2_10 HONDA CR-V 1999 RD1-RD3 / 1.G User Guide

Clutch
Speciaf Tools ....,..... ..........' 12-2
lllustrated lndex ........... .'." 12'3
Clutch Pedal
Adjustment ........."."."".12-4
Clutch Master Cylinder
RemovaUlnstallation '." 12'5
Slave Cylinder
Removal/lnstallation .'.. 12-6
Pressure Plate
RemovaUlnspection ..'." 12-7
Clutch Disc
Removal/lnspection ."'.. 12-8
Flywheel
Inspection ...................... 12-9
Replacement ....................................... 1 2-9
Clutch Disc, Pressure Plate
lnstallation ....................' 12-10
Release Bearing
Removal/lnspection ...... 12'11
lnstaflation ..................... 12-12
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Special Tools
Rel. No. I Tool NumberDescriptionOty Page Reference
a
IA
@
!c,
Lo,
OTJAF - PM70,I1A
07NAF - PR30l00
07LAB - PV00100 or
07924 - PD20003
07746 0010100
07749 - 0010000
07936 - 3710100
Clutch Alignment Disc
Clutch Alignment Shaft
Ring Gear Holder
Attachment, 32 x 35 mm
Driver
Ha nd le
1 | t2-7
1 12-7 , A, 't0, 11
1 12-7 ,9, 10, 1'l
I1 I 12-10
1 12-10
1 12-7 , a, 10, 11
b)
2-2
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FlywheelClutch Disc, Pressure Plate
Replacement (cont'dl
Drive the new bearing
specialtools.
HANOLE DRIVER07749-
ATTACHMET{T-32x35mm07746 -O010100
FLYWHECI-
Align the hole in the flywheel with the crankshaft
dowel pin, and install the flywheel. Install the
mounting bolts finger-tight.
Install the special tool, then torque the flywheel
mounting bolts in a crisscross pattern in several
steps as shown.
Torque:12 x 1.0 mmr03 N.m (10.5 kgl.ln,75.9 tbtftl
into the flywheel using the
12-10
Installation
1. Install the ring gear holder.
CLUTCH ALIGNMENT SHAFT07NAF - PR30100
CLUTCH DISC
RING GEAR HOLDER07LAB _ pvoot(x) or07924 _ PD20003
Apply grease to the spline of the clutch disc, then
install the clutch disc using the special tools.
NOTE: Use only Super High Temp Urea Grease(P/N 08798 - 9002).
lnstall the pressure plate.
PRESSURE PLATE
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Transfer Assembly
Reassembly (cont'd)
Remove transfer 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 212F
(100"C). Let the cover cool to room temperature
before adjusting the starting torque.
lI the measurement is within the specification, go to
step 40.
COVER A
BEARING OUTER RACE
35.
36.
HEAT GUN
13-60
37. Select the 68 mm thrust shim.
THRUST SHIM, 68 mm
Shim No.Part NumberThickne3s
zv23914-P1C-0201.41 mm (0.056 in)
zw23975-P1C-020'1.44 mm 10.057 in)
zx23916 PlC -020'1.47 mm (0.058 in)
ZI23917 -P1C-O201.50 mm (0.059 in)
zz23978-PlC-0201.53 mm (0.060 in)
23941 - PW5 0001.56 mm {0.061 in)
23942-PWs-0001.59 mm (0.063 in)
c23943-PW5-000't.62 mm (0.064 in)
D23944 PW5 - 0001.65 mm (0.065 in)
E23945-PWs-0001.68 mm (0.066 in)
F23946-PW5-0001.71 mm 10.067 in)
G23947-PW5-000'1.74 mm 10.069 in)
23948-PWs-0001.77 mm (0.070 in)
23949-PWs-0001.80 mm (0.071 in)
239s0-PW5-0001.83 mm (0.072 in)
K23951 - PW5 - 0001.86 mm (0.073 in)
L23952-PWs-0001.89 mm {0.074 in)
239s3-PWs-0001.92 mm {0.076 ini
N23954-PW5-0001.95 mm (0.077 in)
o23955-PW5-0001.98 mm (0.078 in)
P23956 - PW5 , 0002.01 mm (0.079 in)
o23957-PWs-0002.04 mm (0.080 in)
R23958-PWs-0002.07 mm (0.081 in)
23959-PW5-0002.10 mm (0.083 in)
T23960-PW5-0002.13 mm (0.084 in)
U23961 - PW5 - 0002.16 mm (0.085 in)
23962-PW5-0002.19 mm (0.086n)
23963-PWs-0002.22 mm (0.087n)
X23964-PWs-0002.25 mm (0.089n)
23965,PWs-0002.28 mm 10.090n)
23966-PW5-0002.31 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 'n}
BZ23942-PW8-0002.49 mm (0.098 in)
cz23943-PW8-0002.52 mm {0.099 ini
DZ23944-PW8-0002.55 mm (0.100 in)
EZ23945-PW8-0002.58 mm (0.102 ini
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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)
13-65
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Ref. No.
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Tool NumberDescriptionOty I Pago Referonc€
Mainshaft Holder
Clutch Spring Compressor Bolt Assembly
Housing Puller
Holder Handle
Oil Seal Driver Aftachment
Attachment, 40 x 50 mm
Clutch Spring Compressor Attachment
Ay'T Pressure Hose, 2210 mm
IVT Pressure Hose Adapter
SCS Service Connector
Companion Flange Holder
Backprobe Set
lVT Oil Pressure Gauge Set w/Panel
A,/T Low Pressure Gauge w/Panel
Adjustable Bearing Puller, 25 - 40 mm
Anachment, 32 x 35 mm
Attachment, 37 x 40 mm
Attachment. 52 x 55 mm
Attachment. 62 x 68 mm
Attachment, 72 x 75 mm
Driver 40 mm l.D.
