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

O TRANSFER HOUSING
O o-RING Replace.
O TRANSFER HOUSING ROLLER BEARING
@ TRANSFER SHAFT
O TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING
O TRANSFER SHAFT COLLAR
@ THRUST SHIM, 25 mm Selective part
€) TRANSFER DRtvE GEAR (HYPoID GEAR}
@ coNtcAL SPRtNG WASHER Reptace,
@ TRANSFER SHAFT LOCKNUT,22 x 1.25 mm Left-hand rhreads, replace.
(D TAPERED ROLLER EEARING
@ TAPERED ROLLER EEARING OUTER RACE(} THRUST SHIM, 68 mm Selective part
@ O-RING Replace.
@ TRANSFER coVER A
(} TRANSFER COVER B
@ o-RING Replace.
(9 TRANSFER DRIVEN GEAR SHAFT (HYPOID GEAR)
@ THRUST SHIM, 35 mm Selective part
@ TAPERED ROLLER BEARING
@ TRANSFER SPACER Reptace.
@ TAPERED RoLLER BEARTNG OUTER RACE
@ TAPERED ROLLER BEARING OUTER RACE
@ TAPERED BOLLER BEARTNG
@ olL SEAL Replace.
@ COMPANION FLANGE
@ o-RING Replace.
@ BACK-UP RING
@ coNtcAL SPRtNG WASHER Reptace.
@ 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 lbnft)
118 N.m (12.0 kgim,87 Ibift)
132 216 N.m (13.5 22.0 kgf.m,
98 - 159 lbift)
6x1.0mm
8 x 1.25 mm
22 x 'l.25 mm
22 x 1.25 mm
Transfer shaft locknut:
Left hand threads
Transfer driven gear shaft locknut
Tightening torque: depending on
Total Starting Torque value
14-233
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Transfer Assembly
Inspection
NOTE: To prevent damage to the transfer housing,
always use soft jaws or equivalent materials between
the transfer housing and the vise.
Trsnsfer Gear (Hypoid gear) Backl8sh M€asurem€nt
1. Set a dial indicator on the companion flange as
snown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.02 - 0.06 in)
Total Starting Torque Meagurgm€nt
3, Rotate the companion flange several times to seat
the tapered roller bearing.
4. Measure the starting torque (companion flange
side) using a torque wrench as shown,
STANDARD:
2.68 - 3.,17 N.m(27.3 - 35.,1 kgf.cm, 23.7 - 30.7 lbf.inl
TRANSFER SHAFT
DIAL INDICATOR
COMPANION FLANGE
14-234
Transfer Gear (Hypoid gear) Tooth Contact Inspection
5, Remove transfer cover B, then apply Prussian Blue
to both sides of the transfer gear teeth lightly and
Rotate the companion flange in both directions until
the transfer gear rotates one full turn in both direc-
tions.
Check the transfer gear tooth contact pattern. Thepattern should be centered on the gear tseth as
snown.
6.
7.
8.lf the statrting torque measurement or the tooth
contact pattern are not correct, disassemble the
transfer assembly, replace worn or damaged parts,
and reassemble it.
TRANSFER DRIVE G€AR
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Transfer Assembly
Reassembly
NOTE:
. While reassembling the transfer assembly:. Check and adjust the transfer gear tooth contact.. Measure and adjust the transfer gear backlash.. Check and adjust the tapered roller bearing stan-
ing torque.
. Coat all pans with ATF during reassembly.. Replace the tapered roller bearing and the bearing
outer race as a set if either part is replaced.. Replace the transfer drive gear and the transfer dri-ven gear shaft as a set if either part is replaced.
Outline of Assembly
1.Select the 35 mm thrusi shim.
Psrtorm this procedute if the transter driven g€ar
shaft or the tapered roller bearing on the transfer
driven gear shaft is replaced.
Prea$emble the parts to check and adiust transtelgear backlash and transfer gear tooth contact.
Disassemble the parts, then assemble the translerdriven gsar shaft and its related pans.
2.
3.
4. Measure and adjust the starting torque oI the
transfer driven gear shaft tapered roller bearing.
5. Assemble the transfer shaft and its related parts.
6. Measure and adiust the total starting torque.
35 mm Thrust Shim Selection
L Select the 35 mm thrust shim if the transfer drivengear shaft or the tapered roller bearing on the trans-
fer driven gear shaft is replaced.
