Pin HONDA CR-V 1999 RD1-RD3 / 1.G Repair Manual
[x] Cancel search | Manufacturer: HONDA, Model Year: 1999, Model line: CR-V, Model: HONDA CR-V 1999 RD1-RD3 / 1.GPages: 1395, PDF Size: 35.62 MB
Page 505 of 1395
Mainshaft Thrust Clearance
Adjustment (cont'dl
-7. Slide the mainshaft base over the mainshaft.
Attach the mainshaft holder to the mainshaft as
follows:
NOTE:
. Back-out the mainshaft holder bolt and
loosen the two hex bolts.
. Fit the holder over the mainshaft so its lip is
towards the transmission.
. Align the mainshaft holder's lip around the
groove at the inside of the mainshaft
splines, then tighten the hex bolts.
MAINSHAFT HOLDERBOLT
MAINSHAFT EASE07GAJ - PG20130
-9. Seat the mainshaft fully by tapping its end with
a plastic hammer.
-10. Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft
base.
07GAJ - PG20130
-8.
t--E-Hlf\f,A l\. xex
l"\y I aors
t____=__)"n-____"8
\
MAINSHAFTHOLDER07GAJ - PG20110
- 11. Zero a dial gauge onthe end ofthe mainshait.
-12. Turn the mainshaft holder bolt clockwise; stop
turning when the dial gauge has reached its
maximum movement, The reading on the dial
gauge is the amount of mainshaft end play.
NOTE: Turning the mainshaft holder bolt more
than 60 degrees after the needle of the dial
gauge stops moving may damage the transmis-
sion.
MAINSHAFT HOLDER07cru - PG20110
-13. lf the reading is within the standard, the clear-
ance rs correct.
lf the reading is not within the standard,
recheck the shim thickness.
Standard: 0.11 - 0.18 mm (0.00i1- 0.007 inl
DIAL GAUGEMAGNET STAND AASE07979 - PJ40001
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Page 506 of 1395
Transmission Assembly
Reassembly
1. Install the differential assembly in the clutch hous-
Ing.
Install the spring washer and washer with the angle
against the clutch housing as shown.
Tape the mainshaft splines. insert the mainshaft
and countershaft into the shift forks, and install
them as an assemblv.
Tape the mainshattsplines.
DIFFERENTIAL ASSEMBLY
4. '97 - 99 models: Install the reverse idle gaar and
reverse gear shaft in the clutch
housing.'00 model: Install the coller, thrust washer, reverse
idler gear and the reverse gear shaft in
the clutch housing.
THRUST WASHER
COLLER
NOTE: Install the reverse gear shaft ('00 model) in
the direction shown.
5. Install the reverse shift holder in the clutch housing
with the sth/reverse shift piece pin positioned in the
slot of the reverse shift fork.
5x1.0mm15 N'm 11.5 kgt.m, 11 lbf.ftl
model
REVERSE SHIFT HOLDER
(cont'd)
13-67
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Page 507 of 1395
Transmission Assembly
Reassembly (cont'dl
6. Installthe reverse lock cam on the clutch housing.
6x1.0mm15 N.m (1.5 kgf.m, 11 lbf.ftl
REVERSE LOCK CAM
7. lnstall the oil seal.
HANDLE07749 - 001mO
ATTACHMENT,32x35mm07745 - 0010100
OIL SEALReplace.
Install the select lever, spring washer, and springs
on the select arm.
SELECT LEVER
SELECT BETURNSPRING
5TH/REVERSESELECT RETURN
SPRING PINReplace.
SELECT ARM
9. Installthe select arm and spring pin.
13-68
10. Apply liquid gasket (P/N 08718 - 0001 or 08718 -
0003) to the select spring bolt threads, then install
the select spring bolt.
SELECT SPRING BOLT
39 N.m la.o kgf'm,29lbtft)
'I 1.Install the oil guide M plate.78 mm shim, and oil
guner plate in the transmission housing.
