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

znd, 3rd, and ,lth Clutch Pressurs Measuremenl'97 - 98 Modols:
1. Stan the engine, and shift to E position.
2. Run the engine at 2,000 rpm, then measure 2nd
clutch pressure.
3. Shift to E position, and hold the engine at 2'000
rpm, then measure 3rd clutch pressure.
4. Shift to E position, and hold the engine at 2,000
rpm, then measure 4th clutch pressure.
5. Shift to @ position, and hold the engine at 2,000
rpm, then measure 4th clutch pressure.
4TH CLUTCH PRESSUREINSPECTION HOLE
'99 - 00 Models:
1. Start the engine, and shift to El position.
2. Run the engine at 2,000 rpm. then measure 2nd
clutch pressure.
3. Shift to E position, and turn the Over-Drive (O/D)
OFF by pressing the O/D switch (O/O OFF indicator
light comes on).
4. Hold the engine at 2,000 rpm, then measure 3rd
clutch Pressure.
5. Turn the Over-Drive ON by pressing the O/D switch
(O/D OFF indicator light goes out), and hold the
engine at 2,000 rpm, then measure 4th clutch pres-
sure.
6. Shift to E position, and hold the engine at 2,000
rpm, then measure 4th clutch prgssure
2ND CLUTCH PRESSUREINSPECTION HOLE
3RD CLUTCH PRESSUREINSPECTION HOLE
'"r.,-ur"" "..#
- -t"1' -.
INSPECTION HOLE
PRESSURESHIFT LEVER
POSmONSYMPTOMPROBABLE CAUSE
FLUID PRESSURE
StandardServico Limit
2nd ClutchtrNo or low 2nd
pres$ure
2nd Clutch800 - 850 kPa
\A.2 - 8.1 kgtlcm2,'120 - '124 psil
760 kPa
(7.7 kgf/cm', 110 psi)
3rd ClutchE (97 - s8)
Elwith Over-
Drive is OFF(99 - 00)
No or low 3rd
pressure
3rd clutch
4th clutchE (97 ,98)
E (99 - oo)
No or low 4th
pressure
4th Clutch
EServo Valve or 4th
Clutch
14-163
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Transfer
4.
Inspection
@E Mako suro lifts, jacks, and safety standsare placod properly lsoe section t).
1. Raise the front of the vehicle, and make sure it issupported securely.
2. Set the parking brake, and block both rear wheelssecurely.
Shift to E position.
Make a reference mark across the propeller shaftand the transfer assembly flanges.
Separate the propeller shaft from the transferassembly.
8 x 1.25 mm32 N.m 13.3 kgl,m,24 lbf.ftlReplace.
14-164
\
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 inl
7. lf the measurement is out of standard, remove thetransfer assembly and adjust transfer gear backlash{see page '14-232 thru 14-2491.
8. Check for fluid leaks between the mating faces oftransfer cover A and cover B.
9. lf there is a fluid leak, remove the cover, and reDlacethe O-ring.
'10. Check for fluid leaks between the mating face of thetransfer assembly and transmission.
11. lf there is a fluid l€ak, remove the transf€r assem-bly, and replace the O-ring,
12. Check the transfer oil seal for damage and fluidle8ks.
13, lf oil seal replacement is required. remove the trans-fer assembly, replace the oil seal, and adjust thetotal starting torque (see page 1+232 thtu ]'4-249||.
NOTE: Do not replace the oil seal with the transferassembly on the transmission.
COMPANION FLANGE
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Transfer Assembly
Removal
@ Make sure the lifts, iacks, and safety
stands are placed properly (see section 11.
1. Raise the front of the vehicle, and make sure it is
supported securely.
2. Set the parking brake, and block both rear wheels
securelv.
3 Drain the automatic transmission fluid (ATF).
Reinstall the drain plug with a new sealing washer'
DRAIN PLUG'18 x'1.5 rnm49 N.m 15.0 kgf.m, 36 lbl.ftl
4. Remove the guard bar and the splash shield.
GUARD 8AR
14-165
5.Disconnect the primary heated oxygen sensor
{Primary HO2S) connector.
