Page 4 HONDA CR-V 1998 RD1-RD3 / 1.G Workshop Manual

Pressure Plate
Removal/lnspection
1.Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard lNewl: 0.6 mm {0.02 in) max.
Service Limit: 0.8 mm (0.03 in)
HANDLE07936 - 3710100
CLUTCH ALIGNMENT DISCOTJAF - PM7O11A
CI.UTCH ALIGNMENT SHAFT07NAF - PR30100
FEELER GAUGE
lf the height is more than
the pressure Plate.
the service limit, replace
2. lnstall the sDeciallools as shown.
RING GEAR HOLDER ADJUSTER NUT
ENGINE BLOCKADJUSTER BOLT
BOLT
NUT WASHER
To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps. then remove the pressure plate.
4. Inspect the pressure plate surface for wear, cracks,
and burning.
5. Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Inspect for warpage using a straight edge and feeler
gauge. Measure across the pressure plate.
Standard lNew): 0.03 mm 10.001 in) max.
Service Limit: 0.15 mm (0.006 inl
6.
FEELER GAUGE
lf the warpage is more than the service limit,
replace the pressure plate.
PRESSURE PLATE
PRESSURE PLATE
12-7
www.emanualpro.com

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
www.emanualpro.com

Special Tools
ll
Ref. No. I Tool NumberDsscriptionOty I Page Roterence
o
o,6)
@-o
\9'
a
@6r
@
o
@
@
@
@
@
@
@
@
@
07GAD - PG40100
07GAJ - PG20110
07GAJ - PG20130
07HAJ - PK40201
07JAC - PH80000
07JAD - PH80101
07JAD - PH80400
07LAD - PW50601
07RAB - 0020000
07746 - 0010100
07746 - 0010300
07746 - 0010400
07746 - 0010500
07746 - 0010600
07746 - 0030100
07746 - 0030300
07746 - 0030400
07749 - 0010000
07947 - SD90200
07979 - PJ40001
Driver Attachment
Mainshaft Holder
Mainshaft Base
Preload Inspection Tool
Adjustable Bearing Remover Set
Driver Attachment
Pilot, 28 x 30 mm
Attachment, 40 x 50 mm
Companion Flange Holder
Attachment,32 x 35 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Attachment, 62 x 68 mm
Attachment, 72 x 75 mm
Driver, 40 mm l.D.
Attachment. 30 mm l.D.
Attachment, 35 mm l.D.
Handle
Attachment
Magnet Stand Base
1
1
1'l
1
1
1
1
1
1'I
1
1
1
1
13-43
13-66
13-66
13-41
13-62. 63
13-43, 53
13-43
13-39, 49
13-48,54,57,58
13-18, 68
13-27,34, 62
13-40. 51't3-40, 50. 51, 61,
oz, oJ
13-40
13-27 ,34,35, 49,
tJ-5C
13-27,34
13-14,27.34, 40,
43, 49, 50, 51, 53,
61,62,63,68'13-49
13-66
* Must be used with commercially available 3/8" - 16 Slide Hammer.
o@(9ta\
oG)
,d,(oo@(9(}@o@
.A IAa 5-z
Special Tools
www.emanualpro.com

Transfer Assembly
lnspection
@ Make sure tifts, iacks, and satety stands
are placed properly (see section 1).
L Raise the front of the vehicle, and support it with
safety stands (see section 1).
2. Set the parking brake, and block both rear wheels
securely.
3. Shift to neutral oosition.
4. Make a reference mark across the DroDeller shaft
and the transfer assembly flanges,
REFERENCE
8 x 1.25 mm32 N.m (3.3 kg{.m.24 rbf.ftlReplace.
Separate the propeller shaft from the transfer
assemDty.
5.
13-4
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 in)
COMPAf{ION FI-ANGE
1.lf the measurement is out of specification, remove
the transfer assembly and adjust transfer gear back-
lash (see page 13-44 thru '13-61).
Check the transfer oil seal for damage and fluid
teaKs.
lf oil seal replacement is required, remove the trans-
fer assembly, replace the oil seal, and adjust the
total starting torque (see page 13-44 thru 13-61).
NOTE: Do not replace the oil seal when the transfer
assembly is installed on the transmission.
www.emanualpro.com