NOTE: Select the 78 mm shim according to the
measurements made on page 13-64,
OIL GUIDE M PLATE
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Page 508 of 1395
12. Apply liquid gasket to the surface of the transmis-
sion housing as shown.
Note these items:
. Use liquid gasket (P/N 08718 - 0001 or 08718 -
0003).
. Remove the dirty fluid from the sealing surface.
. Seal the entire circumterence of the bolt holes to
prevent fluid leakage.
. lf 20 minutes have passed after applying liquid
gasket, reapply it and assemble the housings.
a Allow it to cure at least 20 minutes after assem-
bly betore filling the transmission with MTF.
Install the 14 x 20 mm dowel pins.
Set the stopper ring as shown. Place the transmis-
sion housing over the clutch housing, being careful
to line up the shafts. Be sure to align the stop ring
with the 5th shift fork finger tip.
r3.
14.
TRANSMISSION HOUSING
SHIFT FORK
vk..*,
Align point
17.
the 32 mm sealing bolt.
15. Lower the transmission housing with the snap ring
pliers. and set the snap ring into the groove of the
countershaft bearing.
Check that the snap ring is securely seated in the
groove of the countershaft bearing.
Dimension A as installod: 3.6 - 6.3 mm
(0.142 - 0.2/8 in)
16.
32 mm SEALING BOLT25 N m 12.5 kgf.m, 18 lbf.ftlSNAP RING
(cont'd)
13-69
Apply liquid gasket (P/N 08718 - 0001 or 08718 -
0003) to the 32 mm sealing bolt threads, then install
SNAP RING PLIERS
DOWEL PINS
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Page 510 of 1395
22. Turn the select lever and shift arm shaft counter-
clockwise, then insert the shift arm shaft.
INTERLOCK EOLT39 N.m (4.0 kqt ft, 29 lbf ft)SELECT ARM
SHIFT ARM A
Align the shift arm A groove and select arm finger
by turn the shift arm shaft and select lever clock-
wise. then installthe shift arm shaft assembly.
Apply liquid gasket (P/N 08718 - 0001 or 08718 -
OO03) to the threads, then install the interlock bolt'
Apply liquid gasket to the surface of the shift arm
cover as snown.
Note these items:
. Use liquid gasket (P/N 08718 - 0001 or 08718 -
0003).
. Remove the dirtv oilfrom the sealing surface.
. Seal the entire circumference of the bolt holes to
prevent oil leakage.
. lf 20 minutes have passed after applying liquid
gasket. reapply it and assemble the housings.
a Allow it to cure at least 20 minutes after assem-
bly betore filling the transmission with MTF.
23.
-->.-
(
SHIFT ARM SHAFT
SHIFT ARM COVER ASSEMBLY
10 x 12 mft DOWEL PIN
t1
26. Install the shift arm cover assembly.
I x 1.25 mm27 N m 12.8 kgt m,20 lbf'ft)
Install the transfer assemblY.
NOTE: Lubricate MTF to the O-ring and contact
areas.
10 x 1.25 mm44 N.m 14.5 kgf.m, 33 lbl.ftl
13-71
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Page 511 of 1395
Transmission Assembly
1.
Installation
Check that the dowel pins are installed in the clutch
housing.
Apply grease to the release fork and release bear-
ing.
{P/N 08798 - 90021{P/N 08798 - 9002)0.{ - 1.0 g
{0.0'l - 0.04 ozl
RELEASEBEARING
(P/N 08798 -
9002)
RELEASEFORKBOOT
?
(P/N 08798 - 9002)'1.0 - 1.6 g {0.0,1- 0.06 o2l
Install the release bearing, release fork, and release
fork boot to the clutch housing.
Install the starter motor and hose clamp.
10 x 1.25 mm4{ N'm (4.5 kgf.m,32 tbf.ftl
13-72
HOSE
5. Place the transmission on the transmission jack,
and raise it to the engine level.
