 0001.65 mm (0.0650 in)
23957-P16-0001.68 mm (0.066't in)
23958- P16 - 0001.71 mm (0.0673 in)
23959-P16-0001.74 mm {0.0685 in)
T23960-P16-0001.77 mm {0.0697 inl
23961 - P16 - 0001.80 mm (0.0709 in)
23962-P16-0001.83 mm (0.0720 in)
23963-P16-000'1.86 mm (0.0732 in)
X23964-P16-0001.89 mm (0.0744 in)
23965-P16-0001.92 mm (0.0756 in)
z23966-Pl6-0001.95 mm (0.0768 in)
23967-Pl6-0001.98 mm (0.0780 in)
AB23968-P16-0002.01 mm (0.0791 in)
23969-Pl6-0002.04 mm (0.0803 in)
AD23970 - Pl6-0002.07 mm {0.0815 in)
AE23971 - P16 - 0002.10 mm {0.0827 in}
23972-P16-0002.13 mm (0.0839 in)
23973-P16-0002.16 mm (0.0850 in)
AH23974-P16-0002.19 mm (0.0862 in)
AI23975-P16-0002.22 mm 10.087 4 inl
AJ23976-Pl6-0002.25 mm {0.0886 in}
AK23977-P16-0002.28 mm {0.0898 in)
23978-Pl6-0002.31 mm (0.0909 in)
23979-Pl6-0002.34 mm (0.0921 in)
AN23980-P16-0002.37 mm (0.0933 in)
7, Check the thrust clearance in the manner described
Delow.
NOTE: Measurement should be made at normal
room temperature.
-1. Install the 78 mm shim selected and oil guide
plate in the transmission housing.
78 mm SHIM
OIL GUIDE PLATE
Install the spring washer and washer on the
ball bearing.
NOTE:
. Clean the spring washer, washer and thrust
shim thoroughly before installation.
. Install the spring washer, washer and thrust
shim properly.
WASHER
g
,-g
SPRTNG*ASHER
Install the mainshaft in the clutch housing.
Place the transmission housing over the main-
shaft and onto the clutch housing.
Tighten the clutch and transmission housings
with several 8 mm bolts.
NOTE: lt is not necessary to use sealing agent
between the housings.
Tap the mainshaft with a plastic hammer.
-2.
-5.
(cont'd)
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