2.0 HONDA CR-V 1999 RD1-RD3 / 1.G Owner's Manual

O TRANSFER HOUSING
@ O-RING Replace.
O DAMPER HUB
G) NEEDLE BEARING
G) TRANSFER DRIVEN GEAR
G) TRANSFER SHAFT
O TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING
€) TRANSFER SHAFT COLLAR
@ THRUST SHIM, 25 mm selective part
6D TRANSFER DRIVE GEAR (HYPOID GEAR)
@ CONICAL SPRING WASHER RePlace
GD TRANSFER SHAFT LOCKNUT.22 x 1.25 mm Left-hand threads, replace'
E) TAPERED ROLLER BEARING
@ TAPERED ROLLER BEARING OUTER RACE
@ THRUST sHlM. 68 mm selective part
O o.RlNG Replace.
@ TRANSFER COVER A
GD TRANSFER COVER B
@ O-RING Replace.
€) TRANSFER DRIVEN GEAR SHAFT (HYPOID GEAR}
@ THRUST SHIM, 35 mm Selective Part
@ TAPERED ROLLER BEARING
@ TRANSFEB SPACEB RepIace.
@ TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING OUTER RACE
@) TAPERED ROLLER BEARING
@ olL SEAL Replace.
@ COMPANION FLANGE
@ O-RING Replace.
@ BACK-UP RING
@ coNtcAL SPRING WASHEB Replace.
(o 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 lbf'ft)
118 N.m (12.0 kgf.m, 86.8 lbf'ftl
132 - 216 N.m (13.5 - 22.0 kgf'm,
97.6 - 159 lbf.ft)
6x1.0mm
8 x 1.25 mm
22 x 1 ,25 mm
22 x 1 .25 mm
Transfer shaft locknut:
Lett-hand threads
Transfer driven gear shaft locknut
Tightening torque: dePending on
Total Starting Torque vaiue
13-45
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TOROUE WRENCH
10. Hold the transfer shaft with a 14 mm Allen wrench
clamped in a bench vise.
lil mm ALLEN WRENCH
Tighten the transfer shaft locknut.
NOTE:
. The transfer shaft locknut has left-hand threads,
. Do not stake the locknut in this step.
TOROUE: 118 N.m (12.0 kgf.m,86.8 lbf.ft)
Temporarily install the transfer cover A without the
O-ring.
11.
rl0ustNG
TRANSFER COVER A
8xL25mm24 N.m (2.4 kgt.m. 17 lbnftl
'14.
Rotate the companion flange several times to seat
the tapered roller bearing.
Set a dial indicator on the companion flange, then
measure the transfer gear backlash.
STANDARD: 0.06 - 0.15 mm 10.002 - 0.006 in)
COMPANION FLANGE
lf the measurement is not within the standard,
remove the transfer shaft locknut and replace the 25
mm thrust shim. Select and install a new 25 mm
thrust shim. then recheck the measurement. Do not
use more than one 25 mm thrust shim to adjust the
transfer gear backlash,
THRUST SHlM,25 mm
DIAL INDICATOR
Shim No.Part NumbelThickness
I2941r - P1C - 0001.70 mm 10.067 in
229412-PlC-000'L73 mm (0.068 in
329413-P1C-0001.76 mm (0.069 in
29414-PlC-0001.79 mm (0.070 in
529415-P1C-0001.82 mm (0.072 in
629416-PlC-0001.85 mm (0.073 in
7294'17-PrC-0001.88 mm (0.074 in
8294'18-P1C-0001.91 mm (0.075 in)
29419-PlC-0001.94 mm (0.076 in)'1029420-P1C-0001.97 mm 10.078 in)
1129421 - P1C - 0002.00 mm (0.079 in)
1229422 -P1C - 0002.03 mm (0.080 in)
1329423-P1C-0002.06 mm (0.081 in)
l429424-P1C-0002.09 mm (0.082 in)
29425-P'tC-0002.12 mm (0.083 in)
1629426-P1C-0002.15 mm (0.085 in)
1729427 -P1C-0002.18 mm {0.086 in)'1829428-P1C-0002.21 mm {0.087 in)
1929429-P1C-0002.24 mm 10.088 in)
(cont'd)
13-55
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Transfer Assembly
Reassembly (cont'dl
26. Secure the transfer housing in a bench vise with
soft jaws.