Attachment, 35 mm LD.
Driver
07GAB - PF50101 or
07GAB - PF50100
07GAE - PG40200 or
OTGAE _ PG4O2OA
07HAC - PK40102
07JAB - 001020A
07JAD - PH80101
07LAD - PW50601
07LAE - PX40100
OTMAJ - PY4O114
07MAJ - PY40120
07 PAZ - 0010100
07RAB - TB4010A or
07RAB.TB40lOB
07sAz - 001000A
07406 - 0020400
07406 - 0070300
07736 - 4010008 or
07736 - A010004
07746 - 0010100
07746 - 0010200
07746 - 0010400
07746 - 0010500
07746 - 0010600
07746 - 0030100
07746 - 0030400
07749 - 0010000
07947 - SD90200Seal Driver Aftachment
1
1
1
1,l
1
I
2
1'l
1
I
1
1
1
1
1
1
I
1
14-181 , 254
14-216,219
14-189't4-236,242,245,246
't 4-225, 241
14-237
14-216,2't9
14-161
14- 161
14-57
14-236,242,245,246
14-58, 157
14-161
14-161'14-229,230
14-211, 2't2
14-231
14-239
14-212, 227 , 228,229, 230, 238,
14-239, 249
14-221 ,229't 4-207 , 223,226, 237 , 241
14-237,241
1 +21 1, 2't2, 225, 227, 228, 229,
14-230, 237 , 238, 239, 24't, 249't4-225
lf the top arm is too short, replace it with 07SAC - pOZ01OO1.
07HAE - PL50101 may be used to substitute one of these tools.Must be used with commercially available 3/8"-16 slide hammer.
E----G
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14-2
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Pressure Testing
Changing
NOTE: Keep all foreign particles out of the transmis-
sion.
1. Bring the transmission up to operating temperature
(the radiator fan comes on) by driving the vehicle.
Park the vehicle on level ground. turn the engane
off. then remove the drain Plug.
NOTE: lf a cooler flusher is to be used, see page
14-264 and 14-265.
TRANSMISSIONEND COVER
DRAIN18 x 1.5 mmSEALING WASHEBReplace.49 N.m {5.0 kgt.m, 36 lbf.tl)
Reinstall the drain plug with a new sealing washer,
then refill the transmission with the recommended
fluid to the uDper mark on the dipstick. Always use
Genuine Honda Premium Formula Automatic
Transmission Fluid (ATF) Using a non-Honda ATF
can affect shift quality.
Automatic Transmission Fluid Capacity:
4WD;
2.9 { (3.1 US qt. 2.6 lmp qt) 8t change
5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul
2WD:
2.7 | l2.S US qt,2.1lmp qtl ai change
5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul
2.
a
a
1.
Wlrile testing, be careful of the rotaling wheols.
Mako sure lifts, iacks, and safety stands ar€ placed
properly (see scction 11.
Before testing, be sure the transmission fluid is
filled to the proPer level.
4WD:
Raise the vehicle (see section 11.
2WD:
Raise the front of the vehicle, and make sure it is
securely supported. Set the parking brake, and block
both rear wheels securely.
Allow all four wheels {4WD) or front wheels (2wD}
to rotate freely.
Warm up the engine (the radiator fan comes on),
then stop it and connect the tachometer.
Connect the oil pressure gauges to each inspection
hole securely, and do not allow dust or other foreign
particles to enter the inspection holes.
TOROUE: 18 N'm ll.8 kgf'm, 13 lbf'ft)
5.
A/T PRESSURE HOS€,2210 mm07MAJ - PYiOllA
{4 Requircd}
,4'/"' ,a
W'
A/T PRESSURE HOSEADAPTER07MAJ - PYt0120(il Rcquiledl
6. Measure the following Pressure:. Line Pressure ..........,14-162
. 1st. 1st-hold Clutch Pressure .............'. 14-162
. 2nd,3rd and 4th Clutch Pressure .......... 14-163
7. Install new sealing washers and the sealing bolts in
the inspection holes, and tighten to the specified
toroue.
(cont'd)
A/T OIL PRESSUREGAUGE SET W/PANEL07{06 - 0020400
/4\\-J-- (
+..\.-.\-'-\
A/T LOW PBESSUREGAUGE w/PANEL07406 - 0070300
TOROUE: 18 N'm 11.8 kgf'm, 13 lbf'ft)
14-161
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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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Special Tools
Ret. No.Tool NumberOescriptionotvPage Reler€nce
o
@aa
@/il
tol
J - 38592
07GAD - PH7020'1
07JAB - 0010204
OTRAB _TB40lOB
07749 - 0010000
07965 - 6920101
Transfer Case Oil Seal lnstaller
Seal Driver
Holder Handle
Flange Holder
Driver
Hub Dis/Assembly Tool
1
1
1
1
1
1
15-20
15-19
tc-zt, z9
15-21,25
15-19
15-19
6\
@
15-2
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Oil Seals
Replacement
1. Remove the oil seals from the differential housing.
Right side:
Left side:
2. Install the oil seals squarely using the special tools.
Be carelul not to damage the lip ol the oil seals.
Right side: Installation depth of the oil seal is 9 mm
(0.35 in) below the edge of the differential housing.
OIL SEAL
OIL SEAL
Left side: Install the oil seal flush with the edge of
the differential carrier assembly.
OIL SEAL
HUB DIS/ASSEMBLY TOOL07965 - 6920101
(cont'd)
15-19
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