No start HONDA CR-V 2000 RD1-RD3 / 1.G Workshop Manual

O TRANSFER HOUSING
@ O-RING Replace.
O DAMPER HUB
G) NEEDLE BEARING
G) TRANSFER DRIVEN GEAR
G) TRANSFER SHAFT
O TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING
€) TRANSFER SHAFT COLLAR
@ THRUST SHIM, 25 mm selective part
6D TRANSFER DRIVE GEAR (HYPOID GEAR)
@ CONICAL SPRING WASHER RePlace
GD TRANSFER SHAFT LOCKNUT.22 x 1.25 mm Left-hand threads, replace'
E) TAPERED ROLLER BEARING
@ TAPERED ROLLER BEARING OUTER RACE
@ THRUST sHlM. 68 mm selective part
O o.RlNG Replace.
@ TRANSFER COVER A
GD TRANSFER COVER B
@ O-RING Replace.
€) TRANSFER DRIVEN GEAR SHAFT (HYPOID GEAR}
@ THRUST SHIM, 35 mm Selective Part
@ TAPERED ROLLER BEARING
@ TRANSFEB SPACEB RepIace.
@ TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING OUTER RACE
@) TAPERED ROLLER BEARING
@ olL SEAL Replace.
@ COMPANION FLANGE
@ O-RING Replace.
@ BACK-UP RING
@ coNtcAL SPRING WASHEB Replace.
(o 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 lbf'ft)
118 N.m (12.0 kgf.m, 86.8 lbf'ftl
132 - 216 N.m (13.5 - 22.0 kgf'm,
97.6 - 159 lbf.ft)
6x1.0mm
8 x 1.25 mm
22 x 1 ,25 mm
22 x 1 .25 mm
Transfer shaft locknut:
Lett-hand threads
Transfer driven gear shaft locknut
Tightening torque: dePending on
Total Starting Torque vaiue
13-45
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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.
Transter Gaar (Hypoid goar) Backlssh M€asurement
1. Set a dial indicator on the companion flange asshown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.002 - 0.006 in}
Total Sta.ting Torquo Msasuremont
3. Rotate the companion flange several times to seatthe tapered roller bearing.
4. Measure the starting torque (companion flange
side) using a torque wrench.
STANDARD:
2.68 - 3.47 N.m
{27.3 - 35.4 kgf.cm.23.7 - 30.7 tbt.in)
DIAL INDICATOR
COMPANION FLANGE
13-46
Transfer Gear lHypoid gearl Tooth Contaqt Insp€ction
5. Remove transfer cover B, then apply Prussian Blueto both sides of the transler gear teeth lightly andevenlv.
Rotate the companion flange in both directions untilthe transfer gear rotates one full tuln in both direc-tions.
Check the transfer gear tooth contact pattern.7.
lf the measurements or the tooth contact Datternare not within the standard. disassemble the trans-fer assembly, replace worn or damaged parts, andreassemble it.
TRANSFER DRIVE GEAR
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Transfer Assembly
Reassembly
Note these items during reassembly:. While reassembling the transfer assembly:- Check and adjust the transfer gear tooth contact.- Measure and adjust the transfer gear backlash.- Check and adjust the tapered roller bearing start-Ing rorque.
. Coat all parts with MTF during reassembly.. Replace the tapered roller bearing and the bearingouter race as a set if either part is replaced.. Replace the transfer drive gear and the transfer dri-ven gear shaft as a set if either part is replaced,
Outline of Assembly
1.Select the 35 mm thrust shim.
Perform this procedure if the transler driven gear
shaft or the tapered roller bearing on the transferdriven gear shaft is replaced.
Preassemble the parts to check and adjust transfergear backlash and transfer gear tooth contact.
Disassemble the parts, then assemble the transferdriven gear shaft and its related parts.
4. Measure and adjust the staning torque of the trans-fer driven gear shaft tapered roller bearing.
5. Assemble the transfer shaft and jts related parts.
6. Measure and adjust the total starting torque.
35 mm Thrust Shim Seleqtion
1. Select the 35 mm thrust shim if the transfer drivengear shaft or the tapered roller bearing on the trans-fer driven gear shaft is replaced.
