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

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
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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
1. Remove the transfer assemblv.
O-RINGReplace.
Remove the shift arm cover assembly, and wiDe itclean of the sealant.
SHIFT ARM COVER ASSEMBLY
10 x 12 mm DOWEL ptN
13-14
3. Remove the interlock bolt.
SELECT ARM
SHIFT ARM SHAFT
Turn the select lever counterclockwise, then removethe shift arm A finger from the groove of the shiftforks.
Turn the shift arm shaft counterclockwise andremove the select arm finger from the groove of theshift arm A. then remove the shift arm shaft assem-blv.
Remove the vehicle speed sensor (VSS).
5.
6.
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7. Remove the set ball screws, washers, springs, steel
balls. and back-uP light switch.
STEEL BALLD. 5/16 in
8. Remove the flange bolt. drain plug, and filler plug
DRAIN PLUG
WASHERReplace.
LIGHT SWITCH
FILLER PLUG
WASHERReplace.
FLANGE BOLT
9. Remove the transmission housing mounting bolts
in a crisscross pauern in several steps.
10. Remove the 32 mm sealing bolt
Expand the snap ring on the countershaft ball bear-
ing, and remove it from the groove using a pair of
snap ring plier.
Separate the transmission housing from the clutch
housing.
Remove the dowel pins, and wipe it clean of the
sealant.
'I t.
(cont'd)
13-15
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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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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
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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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2.
Clearance InsPection
1. Measure the clearance between the shift arm A and
select arm.
Standard: 0.05 - 0 25 mm (0.002 - 0'01 inl
Service Limit:0.5 mm (0.02 in)
lf the clearance are more than the service limit,
measure the diameter of the select arm pln
Standard: 7.9 - 8.0 mm (0.311 - 0.315 in)
SELECTARM
lf the diameter of the select arm pin is less than
the service limit, replace the select arm wrtn a
new one.
lf the diameter of the select arm pin is within the
service limit, replace the shift arm A with a new
one.
SELECT ARM
SHIFT ARM A
SHIFT ARM C
SHIFT ARM B
3. Measure the clearance between the shift arm B and
shift arm c.
Standard: 0.05 - 0.25 mm (0.002 - 0.01 inl
Seryice Limit:0,5 mm (0.02 inl
lf the clearance are more than the service limit,
measure the diameter of the shift arm C.
Standard: 12.9 - 13.0 mm (0 508 - 0.512 in)
SHIFT ARM C
lf the diameter of the shift arm C is less than the
service limit, replace the shift arm C with a new
one.
lf the diameter of rhe shift arm C is within the
service limit, replace the shift arm B with a new
o ne.
13-19
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Reverse Shift Holder
Clearance Inspection
1.Measure the clearances between the reverse shift
holder and sth/reverse shift Diece Din.
Standard:A: 0.05 - 0.35 mm (0.002 - 0.014 in)
8: 0.4 - 0.8 mm 10.02 - 0.03 inl
Service Limit: A: 0.5 mm (0.02 in)
B: 1.0 mm 10.0,[ in]
2.lf the clearances are more than the service limit.
measure the widths of the groove in the reverse
shift holder.
Standard: A: 7.05 - 7.25 mm {0.278 - 0.285 inl
B: 7.4 - 7.7 mm (0.29 - 0.30 inl
lf the widths of the grooves are not within thestandard, replace the reverse shift holder with a
new one.
lf the widths of the grooves are within the stan-
dard, replace the sth/reverse shift piece with anew one.
PIECE PIN
REVERSE SHIFT HOLDER
13-20
3. Measure the clearance between the reverse idler
gear and reverse shift holder.
Standard: 0.5 - 1.1 mm {0.02 - 0.0i1 in}
Service Limit: 1.8 mm (0.07 in)
REVERSEIDLERGEAR
lf the clearance is more than the service limit. mea-
sure the width ot the reverse shift holder.
Standard: 13.0 - 13.3 mm (0.512-0521inl
It the width is not within the standard, replace
the reverse shift holder with a new one.
lf the width is within the standard, reolace the
reverse idler gear with a new one.
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Shift Fork Assembly
Disassembly/ReassemblY
I erior,o reassembling, clean all the pans in solvent, dry them, and apply lubricant to any contact parts
1ST/2ND SHIFT FORK
SHIFT PIECE
PIN PUNCH, 5.0 mm
3RD/,|TH SHIFT FoRK
5TH/REVERSE
13-21
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