COMPANION FLANGE HOLDER07RAB - 002tD00
27. 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:
0.98 - 1.39 N.m
{10.0 - 1i1.2 kgf.cm, 8.68 - 12.3 lbf in}
TIGHTENING TOROUE:
132 - 216 N.m
(13.5 - 22.0 kgf.m, 97.6 - 159 lbf.ft)
NOTE:
. Rotate the companion flange several times to
seat the tapered roller bearing, then measure the
startrng torque.
. lf the starting torque exceeds 1.39 N.m (14.2
kgf.cm, 12.3 lbf.in), .eplace 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
torque.
28. Stake the locknut into the transfer driven oear shaft
using a 3.5 mm punch.
0.7 - 1.2 mm(0.03 - 0.05 inl
Point to bestaked.
Install the transfer shaft assemblv in the transfer
housing, then install the tapered roller bearing,
transfer shaft collar, 25 mm thrust shim, transfer
drive gear, conical spring washer, and transfer shaft
locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut and transfer shaft
with MTF before installing the locknut.
. lnstall the conical spring washer in the direction
snown.
TMNSFER SHAFTASSEMBLY
TRANSFER HOUSING
TAPERED ROLLERBEARING
TRANSFER SHAFTCOLLAR
TRANSFER DRIVEGEAR
PUNCH3.0-3.5 mm10.12 - 0.1a inl
THRUST SHIM, 25 mmSelective part
CONICAL SPRINGWASHEBReplace.
LOCKNUTReplace.
29.
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30. Hold the transfer shaft with a 14 mm Allen wrench
clamDed in a bench vise.
NOTE: The locknut has left-hand threads.
TOROUE: 118 N.m (12.0 kgt'm,86.8 lbf'ft)
31. Stake the locknut on the transfer shaft using a 3.5
mm Dunch.
PUNCH3.0 - 3.5 mm{0.12 - 0.14 inl
14 mm ALLEN WRENCH
Totsl Starting Torquo Inspoction and Adiustment
32. Temoorarilv install transfer cover A without the O-
ring.
TRANSFER HOUSING
TRANSFER COVER A
oEl
€lE/Ehvc/E\\g8 x 1 .25 mm24 N.m (2.4 kg{ m, 17 lbtftl
5t.Secure the transfer housing in a bench vise with
soft jaws. then rotate the companion flange several
times to fit the tapered roller bearing,
TOROUE WR€NCH
34. Measure the total starting torque.
TOTAL STARNNG TOROUE:
1.70 - 2.08 N.m 117.3 - 21.2 kgf.cm, 15.0 - 18.i1 lbf inl
+ Transter Driven Gear Shaft Starting Torque Value
(wrot€ down in step 27).
(cont'd)
13-59
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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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CHECK BALL
i)L)
lo
CHECK BALLS
lST ACCUMULATORCHOKE
CHECK EALLMAIN VALVE BODY(Sectionalview)
SPRING SPECIFICATIONSUnit: mm (in)
No.Springs
Standard {New)
Wire Dia.o.D.Froe LengthNo. of Coils
o
@
@
@
Relief valve spring
Modulator valve spring
CPB valve spring
1-2 shift valve spring
2nd orifice control valve spring
Servo control valve sPring
1.1 (0.043)
1.4 (0.055)
0.9 (0.03s)
0.9 (0.035)
0.7 (0.028)
1.0 t0.039)
8.6 (0.339)
9.4 (0.370)
8.1 (0.319)
7.6 (0.299)
6.6 (0.260)
8.1 {0.319)
37.1 (1.461)
35.0 (1.3781
41 .2 \1 .8581
41.3 (1.626)
34.8 (1.370)
52.1 (2.051)
'13.4
10.9
20.8
14-197
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Regulator Valve Body
Disassembly/lnspection/Reassembly
NOTE:
o Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with com-
pressed air. Blow out all passages.
. Replace the valve body as an assembly if any parts are worn or damaged.
. Checkall valvesforfree movement. lf anyfail toslidefreely, see Valve Body Repair on page l4-192.
'1. Hold the regulator spring cap in place while removing the stop bolt. The regulator spring cap is spring loaded Once
the stop bolt is removed, release the spring cap slowly so it does not pop out.
2. Reassembly is the reverse order of disassembly.
NOTE:
. Coat all parts with ATF during reassembly.
