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

Sub-shaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricate all parts with ATF before reassembly.
. Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
. Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
6 x 1.0 mrr12 1{.mll.2 ksl.m, 8.7 lbt.ftl
SUB.SHAFTCheck splines tor excessivewear ano damage,Check bearing surlace for scoring,scralches and excessive wear-
t{EEDLE BEARINGSTOP
IST.HOLO CLUTCHASSEMBLY
o,Rtl{GSReplace.
TI{RUST WASI{ER
THFUST TEEOLCBEARI G
I{EEDLE B€ARI G
TRAi{SMTSStON tl()UStNG
14-210
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Disassembly/Reassembly
1.Remove the ATF guide cap by pushing the sub-shaft
inside the transmission housing.
Remove the 1st-hold clutch assembly by pulling,
then removing the sub-shaft.
Install new O-rings on the sub-shaft.
NOTE: Wrap the shaft splines with tape to prevent
damaging the O-rings.
Place the sub-shaft in the transmission housing,
and install the'lst-hold clutch assembly,
Install the new ATF guide cap using the special
tools. Install it in the direction shown.
ATTACHMENT,32x35mm07746 - 0010t00
14-211
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Sub-shaft Bearings
Replacement
NOTE: Lubricate all parts with ATF before reassembly.
1. Expand the snap ring with snap ring pliers. thenpush the bearing out of the transmission housing
using the special tools and a press as shown.
Remove the needle bearing stop.
Remove the needle bearing from the transmission
housing using a drift.
ATTACHMENT,ai:l x 68 mm07746 - 00105q)
14-212
SNAP RING
4. Install a new needle bearing in the housing using
the sOecial tools and a oress as shown.
7.
cI
32x35mm077/46 - qt10t(x,
Expand the snap ring with snap ring pliers, then
insert the ball bearing part-way into the housing
using the special tools and a press as described in
step 1. Install the bearing with the groove facing
outside the housing.
Release the pliers, then push the bearing down into
the housing until the snap ring snaps in place
around it.
After installing the ball bearing verify the fottowing:
. The snap ring is seated in the bearing and hous-
Ing grooves.
. The ring end gap is correct.
ENDGAP:0-7mml0 - 0.28 inl
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Glutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetorcleaner, and dry them with compressed air.. Blow out all passages.
o Lubricate all parts with ATF before reassembly.
1. Inspect the check valve; if it's loose, replace the pis_ton.
CHECK VALVE
2. Install new O-rings on the clutch piston.
PtsTot{
14-218
3. Install th€ piston in the clutch drum. Apply pressure
and rotate it to ensure proper seating, Lubricate thepiston O-ring with ATF betore insta ing the piston.
NOTE: Oo not pinch the O-ring by installing the pis_ton with too much force.
CLUTCH DRUM
Install the return spring, and spring retainer, thenposition the snap ring on the retainer.
4.
SI{AP RING
SPAI'{G RETAIIIER
REIURN SPRING
CLUTCH DRUM
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Clutch
Installthe snap ring.
Reassembly (cont'd)
7.
S AP RIIG
8. Remove the special tools.
9, Install the disc spring in the direction shown.
1ST, 2ND, 4TH, lST-HOLD CLUTCH:
3RD CLUTCH:
Dlsc sPRrrtc
CIUTCH ORUM
otsc sPfitl{c
14-220
10.Soak the clutch discs thoroughly in ATF for a mini_mum of 30 minutes. Before installing the platesand discs, make sure the inside of the clutch drumis free of din or other foreign matter
Starting with a clutch plate, alternatelv install theclutch plates and discs. Install the clutch end platewith its flat side toward the disc.
CLUTCH EI{D PI.ATEInstall in this directior.
CLUTCHCLUTCH EI{D PLATE
12. Install the snap ring.
SCREWDRIVER
't1.
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13. Measure the clearance between the clutch end plate
and top disc with a dial indicator. Zero the dial indi-
cator with the clutch end plate lowered, and lift it up
to the snap ring. The distance that the clutch end
plate moves is the clearance between it and the top
dtsc.