6. Install the transmission mounting bolts and the rear
engine mounting bolts.
TRANSMISSIONMOUNTING EOLT12 x 1.25 mn
7.
64 N.m {6.547 tbt.ft)
REAR ENGINE MOUNNNG BOLTSReplace.Itl x 1.5 mm8:l N.m 18.5 kgt m, 61 lbf.ft)
Rise the transmission, then install the transmission
mount bracket and transmission mount.
. Torque the mounting bolts and nuts in thesequence shown.
. Check that the bushing are not twisted or offset.
O. @: 12 x 1.25 mm
64 N.m (6.5 kgf.m, 47 lbf'ft)
O: Temporary tightening
@: 12 x 1.25 mm
74 N.m (7.5 kgf'm,54 lbf.ft)
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Page 513 of 1395
Transmission Assembly
Installation (cont'dl
13. Installthe balljoints onto the lower arms.
DAMPER PINCH BOLT10 x 1.25 mm43 N.m {a.a kgf.m,32 rbfft)
SELF.LOCKING NUT'12 x 1.25 |nm6il N'm 16.5 kgtin, 47 lbtftlReolace.
Replace.
14.
PROPELI"ER SHAFT
13-74
12 x 1.25 mm,19 - 59 N.m(5.0 - 6.0 kgi.m, 36 - € lbfttl
Install the right damper fork bolt.
Install the propeller shaft to the transfer assembly
by aligning the reference marks.
E x 1.25 mr'|
15.
REFERENCE MARKS
32 N.m 13.3 kst m, 2a lbf.ftl
TRANSFER
Install the exhaust pipe A, then connect the heated
oxygen sensor (HO2S) connector.
GASKETSReplace.
HO2S CONNECTOR
10 x 1.25 mm5,1N.m 15.5 kgtm.() tbt filReplace.
SELF.LOCKING
SELF.LOCKING NUT8 x 1.25 mm16 N.rn 11.6 kg{.m,12lbtfr)Replace.
GASKETReplace.
8 x 1.25 rr|ln22 N.m (2.2 tgf.m, 16 lbl.ftlReplac6.
'17. Installthe guard bar and the splash shield.
SPLASH SHIEI.I)I x 1.25 mm24 N.m l2.a kgf.m.17 tbtft)GUARD BAR
6x1.0mm9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
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Page 514 of 1395
18.
19.
Refill the transmission fluid (see page 13-3)
Install the four upper transmission mounting bolts.
12 x 1.25 mm6it N.m 16.5 kgf m,il7 lbf.ftl
20. Connect the vehicle speed sensor (VSS) connector.
------------,-
VSS CONNECTOR
21, Install the cable bracket from the clutch housing.
8 x 1.25 mm27 N.m (2.8 kgt'm. 20 lbtftl
COTTER PINR€place.
STEELWASHER
COTTEN PINReplace.
STEELWASHER
PLASTICWASHER
22.
)a
SELECTCABLE
lnstall the shift cable and select cable to the levers,
then install plastic washers, steel washers, and cot-
ter prns,
Connect the back-up light switch connector. and
install the wire harness clamP.
6x1.0mm9.8 N.m {1.0 kgf.m,
HARNESS CLAMP
(cont'd)
13-75
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Page 516 of 1395
Gearshift Mechanism
Overhaul
Note these itemsl
. InsDect rubber parts for wear and damage when disassembling'
. Check that the new cotter pin is seated firmly.
