Oil HONDA CR-V 1998 RD1-RD3 / 1.G Manual Online

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.
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12. Disconnect the heated oxygen sensor (HO2S) con-
nector, then remove the exhaust pipe A.
GASKETReplace.
HO2S CONNECTOR
NUTReplace.
EXHAUST
SELF.LOCKINGReplace.
GASKETReplace.
Mark reference marks on the joint of the transfer
and the propeller shaft.
8 x 1.25 mmReplace.
Separate the propeller shaft from the transfer
assemDly.
REFERENCE MABKS
14.
15. Remove the cotter pins, and castle nuts. then sepa-
rate the ball ioints from the lower arm (see sectlon
18).
OAMPER PINCH BOLT
CASTLE NUTNUTReplace.
17.
16.
DAMPER FORKFOFKEOLTReplace.
Remove the right damper tork bolt, then separate
right damper fork and damPer.
Pry the right driveshaft out of the differential, and
pry the left driveshaft out of the intermediate shaft
(see section 18).
Pull out the inboard ioint, and remove the right and
left driveshaft (see section 18).
Tie plastic bags over the driveshatt ends. Coat all
precision finished surfaces with clean engine oil
18.
19.
\
{cont'd}
13-9
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Transmission Assembly
Removal (cont'd)
20. Remove the intermediate shaft.
21.Tie plastic bags over the both ends of the intermedi-
ate shaft. Coat all precision finished surfaces withclean engine oil.
Remove the rear engine stiffene. and clutch hous-Ing cover.
13-10
23. Remove the right front mounvbracket.
RIGHT FRONTMOUNT/BRACKET
Place a jack under the transmission, raise it just
enough to take it off of the mounts, then remove
the transmission mount bracket and transmission
mount.
TRANSMISSION MOUNT
MOUNT BRACKET
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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
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C) TRANSMISSION HANGER
O INTERLOCK BOLT
O 32 mm SEALING BOLT
@ STEEL BALL {5/16 in.)
€) SPRING 26.1 mm {1.03 in.l
@ wasHER Replace.
O sET BALL scREw
@ WASHER Replace.
€) FLANGE BOLT
@ oll SEAL Replace.
@ DRAIN PLUG
@ WASHER Replace.
@ FILLER PLUG
@ WASHER Replace.
(9 10 x 12 mm DOWEL PIN(D SPRING 25.6 mm 11.01 in.l
€' THRUST WASHER
@} SHIFT ARM C(3 CONICAL SPRING WASHER
@ SPECTAL BOLT
8] SHIFT ARM COVER
@ OIL SEAL Replace.
€! SHIFT LEVER
@I BREATHER CAP(2! SHIFT ARM SHAFT ASSEMBLY
@ SPRING PIN Replace.O SELECT ARM
€!} THRUST WASHER
@ sTH/REVERSE SELECTRETURN SPRING
@ SELECT RETURN SPRING
€) OIL GUTTER PLATE
@ 78 mm SHIM
@ OIL GUIOE M PLATE
@ SELECT SPRING BOLT
@ OIL SEAL Replace.
@ SELECT LEVER
O BACK.UP LIGHT SWITCH
@ WASHER Replace.OO TRANSMISSION HOUSING
13-13
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Transmission Assembly
Disassembly (cont'dl
14. Remove the oil gutter plate, 78 mm shim, and oilguide M plate.
OIL GUIDE M PLATE
15. Remove the select spring bolt.
OIL GUTTER PLATE
SELECT SPRING BOLT
13-16
18. Remove the oil seal.
16.Remove the spring pin using the pin punch and apair of diagonal cutters.
PIN PUNCH, 5.0 mm
17. Remove the select lever, springs, washer, and selectarm.
SEL€CT LEVER
{
V
OIL SEALReplace.
THRUST WASHER
Replace.
SELECT ARM
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Shift Arm Cover/Shift Arm Shaft Assembly
Disassembly/Reassembly
Shift Arm Cover Ass€mbly
1. Remove the breather cap and set ball screw, washer,
spring. and steel ball.
BREATHER CAP
SPRINGL,25.6 mm (1.01 in.l
T BALL SCREW22 N.m 12.2 kgtm, 16lbf.ftl
Remove the special bolt and conical spring washers.
SHIFTARMCOVER
THRUST WASHER
SHIFI ARM C
WASHER 8x1.0mft
SHIFT LEVER
29 N.m 13.0 kg{.m,z2 tbt.ftl
arm C, and thrustRemove the shift lever, shift
washer from the shift arm cover.
Remove the oil seal.
NOTE: lnstall the thrust washer
face toward shift arm cover.