Remove exhaust pipe A.
SELF-LOCKINGNUTBeplace.
7.
SEI-F.LOCKINGNUTReplace.
NUTReplace
Remove the shift cable cover.
Remove the snap pin and control pin, then separate
the shift cable from the control lever. Do not bend
the shift cable excessively.
(cont'd)
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Transfer Assembly
Installation (cont'dl
Install the exhaust pipe A.
Connect the primary heated oxygen sensor (Primary
H02S) connector,
GASKETReplace.EXHAUST PIPE A
SELF.LOCKING NUT10 x 1.25 mm54 N.m {5.5 kgf.m,40 rbf.ft)Replace.
NUT8 x 1.25 mm16Nm11.6kgf.m,12 lbf.fOReplace.
-LOCKING
SELF-LOCKING NUT8 x 1.25 mm22 N.m (2.2 kgl.m,16 rbr.fttReplace.
10. Installthe splash shield and the guard bar.
6x1.0mm9.8 N.m {1.0 kgt.m,7.2 tbt.ftt
14-168
'I 'I.
12.
Refillthe transmission with ATF (see page 14-161).
Start the engine, and run it to normal operating tem-perature (the radiator fan comes on), Turn theengine off and check ATF level.
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Transmission
Removal
@
2.
'1.
Make sure lifts. iacks, and safety stands aro placed
properly, and hoist brackets are attached to the col-
rest position on the engine lsee section 11.
Apply th€ parking brake and block the r€ar wheels,
so vehicls will noi roll off the stands and fall on you
while working under it.
NOTE: Use fender covers to avoid damaging painted
surfaces.
Disconnect the negative terminal, then disconnect
the positive terminal from the battery.
Remove the intake air duct and the air cleaner hous-
ing assembly,
Remove the starter cables. Remove the harness
clamp from the clamp bracket.
5.
STARTERCABLES
Remove the transmission ground cable terminal
and the radiator hose clamp lrom the transmission
hanger.
Disconnect the lock-up control solenoid valve con-
nector, then remove the harness clamp from the
clamp bracket.HARNESS CLAMP
RADIATOR HOSECLAMP
CONTROLSOLENOID VALVECONNECTOR
CLAMP
6. Disconnect the vehicle speed sensor (VSS), the coun-
tershaft speed sensor, and the A/T gear position
switch connectors.
A/T GEAR POSITIONSWITCH CONNECTOR
VEHICLE SPEEDSENSOR |VSS'
CONNECTORBfiACKET
SPEED SENSORCONNECTOR
7. Remove the transmission housing mounting bolts.
MOUNTING BOLTS
(cont'd)
14-169
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Transmission
Removal (cont'd)
8. Disconnect the mainshaft sp€ed sensor, the shift
control solenoid valve, and the linear solenoid con-
necrors,
Remove the drain plug. and drain the automatic
transmission fluid {ATF). Reinstall the drain plug
with a new sealing washer.
DRAIN18 x 1.5 mm4e N.m rs.o ksr.m. 36 rbrft) ;:i:$: *o"*."
SENSOR CONNECTOR
14-170
OAMPER FORKReplace.
10. Remove the guard bar and the splash shield.
Remove the cotter pins and castle nuts, then sepa-
rate the ball joints from the lower arms (see section
18).
Remove the right damper fork bolt, then separateright damper fork and damper.
11.
12.
SELF.LOCKINGNUTReplace.
CASII.E NUT
DAMPER FORKBOLT
DAMPER PINCH BOLT
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13.Pry the right driveshaft out of the differential. and
orv the left driveshaft out of the intermediate shaft
{see section 16).
Pull out the inboard joint, and remove the right and
left driveshaft (see section 18).
Tie plastic bags over the driveshaft ends. Coat all
Drecision finished surfaces with clean engine oil.
Disconnect the primary heated oxygen sensor
(Primary HO2S) connector.
Remove exhaust pipe A.
GASKETReplace.
14.
16.
't7 .
ORIVESHAFT
Replace.
EXHAUST
14-171
18.