. Be carelul not to damage the guide pipe when removing the cables'
CHANGE LEVER KNOS8 N.m (0.8 kgl.m, 5.8 lbf.ft)
SELECT CABLE
PLATESReplace.WASHEB
I curur(PlN I I
\II
\"1 a,?-@ -.4'
-(
I
\
6x9.8
Guide pipe in theDOOI,
COTTEF PIN
PLASTIC WASHERGUIDE PIPESSHIFT CABLE
'l.0 mmN.m {1.0 kgf.m, 7.2 lbf.ftl
(stLlcoNE
GREASEI
LEVER ASSEMBLY
8 x 1.25 mm13 N.m 11.3 kgt'm,9.4lbf ft)
FLOATINGCOLLAR
13-77
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Page 517 of 1395
Automatic Transmission
Special Tools . 14'2OescriptionGeneral Operation . .... 14 3Power Flow . . .. '14_6
Electronic Control System .. .. . . .. .14_15Hydraulic Control .. 14 24Hydraulic Flow....-....... .. . .... .. .. . 14_29Lock'up Syslem .. .'t4'39Electrical SystemComponenl Locdlrons 14 45
PCM Circuil Dragram (A/T Control Svstem)'97 Model ....................... . . .. - . ... .14-46'98Model ................. . ... .. .. .1450'99 00Models.... . .... . . . 1452
PCM Terminal Voltage/Measuring ConditionsA"/T Control System-'97Model ...... ..14'48A,/T Control System -'98 00 Models . . .. . . 14 54
Troubleshooting Procedures .. ..... ... - 14_56Svmotom to comoonent CharlEiectr,cal Syslem -'97 Model . . 14 60Electrical System -'98 - OO Models . .. . . 14_62Electrical Troubleshooting ('97 Model)Troubleshooting Flowaharts .... ..... . .. . . 14_64
Electrical Troubleshooting ('98 - 00 Models)Troubleshootinq Flowclt"n" .... . ....- . .14-93ElectricalTroublesliooting('99 00Models)Troubleshootino FlowchartO/D OFF Indicator Light Does Not Come On 14 131
O/D OFF Indicator Liaht On ConstantlY . . . .1!-132O/D OFF Indicator Light Does Not Come OnEven Though O/D Switch ls Pressed . .... - 14_133
Lock up Control Solenoid Valve A,/B AssemblyTest....................-......... . .14-135Replacement . .ll_135Shifr ControlSolenoid Valve Ay'B Assembl,Test .............................. . .. 14-136
Replacement..............- . .14'136Linear Solenoid AssemblYTest.............................................. .. .... . 14_137Replacement .. . 14138Marnshaftlcountershafl Speed SensorsReplacement ...-... 14_138A/T Gear Position SwitchTest ..........................-... . .. 14-139ReplacementA/T Gear Positionlndicator.................. 14-140
Valve Eodynepair ............................... ..... . . .. - . .. ... 14 192
Assembly .................... .. 1{_193
Valve CapsDesciiption....-........................ .. ...... 14194
tnspeition ................... .. 14' 195
N4ain Valve BodyDisassembly/lnspection/Reassemblv - ...... .. 14_196
Secondarv Valve BodYDisassemblv4nspectron/ReassemblY .. . 14 198
Reoulator Valve Bodvbisassembtv,lnspiction/Reassemblv . 14199
Servo EodvDisassembly/lnspection/Reassembly ... ....14'200
Lock'uo Valve BodYDis;ssembly/lnspection/Reassembly .... . 14_201
MainshaftDisassembly/lnspection/Reassembly .. .. .. ..14'202
Inspection ....-.............. ..11_203
Sealing RingsReilaceient ...... ..... . 14'204
CountershaftDisassembly/lnspection/Reassembly .. . . . . . 11-205
Disassembly/Reassemb|y . . ........ ...... . .. 14_206Inspedron ................ . .... . 14 207
One wav ClutchDisassembly/lnspection/ReassemblY ... 11_209
Sub-shaftDisassembly/lnspection/Reassembly ... . .. . 14-210
oisassembly/Re6ssembly . . ... .-...... . . ..14-211
Sub-shaft BearingsReplacement .......14'212
Clutchllfustrated Index .......... . . .14-213
Disassembly .... .. .....14-216Reassembfy .... . .. .. . 14'218
Differentialllfustrated Index " 14-222Backlash Inspection . .... . .14'223
Bearing Repiacement .. 11-223
Differe-ntial Carrier Replacement .. .. . . . .. ..11-2?4
OifSeal Replacement. . .. 14'225
Side Clearance lnspection . . - .. ... . - ...... . .. 11'226
Transmission Housing BearingsMainshaJVCountershaft EearingsRepfacement .......14221Sub'siralt Eearing Replacement . . . . . . . . . ..11'224
Toroue Converter Housing BearingsMainshattEearing/OilSe6lReplacement . .. l4229
Countershaft Bea;ing Replacement.. .... .. ..14-230
Input Test - '97 - 98 ModelsInput Test '99 - 00 Models
Symptom to-Component ChartHydraulic System ...............
