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

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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Transmission Housing Bearings
Mainshaft/Countershaft Bearings Replacement
1. Expand each snap ring with snap ring pliers, then
push the bearings out of the transmission housing
using the special tools and a press as shown.
Do not remove the snap rings unless it's necessary
to clean the grooves in the housing.
DFIVER077a9 - 001(xx)o
ATTACHMENT
ATTACHMENT
. Mainshaft Bearing Romoval:
ATTACHMENT, 72 x 75 mm
077/16 - 0010600
. Countqrshaft Bearing Removal:
ATTACHMENT, 62 x 68 mm
07746 - 0010500
MAINSHAFT BEARING
4.
Expand each snap ring with snap ring pliers, then
coat the new bearings with ATF and insert them
part-way into the housing using the special tools
and a press as shown. Install the bearings with the
groove facing outside the housing.
Release the pliers, then push the bearings down
into the housing until the rings snap in place
around them.
077/49 - 0010000
ATTACHMENT
. Mainshaft Bearing Installation:
ATTACHMENT,72 x 75 mm
07746 - 0010600
. Countershaft Bearing Instsllation:
ATTACHMENT, 52 x 68 mm
077'16 - 0010500
After installing the bearings, verify the following:
. The snap rings are seated in the bearing and
housrng grooves.
. The snap rings do not bind.
. The ring end gaps are correct,
l0 - 0.28 in)
SNAP RING
ENDGAP:0-7rnm
14-227
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Transmission Housing Bearings
Sub-shaft Bearing Replacement
1. Expand the snap ring with snap ring pliers, thenpush the bearing out of the transmission housingusing the special tools and a press as shown.
Do not remove the snap ring unless it,s necessaryto clean the groove in the housing.
ATTACHMEI{T,5:l x 68 mm07r{5 - @10500
SNAP RI]TG
DRIVER07749 - tDl(xx)o
ATTACHMENT,6:l x 68 mm077a6 - (X,r0500
14-228
SNAP RING
Expand the snap ring with snap ring pliers, thencoat the new bearing with ATF and insert it part-way into the housing using the special tools and apress as shown. lnstall the bearing with the groovefacing outside the housing.
Release the pliers, then push the bearing down intothe housing untilthe ring snaps in place around it.
DRIVER07743 - 0010mo
ATTACHMENT,{i:l x 68 mm07746 - 0010500
GROOVE
After installing the bearing, verify the following:
. The snap rjng is seated in the bearing and hous_ing grooves.
. The snap ring does not bind.. The ring end gap is correct,
ENDGAP:0-7mm
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Torque Gonverter Housing Bearings
Mainshaft Bearing/Oil Seal Replacement
1. Remove the mainshaft bearing and oil seal using
the soecial tool.
SLIDE HAMMER,3/8" - 16(Commercially available)
ADJUSTABLE EEARINGPULLER,25 - 40 mm07736 - A010008 or07736 - A01000A
ATTACHMENT,62x68mm07746 - 0010500
Install a new mainshaft bearing until it bottoms in
the torque converter housing.
3. Install a new oil seal flush with the torque converter
housing.
ATTACHMENT,
07?46 - 0010m0
07749 - 0010000
14-229
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Torque Gonverter Housing
BearingsGontrol Lever Assembly
Countershaft Bearing Replacement
1. Remove the countershaft bearing using the specialtool.
SLIOE HAMMER,3la" -16(Commercially available)
ADJUSTABLE BEARINGPULLER,25 - 40 mm07736 - A0100OB ol07736 - A01m0A
Install the ATF guide ptate.
Install a new countershaft
converter housing.
COUNTERSHAFTBEARING
bearing in the torque
DRIVER077i19 - 001m00
14-230
ATF GUIDE PLATE
Replacement
Check the condition and movement of the control leverassembly, lf the control lever assembly binds or doesnot move smoothly. replace it.
1. Remove the 6 x 1.0 mm bolt and lock washer.
2. Remove the change shaft trom the torque converterhousing.
3. Remove the control lever assembly from the controlshaft.
4. Install the new control lever assembly in the reverseorder of disassembly, until it bottoms in the torqueconverter housing.
LOCK WASHERReplace.
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Reverse ldler GearPark Stop
lnstallation
1. lnstall the reverse idler gear'
lnstallthe reverse idler gear shaft holder and needle
bearing into the transmission housing, then tighten
the bolts.
6 x 1.0 mm12 N.ft ll.2 kgl']n,a.7 rbl.frl
't.
Inspection/Adi ustment
Set the park lever in the E position.
