Washer HONDA CR-V 1997 RD1-RD3 / 1.G Repair Manual

MainshaftSealing Rings
Inspection (cont'dl
It the clearance is out of standard, remove the
thrust washer and measure its thickness.
Select and install a new washer, then recheck the
clearance, and make sure it is within standard.
THRUST WASHER 36.5 x 55 mm
No.Part NumberThickness
190441 - PG4,0104.00 mm (0.157 in)
290442-PG4-0104.05 mm (0.159 in)
90443-PG4-0104.10 mm {0.161 in)
90444-PG4-0104.15 mm {0.163 in)
90445-PG4-0104.20 mm (0.'165 in)
690446-PG4-0104.25 mm {0.167 in)
190447-PG4-0104.30 mm (0.169 in)
890448-PG4-0104.35 mm (0.171 in)
I90449-PG4-0104.40 mm (0.173 in)
1090450-PG4-0004.45 mm (0.175 inl
14-204
Replacement
The sealing rings (35 mm and 29 mm) are synthetic resin
with chamfered ends. Check the condition of the sealing
rings, and replace them only if they are worn, distorted,
or oamageo.
NOTE: Apply ATF to all partsduring assembly.
1. For a better fit, squeeze the sealing ring together
slightly before installing them.
Install new sealing rings on the mainshaft.
After installing the sealing rings, verify the follow-
ing:
. The sealing rings are fully seated in the groove.
. The sealing rings are not twisted.
. The chamfered ends of the sealing rings are
properly joined.
SEALING RINGInstall the sealing ringmating faces as shown.
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Countershaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricate all pans with ATF before reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmov\
ement.
. Before installing the O-rings, wrap the shaft spllnes with tape to prevent damaging the O-rings.
. Locknut has left-hand threads.
. Install the conical spring washer in the direction shown.
R€VERSE GEAR
LOCKNUT IFLANGE NUTI23 x 1.25 mm103-0-103N.mCONICAL SPRINGWASHERReplace.t10.5 - 0 -
75.9 - 0 -
Replace.
10.5 kgl.m,75.9 lbt.lr)
Lelt.hand threads
COUNTERSHAFTCheck splines for excessivewear and damage.
REVERSE SELECTORHUB
4TH GEAR
NEEDLE EEARING
NEEOLE BEARING
REVERSESELECTOR
OISTANCE COLLAR.28 mmSelective part
2NO GEAR
lST GEAR
I{EEDLE BEARINGCheck bearing surface for scoring,scratches and excessive wear.lST GEAR COLLAR
TRANSn SSTONHOUSI G BEARING
3RD GEAR
NEEDLE BEARING
3RD GEAR COLLAR
THRUST NEEOLE BEARING
SPLINED WASHER
3RO CLUTCH ASS€MBLY
14-205
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Gountershaft
Disassembly/Reassembly
1. Remove the reverse selector hub and countershaft
4th gear using a universal two-jaw lor three-jaw)
puller as shown. Place a shaft protector between
the puller and countershaft to prevent damaging
the countershaft.
{Commercially available)
REVERSESELECTOR HUB
.TH GEAR
14-206
2. Assemble the parts on the countershaft as shown
below.
NOTE;
. Lubricate all parts with ATF during reassembly.
. Before installing the O-rings. wrap the shaft
splines with tape to prevent damaging the O-
rings.
4TH GEAR
BEARI'{G
DISTANCE COLLAR, 28 mmSelective oart
GEAR
THRUST ]{EEOL€ AEARIIIG
GEAR COLLAR
THRUST I{EEDLE EEARII{G
WASHER
3RO CLUTCH ASSEMBLY
SEARII{G
O-RINGSReplace.
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3. Install the reverse selector hub on the countershaft
sub-assembly, and press the hub using the special
tool and a press as shown.
DRIVER to mm l.D.07746 - 0030100
REVERSE SEI.ICTORHUB
COUNTERSHAFTSU&ASSEMBLY
Inspection
Clearance Measurement
NOTE: Lubricate all parts with ATF during assembly.
1. Remove the countershaft bearing from the trans-
mission housing lsee page 14-227).
2. Assemble the countershaft parts using the special
tool and a press as described on this page. Do not
install the O-rings during inspection.
R€VERS€ SELECTORHUB
GEAR
NEEDLE BEARING
DISTANCE COLLAR, 28 mmSelective part
2NO GEAR
THRUST NEEDLE BEARING
GEAR
NEEOLE BEARING
GEAR COLIAR
THRUST NEEDLE BEARING
WASHER
CLUTCH ASSEMBLY
(cont'd)
14-207
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Countershaft
Inspection (cont'd)
3.
4.
Install the countershaft sub-assembly parts, then
installthe park gear using a press and a collar.
Tighten the locknut to 29 N.m (3.0 kgf.m, 22 lbf.ft).
The countershaft locknut has left-hand threads.