Calculate the thickness of the 35 mm thrust shimusing the formula below.
FoRMULA:+ -*-+c=x
A: Number on the existing transfer driven gear shaft
B; Number on the replacement transfer driven gear
shaft
C: Thickness ofthe existing 35 mm thrust shimX: Thickness needed for the replacement 35 mmthrust shim
NOTE: The number on the transfer driven oear
shaft is shown in 'll100 mm.
14-240
EXAMPLE:
C: EXISTING 35 mmTHRUST SHIMThickness: C=1.05 mm
X: REPLACEMENT 35 mmTHRUST SHIMThickness: X=?? mm
Number: A=+2Numbe.: B=-'l
Ar EXISTING TRANSFERDRIVEN GEAR SHAFT
x= A - B .c" 100 100 -
2-1
100 100 '-
= 0.02 + 0.0'l + 1.05=1.08 {mm)
B: REPLACEMENT TRANSFERDRIVEN GEAR SHAFT
Select 35 mm thrust shim thickness of l08 mm(0.043 in). lf the tapered roller bearing on the transfer
driven gear shaft is replaced.
Measure the thickness of the replacement bearingand the existing bearing, and calculate the difference
of the bearjng thickness. Adjust the thickness of the
existing 35 mm thrust shim by the amount of differ-
ence in bearing thickness, and select the replacement
35 mm thrust shim.
THRUST SHIM, 35 mm
Shim No.Part NumberThickness
41361 - PS3 - 0000.72 mm (0.028 in)
41362-PS3-0000.75 mm {0.030 in}
c41363-PS3-0000.78 mm (0.03'1 in)
D41364-PS3-0000.81 mm (0.032 in)
41365-PS3-0000.84 mm (0.033 an)
F41366-PS3-0000.87 mm (0.034 in)
41367-PS3-0000.90 mm (0.035 in)
H41368-PS3-0000.93 mm (0.037 in)
41369-PS3-0000.96 mm 10.038 in)
41370-PS3-0000.99 mm (0.039 in)
K4 r371 - PS3 - 0001.02 mm (0.040 in
41372-PS3-0001.05 mm (0.041 in
M41373-PS3-0001.08 mm (0.043 in
N41374-PS3-000'1.11 mm 10.044 in
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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.
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 lbnin).
NOTE:
Coat the threads of the locknut, and the shaft
with ATF before installing the locknut.
Do not stake the locknut in this step.
STARTING TOROUE:
0.98 - 1.39 N.m
{10.0 - 14.2 kgrf.cm,8.68 - 12.3 lbf'inl
COMPANION FLANGEHOLDER
07JAB - @1020A
14-242
9. Install the transfer shaft in the transfer housing,
then install the tapered roller bearing, transfer shaft
collar.25 mm thrust shim, transfer drive gear, coni-
cal spring washer, and locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut. and the shaft
with ATF before installing the locknut.
. Do not stake the locknut in this step.
TRANSFER
THRUST SXIM,25 mmSelective pan
TRANSFER DRIVEGEAR
CONICAL SPRINGWASHERReplace.
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20. Remove the parts on the transfer shaft, and remove
the transfer shaft from the transfer housinq.
TRANSFER SHAFT
TRANSFER HOUSINGTAPEFED ROLLERBEARNG
TRANSFERCOLLAR
TRANSFER DRIVEGEAR
THRUST SHIM, 25 mmSelective pan
CONICAL SPRINGWASHERReplace.
Transf€r Driven Gear Shaft Starting Torque Inspsction
and Adjustment
21. Secure the transfer housing in a bench vise with
soft jaws, To prevent damage, always use soft jaws
or equivalent materials between the transfer hous-
ing and the vise.
22. Install the special tool on the companion flange,
then remove the transfer driven oear shaft locknut
and the conical spring washer.
COMPANION FLANGE HOLDER07RAB - TB,010A ol07RAB - TB,010B
Replace.
23. Remove the transter driven gear shaft and the com-
panion flange,
24. Install the new transfer spacer on the transfer dri-
ven gear shaft, then install them in the transfer
housrng.
TRANSFER DRIVENGEAR SHAFTTFANSFER SPACERlnstall in this direction.Replace.