Measure the distance between the park pawl shaft
and the park lever roller pin as shown.
STANDARD: 72.9 - 73.9 mm {2.87 - 2.91 in)
PARK STOP
PARK PAWL SHAFT
lf the measurement is out of standard, select and
install the appropriate park stop from the table
below.
PARK STOP
PARK STOP
After replacing the park stop. make sure the dis-
tance is within standard.
',.A\
Measuring /
MarkPart NumberLtL2
124537-PAg-00311.00 mm
(0.433 in)
11.00 mm
(0.433 in)
24538-PAg-00310.80 mm
(0.425 in)
10.65 mm
(0.419 in)
24539-PAg-00310.60 mm
(0.417 in)
10.30 mm
(0.406 in)
14-231
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O TRANSFER HOUSING
O o-RING Replace.
O TRANSFER HOUSING ROLLER BEARING
@ TRANSFER SHAFT
O TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING
O TRANSFER SHAFT COLLAR
@ THRUST SHIM, 25 mm Selective part
€) TRANSFER DRtvE GEAR (HYPoID GEAR}
@ coNtcAL SPRtNG WASHER Reptace,
@ TRANSFER SHAFT LOCKNUT,22 x 1.25 mm Left-hand rhreads, replace.
(D TAPERED ROLLER EEARING
@ TAPERED ROLLER EEARING OUTER RACE(} THRUST SHIM, 68 mm Selective part
@ O-RING Replace.
@ TRANSFER coVER A
(} TRANSFER COVER B
@ o-RING Replace.
(9 TRANSFER DRIVEN GEAR SHAFT (HYPOID GEAR)
@ THRUST SHIM, 35 mm Selective part
@ TAPERED ROLLER BEARING
@ TRANSFER SPACER Reptace.
@ TAPERED RoLLER BEARTNG OUTER RACE
@ TAPERED ROLLER BEARING OUTER RACE
@ TAPERED BOLLER BEARTNG
@ olL SEAL Replace.
@ COMPANION FLANGE
@ o-RING Replace.
@ BACK-UP RING
@ coNtcAL SPRtNG WASHER Reptace.
@ 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 lbnft)
118 N.m (12.0 kgim,87 Ibift)
132 216 N.m (13.5 22.0 kgf.m,
98 - 159 lbift)
6x1.0mm
8 x 1.25 mm
22 x 'l.25 mm
22 x 1.25 mm
Transfer shaft locknut:
Left hand threads
Transfer driven gear shaft locknut
Tightening torque: depending on
Total Starting Torque value
14-233
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Transfer Assembly
Inspection
NOTE: To prevent damage to the transfer housing,
always use soft jaws or equivalent materials between
the transfer housing and the vise.
Trsnsfer Gear (Hypoid gear) Backl8sh M€asurem€nt
1. Set a dial indicator on the companion flange as
snown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.02 - 0.06 in)
Total Starting Torque Meagurgm€nt
3, Rotate the companion flange several times to seat
the tapered roller bearing.
4. Measure the starting torque (companion flange
side) using a torque wrench as shown,
STANDARD:
2.68 - 3.,17 N.m(27.3 - 35.,1 kgf.cm, 23.7 - 30.7 lbf.inl
TRANSFER SHAFT
DIAL INDICATOR
COMPANION FLANGE
14-234
Transfer Gear (Hypoid gear) Tooth Contact Inspection
5, Remove transfer cover B, then apply Prussian Blue
to both sides of the transfer gear teeth lightly and
Rotate the companion flange in both directions until
the transfer gear rotates one full turn in both direc-
tions.
Check the transfer gear tooth contact pattern. Thepattern should be centered on the gear tseth as
snown.
6.
7.
8.lf the statrting torque measurement or the tooth
contact pattern are not correct, disassemble the
transfer assembly, replace worn or damaged parts,
and reassemble it.
TRANSFER DRIVE G€AR
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Disassembly
1. Remove the transfer covers A and B.
2. Cut the lock tabs of the locknut usino a chisel.
LOCK TAB
5.
Put a 14 mm Allen wrench in the gear side of the
transfer shaft, then secure the Allen wrench in a
bench vise.
Remove the transfer shaft locknut and the conical
spring washer. The transfer shaft locknut has left
hand threads.
Remove the transfer shaft, transfer drive gear, 25
mm thrust shim, transfer shaft collar, and tapered
roller bearing from the transfer housing.
TRANSFER SHAFT
THRUST SHIM,25 mrnSelective part
CONICAL SPRINGWASHERReplace.
(cont'd)
1a mm ALLEN WRENCH
14-235
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