Checking
Removal ...,lllustrated Index (4WD)
Interlock SystemInterlock ControlUnit lnputTest. -..... -.. .... . - 14 144* Key Interlock Solenoid Test .- .. . . . - . . . ..... 14_146* Shift Lock Solenoid Test ..............-.-. . .. . ... .... 14 147*Shift LockSolenoidReplacement...... .. . .. .. 14 148* park pin Switch Test ......... 14 119' Park Pin Switch Replacement- '97 - 98 Models ....... 14-150* Park Pin Swirch/Over Drive (O/Di SwitchReplacemenl '99-00Models . .. 14_151over-Drive (O/D) Switch {'99 00 [4odels]Test........_..................... .......14-152Hydr.ulic System
..............._............... t4 142.................................. 14-143
Control Lever AssemblyR6placement ......,.,Reverse ldler Gear
lllustrated lndex
.......... 14-230
14 231
11-231
1nsta1|ation ..................Park StopInspeclion/AdjustmenlTransfer AssemblY.......14.232
RoadTest.............-.... ........ .StallSpeedTest ....._........................ ....... 14-159Fluid Level......_................... 14'160
Disessembly .................... 14-235Transfer Drive Gear BearingReplacementTrans{er Driven Gesf Shaft BearingReplacementTransfer Housing Roller BearingReplacementTransfer Cov€r A Bearing Outer RaceReplacementTransfer Housing Bearing Outer RaceReplacement ......-..,,,,,.....ReassemblvTransmassaonBeassembly ... -.. .... .14 250
Torque Converier/Drive Plate . .-. .... .. . ... .....14_258
Transmissionlnstatlation .................. ....... 14'259
Cooler Flushing . . ......11-261ATF Cooler HosesConnection.................. ....... 14-266I Shift LeverRemoval/lnstallation . .. 14'261
Disassemblv/Reassemblv - '97 - 98 Models . . 14_264
Disassembli/Reassemblv -'99 - 00 Models . 14-269
Over'Orive (O/D) Switch WireClearanceAdjustment. - ... . . . .. .. . 14'270
Detent Spring Replscement . . -.. ... .14'271*Shift CableAdiustment ....... 14'272
Repfacement.............. . 11'273
14 15711-237
11-237
14-238
$-234
11-23914-240
Transmigrion
Inspeclron ....., ...........Transfer AssemblyRemova1,.,,,..............,lnstallalion ........... .. ...Transmission
14 164
14-16514,167
14-169
End Cover/Transmissio . 14'174Transmission Housing .... ... .. . . .... .. 14-176Torque Converter Housingly'alve Body.. - ... -. 14 178
lllustrated lndex (2WD)End Cover/Transmissio ....... 14 180Transmission Housing . . ... . .. .... ... 14'182Torque Convener Housing/r'alve Body ......- 14-184
End CovefRemovat ...................... ....... 14'186Transmission HousingRemoval ...................... .. 14_188Torque Convener HousingA/alve BodYRemovat ................-..... .-..... 14-190
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