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, and transfer
shaft with ATF before installing the locknut.
. Install the conical spring washer in the direction
shown,
TRANSFER HOUSING
O.RINGReplace.
CONICAL SPRINGWASHERReplace.
LOCKNUTReplace.
(cont'd)
BACK.UP RING
14-245
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Transfer Assembly
Reassembly (cont'd)
Secure the transfer housing in a bench vise with
soft jaws. To prevent damage, always use soft jaws
or equivalent materials between the transfer hous-
ing and the vise.
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.s8 - 1.39 N.m
{10.0 - 14.2 kgf.cm,8.68 - 12.3 lbf.in)
TIGHTENING TOROUE:
132 - 216 N.m
{13.5 - 22.0 kgf.m, 98 - 159 lbf.ft)
NOTE;
. Rotate the companion flange several times to
seat the tapered roller bearing, then measure the
starting torque,
. lf the starting torque exceeds 1.39 N.m (14,2
kgf.cm, 12.3 lbf.in), replace 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
rorque.
COi'PANIOI{ FLANGE HOLDER07MB - TBi(tloA otO'RAB - TB,.|}IOB
TOFOUEWRENCH
HOLDER HANDLE07JAB - 001020A
27.
14-246
28. Stake the locknut into the transfer driven gear shaft
using a 3,5 mm punch as shown.
0.7 - 1.2 mm{0.03 - 0.05 inl
PUNCH3.0 - 3.5 mm10.12 - 0.1{ inl
Point to bestaked.
29. Install the transfer shaft in the transfer housing,
then install the tapered roller bearing, transfer shaft
collar,25 mm thrust shim, transter drive gear, coni-
cal spring washer, and transfer shaft locknut on the
transfer shaft,
NOTE:
. Coat the threads of the locknut and transler shaft
with ATF before installing the locknut.. Install the conical spring washer in the direction
snown.
TRANSFER SHAFT
TRANSFER HOUSII{G
THRUST SHIM. 25 mrt|Selective part
CONICAL SPRINGWASHERReplace.
\t)t--/./
.,.-,.,\
Replace.
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30. Put a 14 mm Allen wrench in the gear side of the
transfer shaft. then secure the Allen wrench in a
bench vise. Tighten the transfer shaft locknut. {The
locknut has left-hand threads,)
TOROUE: 118 N.m (12.0 kgf.m, 87 lbt.ft)
Stake the locknut on the transfer shaft using a 3.5
mm ounch.
al
14 mm ALI-EN WRENGH
0.7 - 1.2.nm{0.0:1- 0.C5 in}PU CH3.0 - 3.5 rnm
Total Starting Tolqu€ Insp€ction and Adiustment
32. TemDorarilv install transter cover A without the O-
flng.
HOUSING
TMNSFER COVER A
e
€
v
E- 8x1.25mm24 N'm {2.i1kgt'm, r? bt'ftl
Secure the transfer housing in a bench vise with
soft jaws, then rotate the companion flange several
times to fit the tapered roller bearing. To prevent
damage, always use soft jaws or equivalent materi-
als betlveen the transfer housing and the vise.
Measure the total starting torque.
TOTAL STARTING TOROUE:
1.70 - 2.08 N.m {17.3 - 21.2kgl.cm,15.0 - 18.i1 lbf.in}
+ Transler Driven Gear Sh8ft Starting Torque Value
lwroto down in step 27).
(cont'd)
5J.
34.
14-247
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Transfer Assembly
35.
Reassembly (cont'dl
36.
Remove taansfer cover A.
lf the measurement is out of specification, remove
the 68 mm thrust shim from transfer cover A by
heating the cover to almost 212"F (100"C) using a
heat gun. Do not heat the cover higher than 212"F(100'C). Let the cover cool to room temperature
before adjusting the starting torque,
lf the measurement is within the specification, go to
step 40.
