And HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

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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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
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Release Bearing
lnstallation
NOTE: Use only Super High Temp Urea Grease (P/N
08798 - 9002).
1. With the release fork slid bet\iveen the release bear-
ing pawls. install the release bearing on the main-
shaft while inserting the release tork through the
hole in the clutch housing.
lPlN 08798 - 9002)0.,1- 1.0 I (0.01 - 0 04 ozl
(P/N 087989002)
(P/N 08798 9002)
1.0 - 1.6 g
{0.0,1 - 0,06 ozl
-6.l(P/N 08798 -
r iz]))
| (,4\1t1t
/\[wRELEASEFORKBOOT
Align the detent of the release fork with the release
fork bolt, then press the release fork over the
release fork bolt sequarelv.
12-12
3. Move the release lork right and left to make sure
that it tits properly against the release bear'rng. and
that the release bearing slides smoothlY.
Install the release tork boot; make sure the boot
seals around the release fork and clutch housing.
4.
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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
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MaintenanceBack-up Light Switch
Transmission Fluid
NOTE: Check the fluid with the engine OFF and vehicle
on level ground.
1. Remove the filler plug. then check the level and
condition of the fluid.
FILLER PLUG44 N.m {4.5 kgf.m. 33 lbf ftl
ll
Ptopet Level
\--ril /
HllllllTl /
Hllllrlll /_rf-F{--rno."."
ll| | Replaco.
The fluid level must be up to the filler hole. lf it is
below the hole, add fluid until it runs out. then rein-
stall the tiller plug with a new washer.
lf the transmission fluid is diny, remove the drain
plug and drain the fluid.
FILLEB PLUGa,a N.m 14.5 kgf..n. 33 lbt'ftl
DRAIN PLUG39 N m (4.0 kgf.m, 29 lbf'ft)WASHERReplace.
Reinstall the drain plug with a new washer. and
refill the transmission fluid to the proper level.
NOTE: The drain plug washer should be replaced at
every fluid change.
Reinstall the filler plug with a new washer.
Fluid Capacity
1.7 / {1.8 US qt, 1.5 lmp qtl at oil change
2.1 ! 12.2 US qt, 1.A lmp qtl at overhaul
Alwavs use Genuine Honda Manual Transmission
Fluid (MTF). Using motor oil can cause stiffer shift-
ind because it does not contain the proper additives.
Test/Replacement
1. Disconnect the connectors from the switch.
Terminal side oImale lerminals
BACK.UP LIGHT SWTTCHr 25 N.m 12.5 kgt m, 18 lbf.ftl
WASHERReplace.
Check for continuity between the No. 1 and No. 2
terminals.
. There should be continuity when the shift lever
tnto reverse.
. There should be no continuity when the shift
lever in position except reverse,
lf necessary, replace the switch.
13-3
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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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Removal
!@@ Make sure the lifts, i8cks. and safety stands
are placed properly {see section 1}.
1. 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. Drain the manual transmission fluid Reinstall the
drain plug with a new sealing washer.
4. Disconnect the heated oxygen sensor (HO2S) con-
nector.
SELF.L(rcKNGNUTReplace.
SELF-LOCKI'{GNUTReplac€.
5. Remove exhaust oipe A.
6. Make reference marks across the propeller shaft
and the transfer assembly flanges'
Separate the propeller shaft from the transfer
assembly flanges,
Remove the rear stiffener, then remove the transfer
assembly.
NOTE: While servicing the transfer assembly, do
not allow dust or other foreign particles to enter the
transmission.
7.
REFEREI{CE i'ARKS
Replace.
Replace.
13-5
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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.
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Transmission AssemblY
Removal
@FMak. sw. iack" and safety stands are placed propel-
ly, and hoist brackets are attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the batterY.
2. Remove the intake air duct and air cleaner houslng
(see section 5).
3. Remove the slave cylinder and clutch hose bracket'
NOTE:
. Do not operate the clutch pedal once lhe slave
cvlinder has been removed.
. Take care not to bend the clutch line.
4. Disconnect the
ground cable.
starter cables and transmission
TRANSMISSIONGROUND CABLE
Disconnect the back-up light switch connector and
wire harness clamP.
(cont'd)
13-7
WIRE HARNESS CLAMP
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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
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