Calculate the thickness of the 35 mm thrust shimusing the formula below.
ronrvruu:fi--fr-+c=x
A: Number on the existing transfer driven gear shaftB: Number on the replacement transfer driven gear
shaft
C: Thickness ofthe existing 35 mm thrust shimX: Thickness needed for the replacement 35 mmthrust shim
NOTE: The number on the transfer driven gear
shaft is shown in 1/100 mm.
2.
3.
13-52
EXAMPLE:
C: EXISTING 35 mmTHRUST SHIMThicknoss: C=1.05 mm
X: REPLACEMET{T35 mmTHRUST SHIMThickness: X=?? mm
Number: A=+2Number: B-l
A: EXISTING TRANSFERDRIVEN GEAR SHAFT
x= A - B -.'- 100 100 -
2-1
100 100 '-
= 0.02 + 0.01 + 1.05-'1.08 (mm)
B: REPLACEMENT TRANSFERDRIVEN GEAF SHAFT
Select 35 mm thrust shim thickness ot '1.08 mm(0.043 in). lf the tapered roller bearing on the transferdriven gear shaft is replaced.
Measure the thickness of the replacement bearingand the existing bearing, and calculate the differenceof the bearing thickness. Adjust the thickness of theexisting 35 mm thrust shim by the amount of differ-ence in bearing thickness. and select the replacement
35 mm thrust shim. Do not use more than one 35 mmthrust shim to adjust the transfer gear backlash,
THRUST SHIM. 35 mm
Shim No.Part NumberThickness
41361 - PS3 - 0000.72 mm (0.028 in)
B41362-PS3-0000.75 mm (0.030 in)
c41363-PS3-0000.78 mm (0.031 in)
41364-PS3-0000.81 mm (0.032 in)
E41365-PS3-0000.84 mm (0.033 in)
F4r366-PS3-0000.87 mm (0.034 in)
41367-PS3-0000.90 mm (0.035 in)
n41368-PS3-0000.93 mm (0.037 in)
41369-PS3-0000.96 mm {0.038 in)
41370-PS3-0000.99 mm (0.039 in)
41371 - PS3 - 0001.02 mm (0.040 in)
L41372-PS3-0001.05 mm (0.041 in)
41373-PS3-0001.08 mm (0.043 in)
N41374-PS3-0001.11 mm (0.044 in)
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Transfer Assembly
Reassembly (cont'd)
7.Secure the transfer housing in a bench vise with
soft jaws, then install the special tool on the com-
panion flange. To prevent damage to the transfer
housing, always use soft jaws or equivalent materi-
als between the transfer housing and the vise.
COMPANION FLANGEHOLDER07RAB - 0020000
WRENCH
8. Tighten the locknut while measuring the starting
torque so the starting torque is within 0.98 - 1.39
N.m {10.0 - 14.2 kgf.cm. 8.68 - 12.3 lbf.in).
NOTE:
. Coat the threads of the locknut, and the shaft
with MTF before installing the locknut.
. Do not stake the locknut in this step.
STARTING TOROUE:
0.98 - 1.39 N.m(10.0 - 14.2 kgf.cm, 8.68 - 12.3 lbf.in)
9.Install the transfer shaft assembly in the transfer
housing, then install the tapered roller bearing,
transfer shaft collar,25 mm thrust shim, transfer
drive gear, conical spring washer, and locknut on
the transfer shaft.
NOTE:
. Coat the threads of the locknut, and the shaft
with MTF before installing the locknut.
. Do not stake the locknut in this step.
TRANSFER SHAFTASSEMBLY
TRANSFER
THRUST SHIM.25 mmSelective part
COLLAR
TRANSFER DRIVEGEAR
CONICAL SPRINGWASHERReplace.Replace.
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20. Remove the parts on the transfer shaft, and remove
the transfer shatt from the transfer housinq.
TRANSFER SHAFT
TRANSFER HOUSING
TAPERED ROLLERBEARING
TRANSFER SHAFTCOLLAR
TMNSFER DRIVEGEAR
THRUST SHIM, 25 mmSelective part
CONICAL SPRINGWASHERReplace.