. Align the hole in the regulator spring cap with the hole in the valve body, thenpress the spring cap into the valve
REGULATOR SPSING CAPbody, and tighten the stop bolt.
STOP BOLT6x1.0mm12 N.m 11.28.? tbt.fil
REGULATOR VALVE BODYlnspect for wear, scratches,ano scoflng.
REGULATOR VALVE
No,SpringsStandard {New}
wire Dia.o.D.F ee LengthNo. ot Coils
o
@
@,6
a,
Regulator valve spring A
Regulator valve spring B
Stator reaction spring
Cooler relief valve spring
Torque converter check valve spring'97 Model'98 - 00 Models
Lock-up control valve spring
1.8 (0.071)
1.8 (0.071)
4.5 (0.177)
1.0 {0.039)
1.1 (0.043)
1.2lO.O47l
0.7 t0.028)
14.7 (0.579)
9.6 (0.378)
35.4 (1.394)
8.4 {0.331)
8.4 (0.331)
8.4 (0.331)
6.6 (0.260)
87.8 (3.457)
44.0 t1.7321
30.3 (1.193)
33.8 (1.331)
36.4 (1.433)
32.4 11.2761
38.0 (1.496)
'11.0
1.9
't2.0
12.7
14.'l
14-199
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Servo Body
Disassembly/lnspection/Reassembly
NOTE:
' cleanall parts thoro ugh ly in solvent or ca rbu retor clea ner, a nd dry them with compressed air, Blow out all passages.. Replace the valve body as an assembly if any parts are worn or damaged.. Coat all parts with ATF during reassembly.
ACCUMULATOR COVER
3RO SUB ACCUMULATOR
O-RINGFeplace.
SERVOFORK S
fi,
il
g
1ST ACCUMULATOR PISTON
Replace.
RVO VAL\IRK SHAFT
O.RING
VE/SHIFT
3RD ACCUMULATOR
SPRING SPECIFICATIONS
\_)
SNAP RING
SNAP RING
Unit: mm {in)
@"- -tP
-.t l@SPR|NG RETATNER ,/
No.SpringsStandard lNewl
Wire Dia,o.D.Free LongthNo. of Coil3
o
@J6
@.A
\o,
o
@
@
1st accumuiator spring
4th accumulator spring A
4th accumulator spring B
3rd accumulator spring A
3rd accumulator spring B
2nd accumulator spring C2nd accumulator spring A2nd accumulator spring B
3rd sub accumulator spring
2.1 (0.083)
2.6 {0.102)
2.3 (0.091)
2.8 (0.110)
2.1 (0.083)
2.2 (0.087l-
2.4 (0.094)
r.6 (0.063)
2.7 {0.106)
16.0 (0.6301
17.0 (0.669)'t0.2 t0.402]
17.5 (0.689)
31.0 (1.220)
14.5 {0.571)
29.0 11.1421
9.0 (0.354)
17.0 (0.669)
89.r (3.508)
88.4 (3.480)
51.6 (2.031)
94.3 (3.713)
38.2 (1.504)
68.0 {2.677)
39.0 fi.535)
20.7 (0.815)
39.0 (1.535)
14.2
13.8
15.9
2.6
13.9
2.9
o.l
6.3
14-200
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Lock-up Valve Body
Disassembly/lnspection/Reassem bly
NOTE:
. Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages.
. Replace the valve body as an assembly if any parts are worn or damaged.
. Checkall valvesforfree movement. lf anyfailto slide freely, seeValve Body Repairon page 14-192.
. Coat all parts with ATF during reassembly.
LOCK.UP SHIFT VALVE
\/'
\-.xlO
@-tr
, ^ ,As'. \"o...*
LOCK-UP VALVE EODY
Inspect lor wear, scratches,
and scoring.
VALVE CAP
\uo.*"or".,,
LOCK-UP TIMING VAL
SPRING SPECIFICATIONSUnit: mm (in)
No.SpringsStandard lNewl
Wire Dia.o.D.Fle€ LengthNo. of Coils
O(Lock up shift valve spring
Lock-up timing valve spring
0.9 (0.035)
0.9 (0.035)
7.6 (0.299)
8.1 (0.319)
73.1 t2.902),
81.4 (3.205)
32.0
47 .8
14-201
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