19.
Remove the shift cable cover.
Remove the shift cable.
ilWD:
Remove the snap pin and control pin, then separate
the shift cable from the control lever. Do not bend
the shift cable excessively.
2WD:
Remove the control lever, then separate the shift
cable from the control shaft. Do not bend the shift
cable excessivelv.
Replace.
SHIFT CAELE
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O END COVER
O olL SEAL Replace.
O BALL BEARING
@ A/T GEAR PoSITIoN swITcH coVER
€) A/T GEAn PosrloN swrrcH
@ ROLLER
O coLLARG) o-RING Replace.{9) FEED PIPE FLANGE
@ O-RING Replace.
O SNAP RING
@ 3RD CLUTCH FEED PIPE(D CoUNTERSHAFT LOCKNUT 23 x 1.25 mm Replace.(} coNtcAL SPR|NG WASHER Reptace.
@ PARK GEAR@ ONE.WAY CLUTCH(, COUNTENSHAFT lST GEAR(D NEEOLE BEARING(O COUNTERSHAFT lST GEAR COLLAR
@ o-RING Reptace.
@ lST CLUTCH FEED PIPE
@ O-RING Reptace.
@} FEEO PIPE FLANGE
@ SNAP RING
@ DOWEL PIN
@ END coVER GASKET Feplace.
@ PARK PAWL SToP@ PARK PAWL
@ PARK PAWL SPRING
@ PARK PAWL SHAFT
O} A/T GEAR POSITION SWITCH HARNESS CLAMP
@ PARK LEVER
@ LOCK WASHER Replace.
@ PARK STOP Selective part
@ PARK LEVER SPRING@ DRAIN PLUG
O SEALING WASHER Reptace.
@) MAINSHAFT LOCKNUT2l x 1.25 mm Replace.@ CONICAL SPRING WASHER Replace.@ lST CLUTCH ASSEMBLY
TOROUE SPECIFICATIONS
i!, O-RING Replace.
@ THRUST WASHER
@ THRUST NEEDLE BEARING@ NEEDLE BEARING
@ MAINSHAFI 1ST GEAR@ MAINSHAFT 1sT GEAR coLLAR
@ o-RING Replace.
6!, COUNTERSHAFT SPEED SENSOR@ ROLLER
@) COLLAR@ o-RtNG Replace.
6A FEEo PIPE FLANGE
@ o-RtNG Reptace.
@ SNAP R|NG
@ IST.HOLD cLUTcH FEED PIPE@ SUB-SHAFT LOCKNUT 19 x 1,25 mm Reptace.O coNtCAL SPR|NG WASHER Reptace.E! SUB.SHAFT lST GEAR€} LINEAR SOLENOID ASSEMBLY
@ LTNEAR soLENotD aSSEMBLy GASKET Reptace.
@ HARNESS BBACKET
@ SEALING WASHERS Feptace.
@ ATF COOLER LINE
@ LIN€ BoLT
@ ATF DIPSTICK
@ ATF COOLER LINE
@ LINE BoLT@ SEALING WASHERS Reptace.@ VEHICLE SPEED sENsoR (vss)
@ o-RtNG Beptace.