LOCKNUTReplace.
Transter Driven Gear Shaft Starting Torque Inspection
and Adlustment
21. Secure the transfer housing in a bench vise with
soft iaws.
Install the special tool on the companion flang€,
then remove the transfer driven gear shaft locknut
and the conical spring washer.
COMPANION FLANGE HOLDER
22.
BACK.UP
Remove the transter driven gear shaft and the com-
panion flange.
Install the new transfer spacer on the transfer dri-
ven gear shaft, then install them in the transfer
housing.
TRANSFER DRIVENGEAR SHAFTTRANSFER SPACERInstall in this direction.TRANSFER
25.Install the companion flange, O-ring, back-up ring,
conical spring washer and locknut on the transfer
driven gear shaft.
NOTE:
. Coat the threads of the locknut, O-ring and trans-
fer shaft with MTF before installing the locknut.
. Install the conical spring washer in the direction
shown.
TRANSFER HOUSING
O.RING
COMPANIONFLANGECONICAL SPRINGWASHERReplace.
LOCKNUTReplace.
(cont'd)
13-57
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Transfer Assembly
Reassembly (cont'dl
26. Secure the transfer housing in a bench vise with
soft jaws.
COMPANION FLANGE HOLDER07RAB - 002tD00
27. Install the special tool on the companion flange.
then tighten the transfer driven gear shaft locknut
while measuring the starting torque of the transfer
driven gear shaft.
STARTING TOROUE:
0.98 - 1.39 N.m
{10.0 - 1i1.2 kgf.cm, 8.68 - 12.3 lbf in}
TIGHTENING TOROUE:
132 - 216 N.m
(13.5 - 22.0 kgf.m, 97.6 - 159 lbf.ft)
NOTE:
. Rotate the companion flange several times to
seat the tapered roller bearing, then measure the
startrng torque.
. lf the starting torque exceeds 1.39 N.m (14.2
kgf.cm, 12.3 lbf.in), .eplace the transfer spacer
and reassemble the parts. Do not adjust the
torque with the locknut loose.
. lf the tightening torque exceeds 216 N.m (22.0
kgf.m, 159 lbf'ft), replace the transfer spacer and
reassemble the parts.
. Write down the measurement of the starting
torque: it is used to measure the total starting
torque.
28. Stake the locknut into the transfer driven oear shaft
using a 3.5 mm punch.
0.7 - 1.2 mm(0.03 - 0.05 inl
Point to bestaked.
Install the transfer shaft assemblv in the transfer
housing, then install the tapered roller bearing,
transfer shaft collar, 25 mm thrust shim, transfer
drive gear, conical spring washer, and transfer shaft
locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut and transfer shaft
with MTF before installing the locknut.
. lnstall the conical spring washer in the direction
snown.
TMNSFER SHAFTASSEMBLY
TRANSFER HOUSING
TAPERED ROLLERBEARING
TRANSFER SHAFTCOLLAR
TRANSFER DRIVEGEAR
PUNCH3.0-3.5 mm10.12 - 0.1a inl
THRUST SHIM, 25 mmSelective part
CONICAL SPRINGWASHEBReplace.
LOCKNUTReplace.
29.
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30. Hold the transfer shaft with a 14 mm Allen wrench
clamDed in a bench vise.
NOTE: The locknut has left-hand threads.
TOROUE: 118 N.m (12.0 kgt'm,86.8 lbf'ft)
31. Stake the locknut on the transfer shaft using a 3.5
mm Dunch.
PUNCH3.0 - 3.5 mm{0.12 - 0.14 inl
14 mm ALLEN WRENCH
Totsl Starting Torquo Inspoction and Adiustment
32. Temoorarilv install transfer cover A without the O-
ring.