STEEL BALLD. 5/16 in,
13-18
with the alloy sur-
3. Install in the reverse order of removal.
5. Install the oil seal in to the shift arm cover usino thesDecialtools.
HANOLE07749 - 0010000
ATTACHMENT,32x35mm077a6 - 0010100
OIL SEALReplace.
6. Reassemble the shift arm cover in the reve.se order
of disassembly.
Shift Arm Shaft Assembly
1. Remove the special bolts and conical spring wash-
ers.
SPCCIAL BOLT8x1.0mm29 N.m (3.0 kgf.m,SHIFTARMA 22IbI.ftICONICAL SPRING
SHIFT ARM SHAFT
SPECIAL BOLT8x1.0mm29 N.m {3.0 kgf.m, 22 lbtft}
2. Remove the interlock, shift
from the shift arm shaft.
SPRINGWASHER
arm A, and shift arm B
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Mainshaft Assembly
Inspection
1.Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, and C.
Standard:
A (Ball bearing surface): 27.987 - 28.000 mm
11.1018 - 1.1024 inl
B (Needle bearing surfacel: 37.984 - 38.000 mm(1.4954 - 1.4961 inl
C {Bafl bearing surfacel: 27.977 -27.990 mm
(1.1015 - 1.1020 inl
Service Limit: A:27.94 mm (1.100 in)
B: 37.93 mm (1.'193 inl
C: 27.94 mm 11.100 inl
Inspect oil passages Ior clogging.
lf anv oart of the mainshaft is less than the service
limit. reolace it with a new one.
2. Inspect for runout.
Standard: 0.02 mm (0.0008 in) max.
Service Limit: 0.05 mm 10.002 inl
NOTE: Support the mainshaft at both ends
sh own.
lf the runout is more than the service limit, reDlace
the mainshaft with a new one.
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Synchro Ring, Gear
Inspection
Inspect the synchro ring and gear.
Ar lnspect the inside of the synchro ring for wear.
B: lnspect the synchro sleeve teeth and matching
teeth on the synchro ring for wear (rounded of0.
CCGOOO WORN
Cr Inspect the synchro sleeve teeth and matching
teeth on the gear tor wear (rounded off).
,,

u (-l
GOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface lor wear and roughness.
F: Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks.
2. Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear. Rotate the
synchro ring, making sure that it does not slip.
Measure the clearance between the synchro ring
and gear allthe way around.
NOTE: Hold the synchro ring against the gear even-
ly while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.85 - 1.10 mm (0.033 - 0.0,lil in)
Service Limit: 0.,1 mm 10.02 inl
Double Cone Synchro-lo-Goar Clearance
Standard:
@: {Outer Synchro Ring to Synchto Conel
0.5 - 1.0 mm (0.02 - 0.04 in)
€): {synchro cone to Geal)
0.5 - 1.0 mm (0.02 - 0.0i1inl
@: louter Synchro Ring to Gearl
0.95 - 1.68 mm (0.037 - 0.056 inl
Service Limit:
@: 0.3 mm (0.01 inl
@: 0.3 mm {0.01 in}
@: 0.6 mm {0.02 in)
lf the clearance is less than the service limit, replace
the synchro ring and synchro cone.
SYNCHRO SPRING
SYNCHRO
1.
OUTER SYNCHRO RING
13-37
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Differential
Bearing Outer Race Replacement
Note these items:
. The bearing outer race and tapered roller bearingshould be replaced as a set.. lnspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
'1. Remove the oil seals from the transmission housingand clutch housing (see page j3-43).
2. Drive the bearing outer race and thrust shim out ofthe transmission housing, or remove the bearingouter race and 75 mm shim from the clutch housingby heating the clutch housing to about 212"F(100"C) with a heat gun. Do not reuse the thrustshim if the outer race was driven out.
TRANSMISSIONHOUSING:
ATTACHMENT52x55mm07746 - 0010400
THRUST SHIM
BEARINGOUTER RACE
CLUTCHHOUSING:
13-40
4, lnstallthe oil seal (see page 13-43).
3. Install the thrust shim or 75 mm shim and the bear-ing outer race in the transmission housing andclutch housing using the special tools.
Note these items during bearing replacement:. Install the bearing outer race squarely.. Check that there is no clearance between thebearing outer race, thrust shim or 75 mm shimand housing.
TRANSMISSIONHOUSING:
HANDI-E07749 - 00 xxto
ATTACHMENT,62x68mm077ir6 - 0010500
BEARINGOUIER RACETHRUST SHIM
CLUTCHHOUSING:HANDLE07749 - 001tXX)o
ATTACHMENT.72xt5mm07745 - 00106{x)
OUTER RACE
75 mm SHIM
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