HEAT GUN
14-248
37. Select the 68 mm thrust shim.
THRUST SHIM, 58 mm
Shim No.Part NumberThickness
zv23974-P1C-O201.41 mm (0.056 in)
zw23975-P1C-O201.44 mm (0.057 in)
zx23976-P1C-020'1.47 mm (0.058 in)
ZY23977 - P1C - O201.50 mm (0.059 in)
zz23978-P1C-0201.53 mm 10.060 in)
23941 PW5 - 000'1.56 mm {0.061 in)
B23942-PWs-0001.59 mm 10.063 in)
c23943 - PWs 0001.62 mm (0.064 in)
D23944-PW5-0001.65 mm {0.065 in}
E23945 PWs - 0001.68 mm (0.066 in)
F23946 PWs - 0001.71 mm (0.067 in)
G23947 PWs - 0001.74 mm (0.069 ini
23948-PW5-0001.77 mm (0.070 ini
23949 PW5 0001.80 mm (0.071 in,
J23950-PWs-0001.83 mm {0.072 ini
K23951 - PWs - 0001.86 mm (0.073 in
L23952 PW5 - 0001.89 mm (0.074 in
23953 PWs - 0001.92 mm (0.076 in
N23954 PW5 - 0001.95 mm (0.077 in
o23955 PW5 0001.98 mm (0.078 in
P23956 - PWs 0002.01 mm (0.079 in
o23957-PW5-0002.04 mm (0.080 in
R23958, PWs 0002.07 mm (0.081 in
s23959-PW5-0002.10 mm (0.083 in
T23960 PW5 - 0002.13 mm (0.084 in
U2396'1 PW5 - 0002.16 mm (0.085 in
23962 PWs 0002.19 mm (0.086 in
23963 - PW5 0002.22 mm (0.087 in
X23964 - PW5 0002.25 mm (0.089 in
23965 PW5 - 0002.28 mm (0.090 in
z23966 PWs 0002.31 mm (0.091 in
23967-PWs-0002.34 mm (0.092 in
AB23968-PWs-0002.37 mm (0.093 in)
AC23969-PWs-0002.40 mm (0.094 in)
AD23970-PW5-0002.43 mm (0.096 in)
M23941 PW8 0002.46 mm (0.097 in)
BZ23942-PW8-0002.49 mm (0.098 in)
cz23943 - PW8 0002.52 mm (0.099 in)
DZ23944 PW8 - 0002.55 mm (0.100 in)
EZ23945-PW8-0002.58 mm (0.102 in)
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38. Install the 68 mm thrust shim using the special
tools.
PRESSDRIVER07743 - 001 0000
ATTACHMENT,62x68mrr|077a6 - (x)10500
39.After replacing the 68 mm thrust shim. recheck and
make sure the total starting torque is within the
specification.
AEARING OUTER RACE
40. Install the new O-rings on transfer covers A and B,
then installthe covers on the transfer housing
6x1.0mm12 N.m 11.2 kgt.D,8.7 rbf.ftlTRANSFEN COVER B
O.RINGReplace.
8 r 1.25 rnm24 N.m 12.4 kgl.m, 17 lbf'ftl
Replace.
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Real-time 4WD-Dual Pump System
Troubleshooting (Automatic Transmissionl
When starting and accelerating in forward gesrs {4WDmodel
1. Lift up the vehicle so all four wheels are off theground (see section 1).
2. Make a mark on either No.
shaft.
'I or No.2 propeller
PROPELLER SHAFT
Start the engine, and let it run until it warms up (the
radiator fan comes on at least twice).
With the engine at idle. shift to the E position.
Apply the parking brake firmly. and measure thetime it takes the propeller shaft to rotate 10 times.. lf the measured time is more than 10 seconds,
the 4WD system is normal.
. lf the time is less than 10 seconds, there is aproblem in 4WD system. Check the differential
fluid. lf the differential fluid is normal, replace
the torque control differential case kit.
15-10
When starting and accelerating in revGrsg gear {4WDmodel
1. Lift up the vehicle so all four wheels are off theground (see section 1).
Make a mark on either No.
shaft.
1 or No. 2 propeller
PROPELLER SHAFT
Start the engine. and let it run until it warms up (the
radiator fan comes on at least twicei.
With the engine at idle, shift to the E position.
Apply the parking brake firmly, and measure the
time it takes the proDeller shaft to rotate 10 times,. lf the measured time is more than 10 seconds,
the 4WD system js normal.. lf the time is less than 10 seconds, there is aproblem in 4WD system. Check the differential
fluid. lf the differential fluid is normal, reolace
the torque control differential case kit.
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