Bolt/Nut No.Torque ValuoSizeRemarks
6B
8A
12J
18D
19S
21M
23C
'12 N'm ('1.2 kgf.m,8.7 lbf.ft)
14 N.m (1.4 kgf.m, 10lb{.ft}
22 N.m 12.2 kgf.m, 16 lbf.ft)
28 N'm (2.9 kgf.m,21 lbf.ft)
49 N.m (5.0 kgf.m,36 lbf'ft)
93 N'm {9,5 ksim.69 lbf.ft)
78 N.m {8.0 kgnm,58 lbf.ft)
103* 0- 103 N{n {10.5* 0+ 10.5 kgfn,
75.9-0-75.9 lbf{t)
6x 1.0 mm
6x1.0mm
8 x 1.25 mm
12 x 1.25 mm
18 x 1.5 mm
19 x 1.25 mm
21 x 1.25 mm
23 x 1.25 mm
Line bolt
Drain plug
Sub-shaft locknut
Mainshaft locknut: Left-hand threads
Countershaft locknut: Left-hand
threads
14-175
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r] REVERSE IDLER GEAR SHAFT/HOLDER'A N€EDLE BEARING
..] TRANSMISSION HOUSING
al TRANSMISSION HOUSING OIL SEAL Replace.g SET BING.80 mm Selecrive part
O REVERSE GEAR COLLABE couNTERSHAFT REVERSE GEAB
.9,] NEEDLE BEARINGi9 LOCK WASHER Replace..1!i REVERSE SHIFT FORKO REVERSE SELECToRiJ. REVERSE SELECTOR HUBii' COUNTERSHAFT 4TH GEAR.14 NEEDLE BEARINGiD D|STANCE coLLAR,28 mm Selective part(i3 COUNTERSHAFT 2NO GEABi7-] THRUST NEEDLE BEARING(10 COUNTERSHAFT 3RD GEAR(9 NEEDLE BEARINGE9 COUNTERSHAFI3RD GEAB COLLAR.li THRUST NEEDLE BEARING.?) SPLINEO WASHER,,O 3RD CLUTCH ASSEMBLY
€1 O-RING Beplace.i23 COUNTERSHAFT
4i SHIFT CONTROL SOLENOID COVER
?Z] HARNESS CLAMP BRACKET
?9] SHIFT CONTROL SOLENOID VALVE A/B ASSEMBLY
8 HARNESS CLAMP BRACKET
GI SHIFT CONTROL SOLENOID VALVE FILTER/GASKET
(4 MAINSHAFT 2ND GEARi49 NEEDLE BEARING
@ THRUST NEEDLE BEARING(49 MAINSHAFT
@r SEAL|NG R|NG,35 mm
O SEALING RING,29 mm
@ NEEDLE BEARING
.49 SET RING
€) lST.HOLD CLUTCH ASSEMBLY
O o-RING Replace.6E THRUST WASHER
€9 THRUST NEEDLE BEARING
6' NEEDLE EEARING
€ir SUB-SHAFT 4TH GEAR
6 THRUST NEEDLE BEARING
@ SUB.SHAFT 4TH GEAR COLLAR@ sUB-sHAFf
6I NEEDI-E B€ARING STOP
@ NEEDLE BEARING(6t ATF GUIDE CAP Replace.(64 TRANSMISSION HANGEB
@ BREATHER CAP
i@ MAINSHAFT SPEED SENSOR
6i O-RING Replace.
6D REVERSE IDLER GEAR
@r DOWEL PlN, 14 x 25 mm.6d SNAP RINGS
QlI SUB.SHAFT TRANSMISSION HOUSING BEARING
E) MAINSHAFT TRANSMISSION HOUSING BEABING.2, COUNTERSHAFI TRANSMISSION HOUSINGBEARING
@[E
t,n9t0@)@),lD
04
@
@@:.ro)
ai
Replace-SNAP RINGTHRUST WASHEBTHRUST NEEDLE BEARINGMAINSHAFT 4TH GEARNEEDLE BEARINGSTHRUST NEEDLE BEARINGMAINSHAFT 4TH GEAB COLLAR2NO/4TH CLUTCH ASSEMBLYO-RING Replace.THRUST WASHER,36.5 x 55 mm Selective partTHRUST NEEOLE BEARING
DOWEL PlN, 14 x 25 mmCONNECTOR BRACKETATF MAGNETDOWEL PlN, 14 x 20 mmTRANSMISSION HOUSING GASKET Replace.DIFFERENTIAL ASSEMBLYDOWEL PlN, 10 x 12 mmO-RING Replace.TRANSFER ASSEMBLYTOROUE CONVERTER HOUSING OIL SEAL Replace.TOROUE CONVERTER HOUSING
TOROUE SPECIFICATIONS
Bolt/Nut No.Torque ValueSizeRgmarks
6A
6B
10A
12 N.m (1.2 kgf.m,8.7 lbf.ft)
14 N.m (1.4 kgf.m, 10 lbift)
44 N.m (4.5 kgf.m,33 lbf.ft)
6x 1.0 mm
6x 1.0 mm
10 x 1.25 mm
14-177
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O END COVERiLl OIL SEAL Beplace.