TRANSFER HOUSING
TRANSFER COVER A
oEl
€lE/Ehvc/E\\g8 x 1 .25 mm24 N.m (2.4 kg{ m, 17 lbtftl
5t.Secure the transfer housing in a bench vise with
soft jaws. then rotate the companion flange several
times to fit the tapered roller bearing,
TOROUE WR€NCH
34. Measure the total starting torque.
TOTAL STARNNG TOROUE:
1.70 - 2.08 N.m 117.3 - 21.2 kgf.cm, 15.0 - 18.i1 lbf inl
+ Transter Driven Gear Shaft Starting Torque Value
(wrot€ down in step 27).
(cont'd)
13-59
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Transfer Assembly
Reassembly (cont'd)
Remove transfer cover A.
lf the measurement is out of specification, remove
the 68 mm thrust shim from transfer cover A by
heating the cover to almost 212'F (100'C) using a
heat gun. Do not heat the cover higher than 212F
(100"C). Let the cover cool to room temperature
before adjusting the starting torque.
lI the measurement is within the specification, go to
step 40.
COVER A
BEARING OUTER RACE
35.
36.
HEAT GUN
13-60
37. Select the 68 mm thrust shim.
THRUST SHIM, 68 mm
Shim No.Part NumberThickne3s
zv23914-P1C-0201.41 mm (0.056 in)
zw23975-P1C-020'1.44 mm 10.057 in)
zx23916 PlC -020'1.47 mm (0.058 in)
ZI23917 -P1C-O201.50 mm (0.059 in)
zz23978-PlC-0201.53 mm (0.060 in)
23941 - PW5 0001.56 mm {0.061 in)
23942-PWs-0001.59 mm (0.063 in)
c23943-PW5-000't.62 mm (0.064 in)
D23944 PW5 - 0001.65 mm (0.065 in)
E23945-PWs-0001.68 mm (0.066 in)
F23946-PW5-0001.71 mm 10.067 in)
G23947-PW5-000'1.74 mm 10.069 in)
23948-PWs-0001.77 mm (0.070 in)
23949-PWs-0001.80 mm (0.071 in)
239s0-PW5-0001.83 mm (0.072 in)
K23951 - PW5 - 0001.86 mm (0.073 in)
L23952-PWs-0001.89 mm {0.074 in)
239s3-PWs-0001.92 mm {0.076 ini
N23954-PW5-0001.95 mm (0.077 in)
o23955-PW5-0001.98 mm (0.078 in)
P23956 - PW5 , 0002.01 mm (0.079 in)
o23957-PWs-0002.04 mm (0.080 in)
R23958-PWs-0002.07 mm (0.081 in)
23959-PW5-0002.10 mm (0.083 in)
T23960-PW5-0002.13 mm (0.084 in)
U23961 - PW5 - 0002.16 mm (0.085 in)
23962-PW5-0002.19 mm (0.086n)
23963-PWs-0002.22 mm (0.087n)
X23964-PWs-0002.25 mm (0.089n)
23965,PWs-0002.28 mm 10.090n)
23966-PW5-0002.31 mm {0.091 in)
23967-PWs-0002.34 mm (0.092 in)
AB23968-PWs-0002.37 mm (0.093 in)
AC23969-PWs-0002.40 mm {0.094 in}
AD23970-PW5-0002.43 mm (0.096 in)
M23941 - PW8 - 0002.46 mm {0.097 'n}
BZ23942-PW8-0002.49 mm (0.098 in)
cz23943-PW8-0002.52 mm {0.099 ini
DZ23944-PW8-0002.55 mm (0.100 in)
EZ23945-PW8-0002.58 mm (0.102 ini
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38. Install the 68 mm thrust shim using the special
tools.
DRIVER077€ - 001(xno
THRUST S1{IM,68 mmSelective part
BEARING OUTER BACE
ATTACHMENT.62x68mm077a6 - (x)10500
39.After replacing the 68 mm thrust shim, recheck and
make sure the total starting torque is within the
soecification.
40. Coat the new O-rings with MTF, install them on
transfer covers A and B, then install the covers on
the transfer housing.
6x1.0mm12 N.m 11.2 kgf.m,8.7 tbt.ft)TRANSFER COVER B
TRANSFER
O.RINGReplace.
O.BINGReplace.
TRANSFERCOVER A
8 r 1.25 mm2,r N.m (2.4 kgl.m. 17 lbtft)
13-61
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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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