NOTE: Take measurements in at least three places'
and use the average as the actual clearance.
Clutch End Ptate-to-Top Disc Clearance:
ClutchService Limit
'l st
2nd
3rd
4th
lst-hold
0.65 - 0.85 mm (0.026 - 0.033 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
0.40 - 0.60 mm (0.016 - 0.024 in)
0.50 - 0.80 mm (0.020 - 0.031 in)
SNAP RING
lf the clearance is not within the service limits, select
a new clutch end plate from the following table
NOTE: lf the thickest clutch end plate is installed,
but the clearance is still over the standard, replace
the clutch discs and clutch plates.
MARK
I I rnictness
--:--l----T
14.
CLUTCH END PLATE
14-221
lST CLUTCH END PLATES
2ND and 4TH CLUTCH END PLATES
3RD CLUTCH END PLATES
lST-HOLD CLUTCH END PLATES
MarkThicknass'I22551 P56 - N002.1 mm (0.083 in)
222552-P56-N002.2 mm (0.087 in)
322553 - P56 N002 3 mm (0.091 in)
22554-P56-NOo2.4 mm (0.094 in)
522555 P56 - N002.5 mm {0.098 in)
622556 P56 - N002 6 mm (0.102 in)
722557 - P56 N002.7 mm (0.106 in)
822558 - P56 N002.8 mm (0.110 in)
I22559 - P56 N002.9 rnm (0.114 in)
1022s60 - P56 N003.0 mm (0.118 in)
MarkParl NumberThickness
622556-P56-N002.6 mm (0.102 in)
122557 P56 - N002.7 mm (0.106 in)
822558-P56-N002.8 mm (0.110 in)
22559-P56-N002.9 mm (0.114 in)
1022560 - P56 N003.0 mm (0.118 in)'1122561 PDM - 0003.1 mm (0.122 inl
1222562 - PDM - 0003.2 mm {0.126 in)
1322563 PDM - 0003.3 mm (0.130 in)
22564 PDM - 0003.4 mm (0.134 in)
22565 PDM - 0003.5 mm (0.138 in)
22566 PDM - 0003.6 mm 10.142 in)
1722567-PDM-0003.7 mm (0.146 in)
MarkPart NumberThiclness
I22558 P56 - N002.8 mm (0.110 inl
922559 P56 - N002.9 mm (0.114 in)
1022560 P56 - N003.0 mm (0.118 in)
1122561 PD[4 - 0003.1 mm (0.122 in)
1222562 - PDM 0003.2 mm (0.126 in)
t322563-PDM-0003.3 mm (0.130 in)'1422564-PDN4-0003.4 mm (0.134 in)
1522565-PD[,l-0003.5 mm (0.138 in)
22566 PDM - 0003.6 mm (0.142 in)'t122567 - PoM - 0003.7 mm {0.146 in)
Thickness
2255r-PS5-0032.1 mm (0.083 in)
22552 - PS5- 0032.2 mm {0.087 in)
322553 PS5 - 0032.3 mm (0.091 in)
22554, PS5 - 0032.4 mm (0.094 in)
22555 PS5 - 0032.5 mm (0.098 in)
622556 PS5 - 0032.6 mm {0.102 in)
722557 - PSs 0032.7 mm (0.106 in)
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Differential
lllustrated Index
'lWD:
SET RING, 80 mmSelective part
10 x 1.0 mm103 N.m (10.5 kgt.m,?5.9 tbtftl
FINAL ORIVEN GEARlnspect for excessive wear,Install in this direction.
BALL BEARINGInspect for rough
DIFFERENTIAI.CARRIERlnspect for cracks.
TRANSFER SHAETDNlvE GEARInspect for excessive
SPEEDOMETERDRIVE GEARInstall in thisdirection.
SNAP RINGInstall in thisdirection.