O BALL BEARINGi.) A/T GEAR POSITION SWITCH COVER
i5] A/T GEAR POSITION SWITCH
aq) RoLLER
? COLLABi0 o-BtNG Replace.
€) FEED PIPE FLANGE
f,o) o-RING Replace.
1' SNAP RING
1A 3RD CLUTCH FEED PIPE
O COUNTERSHAFT LOCKNUT 23 x 1.25 mm Replace.
[} coNtcal SPRING WASHER Replace.iO PARK GEAR(!I ONE.WAY CLUTCH
E COUNTERSHAFT lST GEAR
@ NEEDLE BEARING
@ COUNTERSHAFT 1ST GEAR COLLAR
Or o-RtNGS Reptace.
?] lST CLUTCH FEED PIPE
@ o-RING Replace.
e3 FEED PIPE FLANGE
4I SNAP RING
€i DOWEL PINi?0 END COVER GASKET Replace.
?7) PARK PAWL STOP
E9 PARK PAWL
C9 PARK PAWL SPRING
€D PARK PAWL SHAFT
OI A/T GEAR POSITION SWITCH HARNESS CIAMP
@ PARK LEVER
€3 LoCK WASHER Replace.
04 PARK sToP Selective part(!' PARK LEVER SPRING
@ DRAIN PLUG
Ot SEALING WASHER Replace.
60 MA|NSHAFT LocKNuT 21 x 1.25 mm Replace.(9 CONICAL SPRING WASHER Replace.
@ lST CLUTCH ASSEMBLY
TOROUE SPECIFICATIONS
,!4! O-RING Replace.
@I THRUST WASHER@ THRUST NEEDLE BEARINGi.!' NEEDLE BEARINGi MAINSHAFT lST GEAR
@i MAINSHAFT 1ST GEAR COLLAR!r, O-RING Replace.iO COUNTERSHAFT SPEED SENSOR
E ROLLER
@, coLLAR
Ct o-RING Replace.5.] FEED PIPE FLANGE
09 o-RING Replace.
6A SNAP RING
5' IST.HOLD CLUTCH FEED PIPE
@-] SUB-SHAFT LOCKNUT 19 x 1.25 mm Replace.
!t CONICAL SPRING WASHER Replace.
6i' SUB-SHAFT lST GEAR
G) LINEAR SOLENOID ASSEMBLY(6!) LINEAR SOLENOID ASSEMBLY GASKET Replace
G] HARNESS BRACKET
6a SEALING WASHERS Replace.
C' ATF COOLER LINE
@ L|NE BoLT
GI ATF DIPSTICK
GI ATF COOLER LINE
O LINE BOLT
@ SEALING wasHERs Replace.aoo VEHICI.E SPEED SENSOR IVSS)
f,E O-RING Replace.
Bolt/Nut No.Torque ValueSizeRemarks
6A
6B
8A
12J'18D
195
21M
12 N.m (1.2 kgf.m,8.7 lbf.ft)
14 N.m (1.4 kgf.m, 10lbf.ft)
22 N.m 12.2 kgim, 16lbf.ft)
28 N.m (2.9 kgim,21 lbf.ft)
49 N'm (5.0 kgim,36 lbf.ft)
93 N.m (9.5 kgf.m,69 lbf.ft)
78 N.m (8.0 kgf.m,58 lbf.ft)
103+ 0+ 103 N{n (10.5 + 0+ 10.5 kSfm,
75.9' 0 - 75.9 lbfft)
6x1.0mm
6x1.0mm
8 x 1.25 mm
12 x 1 .25 mm
18 x 1.5 mm
19 x 1.25 mm
21 x 1.25 mm
23 x 1.25 mm
Line bolt
Drain plug
Sub-shaft locknut
Mainshaft locknut: Left-hand threads
Countershaft locknut: Left-hand
threads
14-181
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