13-7 HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Manual Transmission
Diff€rential
lndex ...................... ......... 13-38
Backlash Inspestion ..,....,.,.....................,......, 13-38
Final Driven Gear Replacement .................... 13-39
Tapered Roller BearingReplacement ............. 13-39
Bearing Outer Race Replacement ......,.,........ 13-i10
Tapered Roller Bearing PreloadAdiustment ............... 13-il1
Oil Seal Reolacement .................................... 13-/l:}
Transfer Assembly
lllustrated Index ............. 13-il4
Inspection ..,....,.,......,...... 13-46
Disassembly ................... 13-47
Transfer Drive Gear BearingReplacement ...,..................,....................... 13-ilg
Transfer Driven Gear Shaft BearingReplacement .............................................. 13-ilg
Transfer Shaft Disassembly/Reassembly .............. 13-50
Transler Cover A Bearing Outer RaceRep1acement.........,.,.,..........,....,...,.........,., 13-50
Transter Housing Bearing Outer RaceReD1acement.............................................. 13-51
Reassembly ..-............,... 13-52
Mainshaft Bearing/Oil Seal
Beplacement .................. 13-62
Countershaft Bearing
Replacement .,,.,.,., ..,...... 13-63
Mainshaft Thrust Clearance
Adiustment .................... 13-6,1
Transmission Assembly
Reassembly .,.,.,.,..,.,....,., 13-67
fnstaffation .,.,.............,... 13-72
Gearshift Mechanism
Overhaul ................ .........13-17
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Transmission AssemblY
Removal
@FMak. sw. iack" and safety stands are placed propel-
ly, and hoist brackets are attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the batterY.
2. Remove the intake air duct and air cleaner houslng
(see section 5).
3. Remove the slave cylinder and clutch hose bracket'
NOTE:
. Do not operate the clutch pedal once lhe slave
cvlinder has been removed.
. Take care not to bend the clutch line.
4. Disconnect the
ground cable.
starter cables and transmission
TRANSMISSIONGROUND CABLE
Disconnect the back-up light switch connector and
wire harness clamP.
(cont'd)
13-7
WIRE HARNESS CLAMP
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Transmission Assembly
Reassembly lcont'd)
18. Installtransmission hanger, then tighten the bolts in
a crisscross pattern in several steps as shown.
8 x 1.25 mm bolis: 27 N.m 12.8 kgf.m,20 lbf'ft}
TRANSMISSIONHANGER
19.Install flange bolt,
plug.
washers, drain plug. and filler
FILLER PLUG4,r N.m (a.5 kgl.m,33lbtftl
DRAIN PLUG39 N.m {4.0 kg{.m,29lbtftl
WASHERReplace.WASHER
13-70
20. Install the steel balls, springs. washers, set ball
screws, back-up light switch.
WASHERReplace.
STEEL BALLD,5/16 in
21. Installthe vehicle speed sensor (VSS).
VEHICI."E SPEED SENSOR
8 x 1.25 mm22 N.m 12.2 kgl.m, 16 lbt.ftl
SPRING L.26.1 mm 11.03 inl
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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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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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8. Installthe right front mounvbracket.
12 x 1 .25 mm64 N.m (6.5 kgf'm,47 tbf.ftlReplace.
RIGHT FRONTMOUNT/BBACKET
10 x 1.25 mm4,a N.m (4.5 kgf m,
33 tbf ftl
Install the clutch housing cover and rear engine
stiffener.
6xl0mm12 N.m 11.2 kgt.m.8.7 tbf.ft)
HOUSING
'12 x 1.25 mm29 N.m 13.0 kgf.m. 22 lbf'ft)
8 x 1.25 mm24 N.m {2.5 kgf'm'
18 tbl.ft)
10 x 'l .25 mm44 N.m {4.5 kgf m,33 lbf ftl
10. Pour transmission fluid of 1 liter from the driveshaft
inserted hole.
1 1. lnstall the intermediate shaft {see section 18). While
installing the intermediate shaft in the differential.
be sure not to allow dust and other foreign particles
to enter the transmission.
10 r 1.25 mm39 ttm 14.0 kgf.m,29 tbt ftlSET RINGReplace.
12. lnstall the driveshafts (see section 18). While
installing the driveshaft(s) in the differential, be sure
not to allow dust and other foreign panicles to enter
the transmission.
SET RINGReplace.
(cont'd)
13-73
INTERMEOIATE SHAFT
DRIVESHAFT
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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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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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Transmission Assembly
Installation (cont'dl
24. Connect the starter cables and transmission ground
caore.
TRANSMISSIONGROUND CABLE
Apply grease to the push rod on the slave cylinder,
then install the slave cylinder and clutch hose bracket,
NOTE: Use only Super High Temp Urea Grease
{P/N 08798 - 9002).
CI-UTCH HOSEBRACKET
8 x 1.25 mm22 N.m 12.2 kgi-m,16 tbr.f0
6x1.0mm9.8 N.m {1.0 kgf.m,7.2 rbf.ftt_G1(P/N 08798
6x1.0mm9.8 N.m (1.0 kg{.m,7.2 tbt.ttl
13-76
- 9002)
26. Turn the breather cap so that the "F" mark points at
the right side of the vehicle as shown.
27. Install the intake air duct and air cleaner housing(see section 5),
28. Connect the positive (+) cable first. then the nega-
tive (-) cable to the battery.
29. Check the level of the transm ission f lu id.
30. Check the clutch operation.
31. Shift the transmission and check for smooth opera-tion.
32. Check the front wheel alignment (see section l8).
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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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