LOCKNUTLe{t-hand threads
CONICAL SPRINGWASHER
PABK GEAR/ONE.WAYCLUTCH/1ST GEARASSEMBLY
NEEDLE BEANING
lST GEAR COLLAR
TRANSMISSION HOUSINGAEARING
REVERSE GEARCOLLAR
COUNTERSHAFTSUB.ASSEMBLY
14-208
5. Measure the clearance between the 2nd gear and
the 28 mm distance collar with a feeler gauge.
NOTE: Take measurements in at least three places,
and use the average as the actual clearance.
STANDARD: 0.10 - 0.18 mm (0.004 - 0.007 in)
OISTANCE COLLAR,28 mm
FEELER GAUGE
6. lf the clearance is out ot standard, remove the dis-
tance collar, and measure its width.
7. Select and install a new distance collar, then recheck.
DISTANCE COLLAR,28 mm
8. After selecting a new distance collar. recheck the
clearance and make sure it is within standard.
2NO GEAR
No.Part Numberwidrh
190503-PCg-00039.00 mm ('1.535 in)
290504-PCg-00039.'10 mm (1.539 in)
?90505-PCg-00039.20 mm {1.543 in)
90507-PCg-00039.30 mm (l.547 in)
90508*PCg-00039.05 mm (l.537 in)
90509-PCg-00039.15 mm (l.541 in)
790510-PCg-00039.25 mm {1.545 in)
890511-PCg-00038.90 mm { L531 in)
990512-PCg-00038.95 mm ( 1.533 in)
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Torque Gonverter Housing
BearingsGontrol Lever Assembly
Countershaft Bearing Replacement
1. Remove the countershaft bearing using the specialtool.
SLIOE HAMMER,3la" -16(Commercially available)
ADJUSTABLE BEARINGPULLER,25 - 40 mm07736 - A0100OB ol07736 - A01m0A
Install the ATF guide ptate.
Install a new countershaft
converter housing.
COUNTERSHAFTBEARING
bearing in the torque
DRIVER077i19 - 001m00
14-230
ATF GUIDE PLATE
Replacement
Check the condition and movement of the control leverassembly, lf the control lever assembly binds or doesnot move smoothly. replace it.
1. Remove the 6 x 1.0 mm bolt and lock washer.
2. Remove the change shaft trom the torque converterhousing.
3. Remove the control lever assembly from the controlshaft.
4. Install the new control lever assembly in the reverseorder of disassembly, until it bottoms in the torqueconverter housing.
LOCK WASHERReplace.
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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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Disassembly
1. Remove the transfer covers A and B.
2. Cut the lock tabs of the locknut usino a chisel.
LOCK TAB
5.
Put a 14 mm Allen wrench in the gear side of the
transfer shaft, then secure the Allen wrench in a
bench vise.
Remove the transfer shaft locknut and the conical
spring washer. The transfer shaft locknut has left
hand threads.
Remove the transfer shaft, transfer drive gear, 25
mm thrust shim, transfer shaft collar, and tapered
roller bearing from the transfer housing.
TRANSFER SHAFT
THRUST SHIM,25 mrnSelective part
CONICAL SPRINGWASHERReplace.
(cont'd)
1a mm ALLEN WRENCH
14-235
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Transfer Assembly
Disassembly (cont'd)
7.
Secure the transfer housing in a bench vise withsoft iaws. To prevent damage to the transfer hous-ing, always use soft jaws or equivalent materials
between the transfer housing and the vise.
Install the special tool on the companion flange,then loosen the transfer driven gear shaft locknut.
COMPANION FLANGEHOI.DER07RAB - TB4lll0A orOTRAB - TB&TOB
HOLDER HAITDI..E07JAB _ (x)1020a
Remove the transfer driven gear shaft locknut, coni-cal spring washer, back-up ring, O-ring. and com-panion flange.
O.RINGReplace.
BACK-UP RING
CONICALSPRING WASHENReplace.
GEAR SHAFT LOCKNUTReplace.
14-236
9. Remove the transfer driven gear shaft, then removethe transfer spacer from the transfer driven gear
shaft.
TRANSFER DRIVENGEAR SHAFT
Remove the oil seal and the tapered roller bearingfrom the transfer housing.
10.
OIL SEALFeplace-
TAPEREO ROLLERBEARING
TRANSFER HOUSING
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Transfer Gear Bscklash Inspection and Transfer Gear
Tooth Contact Inspection
2. Install the 35 mm thrust shim on the transfer driven
gear shaft, then install the tapered roller bearing
using the special tools and a press.
DRIVER {0 mm LD.077146 - 0030100
TRANSFER DRTVEN ;;.GEAR SHAFT u, 745 - 0O304O0
Place the tapered roller bearing on the bearing outer
race of the companion flange side of the transfer
housrng.
Install the new oil seal on the transfer housing
using the special tools.
OIL SEAL DRIVERATTACHMENT07JAD - PH80101
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.
Install the 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
{cont'd)
TRANSFER
TRANSFER HOUSING
14-241
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