Transfer Assembly
lnstallation
1. Install a new O-ring on the transfer assembly.
8 x 1.25 mm24 N.m (2.4 kgt m,17 rbt.ftl
10 x 1.25 mm44 N.m (4.5 kgJ.m,
2.
DOWEL PIN
Replace.TRANSFEBASSEMBLY
Clean the areas where the transfer assembly con
tacts the transmission with solvent or carburetor
cleaner, and dry with compressed air. Then apply
MTF to the contact areas.
Installthe transfer assembly on the transmission.
NOTE: While installing the transfer assembly on
the transmission, do not allow dust or other foreign
particles to enter the transmission.
lnstall the rear stiffener.
Install the propeller shaft to the transfer assembly
by aligning the reference marks,
8 x1.25 mm32 N.m 13.3 kg{.m,24 tbf.ftl
REFERENCE MARKS
6. Install the exhaust pipe A,
GASKETEXHAUST PIPE A
HO2S CONNECTOR
10 x 1 .25 mm54 N.m (5.5 kgt m,40 tbtfttReplace.
SELF.LOCKING
NUT8 x 1.25 mm16 N.m {1.6 kgf.m,12 tbt.ft)Replace.8 x 1.25 mmzzN.m l2.2kg!-m,16 rbf.trtReplace.
7.Connect the heated oxygen sensor (HO2S) connector.
Relill the transmission with MTF (see page 13-3).
Start the engine, and run it to normal operating tem-
perature (the radiator tan comes on). Turn the
engine off. and check fluid level.
8.
9.
www.emanualpro.com

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
www.emanualpro.com

Transmission Assembly
lllustrated Index
Refer to the drawing below for the transmission disassembly/reassembly.Clean all the pans thoroughly in solvent, and drv with comoressed air.
I LuUri""r" utt the parts with MTF before reassembly.
NOTE:
t This transmission uses no gaskets between the major housings; use liquid gasket (p/N 0g718 - 0001 or oE7l8 - 0003)(see page 13-69, 71).. Always clean the magnet @ whenever the transmissjon housing is disassembled.. Inspect all the bearings for wear and operation.
C) sHrFr FoRK ASSEMBLY.Index page, l3-21(a MAINSHAFT ASSEMBLY.Index page, 13-23(9 28 mm WASHER€) 28 mm SPRTNG WASHERO BALL BEARINGa6) OIL SEAL ReDlace.(D 14 x 20 mm DOWEL ptN
G) couNTERSHAFT ASSEMBLY.lndex page, 13-28
NEEDLE SET PLATENEEDLE BEARINGOIL GUIOE C PLATEMAGNETDIFFERENTIAL ASSEMBLY.lndex page, 13-38O-nlNG Beplace.TRANSFER ASSEMBLY.Index page, '13,44
OIL SEAL Replace.VEHICLE SPEED SENSORCLUTCH HOUSINGREVERSE LOCK CAMREVEESE SHIFT HOLDERREVERSE IDLE GEARREVERSE GEAR SHAFTTHRUST WASHER,20 x 36 x 2COLLER, 15 x 20 x 20
aol
@o@@
(D
i9
@@@(9
@@@e3@
13-12
www.emanualpro.com

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
www.emanualpro.com

Mainshaft Assembly
lndex
Note the Iollowing during reassembly:
. The 3rd/4th, and 5th synchro hubs, and the ball bearing are installed with a press.
. Installthe angular ball bearing with the thin-edged outer race facing the stop ring
prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The
3rd/4th and 5th svnchro hubs, however, should be installed with a press before lubricating them'
ANGULAR EALL BEARINGCheck for wear and operation.Note the directionof installation.SYNCHRO RINGInspection, page l3 37
SYNCHRO HUBlnspection, page 13-36
SYNCHRO SLEEVEInspection, page 13 36
SPRING
SYNCHRO
SYOP RING
TAPER RING
BEARINGCheck Ior wear and operataon.
COLLAR
RINGInspection, page 13-37
SYNCHRO SPRING
SYNCHRO HUBInspection, page 13_36
SYNCHRO SLEEVEInspection, page 13 36
SPFING
RINGInspection, page 13_37
GEARInspection, page 13_25, 37
COLLARInspection, page 13-24, 25
GEARInspection, page 13 24, 37
Inspection,page 13-37
3RD GEARInspeclton,page 13 24,37
BEARINGCheck for wearano operalton.
Inspection, page 13 26
NEEDLE BEARINGCheck for wear and operat,on.
13-23
www.emanualpro.com

Reassembly
NOTE: Refer to page 13-23 for reassembly sequence.
1. Suppon 2nd gear on steel blocks as shown, then
install the 3rd/4th synchro hub using the special
tools and a press as shown.
NOTE: After installing, inspect the operation of the
3rd/ 4th synchro hub set.
PRESS
I
3RD/4THSYNCHRO HUB
DRIVER, ,l(} mm l.O.
07746 - 0030'1 00
2.
2NO GEAR
Install the sth synchro hub using the special tools
and a press.
PRESS
I
DRlvER,40 mm l.D.
077{6 - 00301(x)
ATTACHMENT,35 mm l.D.077i16 - lx)3ollx)
sTH SYNCHBO HUB
3. Install the angular ball bearing using the special
tools and a oress. Note the direction of installation.
PRESS
I
077a6 - 0011x100
HANDLE07749 - 0010000
ATTACHMENT,/Vl x a7 mm
BALL BEARINGNote the dirediono{ installation.
13-27
www.emanualpro.com