BALL BEARINGInspect for rough movement,
14-222
2WDl
SET nlNG, 80 mmSel6ctive part
A,U
,gBc
10 x 1.0 mm103 N.m {10.5 kg[.m,75.9 tbt.ftlLeft-hand threads
FINAL ORIVEN GEARInspect for excessive wear,Install in thls direction.
BALL BEABINGInspect for rough
DIFFERENTIAI.CARRIERInspect for cracks.
ROLLER,5 x 10 mm
SPEEDOMETERDRIVE GEARInstall in thisdirection.
SNAP RINGInstall in thisdirection.
BALL BEARING
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Backlash Inspection
Place the differential assembly on V-blocks.
lnstall the driveshaft and intermediate shaft on the
differential assemblY.
Check the backlash of both pinion gears.
STANDARD: 0.05 - 0.15 mm (0.002 - 0.006 in)
OIFFEBENNAL ASSEMBLY
It the backlash is out of standard, replace the difter-
ential carrier.
1.
DIAL INDICATOR
Bearing Replacement
NOTE: Check bearings for wear and rough movement.
lf bearings are OK, removal is not required.
1. Remove the bearings using a bearing puller.
BEARING PULLER(Commercially available)
lnstall new
snown.
bearings using the sPecial tool
PRESS
14-223
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Differential
Differential Carrier Replacement
NOTE: The illustration shows the 4WD automatic trans-mission differential; the 2WD differential is similar.
1. Remove the snap ring from the differential carrier.
Remove the 5 x 15 mm roller (4WD) or 5 x 10 mmroller (2WDl and the speedometer drive gear.
SPEEDOMETER DRIVE GEAR RoI I FP
Remove the bolts securing the final driven gear andthe transfer shaft drive gear (4WD), then replace thedifferential carrier.
5 x 15 mm (/tWD)5 x 10 mm {2WDl
14-224
SPRING PINGROOVE
Install the final driven gear on a new differential car-rier with its chamfered side facing the carrier andthe transfer drive gear (4WD),
Tighten the bolts to the specified torque.
NOTE: The 2WD differentiat bolt has left-handthreads,
10 x 1.0 mm103 N.m 110.5 kd.m,7s.9 rbr.ft)
7.
FINAL DRIVEN GEAR
TRANSFER SHAFT
Install the speedometer drive gear with its cham-fered side facing the carrier. Align the cutout on thebore of the speedometer drive gear with the 5 x 15mm roller (4WD) or 5 x 10 mm roller (2WD).
Align the hooked end of the snap ring with thespring pin in the pinion shaft. then install the snaoring in the differential carrier groove
SNAP RINGInstall in this direction.Hooked end
PINION SHAFT
{4WDl
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Differential
Side Clearance Inspection
1. Instsll the 80 mm set ring in the transmission hous-Ing,
SET RING, 80 mrn
Install the differential assembly in the torque con-verter housing using the specialtool.
Install the transmission housing on the torque con-verter housing, and tighten the transmission hous-ing mounting bolts (see pages 14-252 and t4-253).
TOROUE: 4a N.m l/r.5 kgf.m, 33 tbt.ftl
14-226
4. Tap on the transmission housing side of the diffsrential assembly with the special tool to seat the dif-ferential assemblv.
DBIVER ilo m.n LO.0t746 - 0030100
Measure the clearancs between the 80 mm set ringand the bearing outer race with a feeler gauge,
STANDARD: 0 - 0.15 mm (0 - 0.006 inl
FEEI..ER GAUGE
lf the clearance is out of standard, remove rne setring and measurs its thickness.
Select and instsll a new 80 mm set ring.
SET RING, 80 mm
Recheck the clearance, and make sure it is withinstandard.
7.
Part NumborThicknoss
90414-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
2.50 mm (0.098 in)
2.60 mm (0.102 in)
2.70 mm (0.106 inl
2.80 mm (0.110 in)
2.90 mm (0.114 in)
3.00 mm (0. t'18 inl
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