shaft HONDA CR-V 2000 RD1-RD3 / 1.G Workshop Manual

Mainshaft Assembly
lndex
Note the Iollowing during reassembly:
. The 3rd/4th, and 5th synchro hubs, and the ball bearing are installed with a press.
. Installthe angular ball bearing with the thin-edged outer race facing the stop ring
prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The
3rd/4th and 5th svnchro hubs, however, should be installed with a press before lubricating them'
ANGULAR EALL BEARINGCheck for wear and operation.Note the directionof installation.SYNCHRO RINGInspection, page l3 37
SYNCHRO HUBlnspection, page 13-36
SYNCHRO SLEEVEInspection, page 13 36
SPRING
SYNCHRO
SYOP RING
TAPER RING
BEARINGCheck Ior wear and operataon.
COLLAR
RINGInspection, page 13-37
SYNCHRO SPRING
SYNCHRO HUBInspection, page 13_36
SYNCHRO SLEEVEInspection, page 13 36
SPFING
RINGInspection, page 13_37
GEARInspection, page 13_25, 37
COLLARInspection, page 13-24, 25
GEARInspection, page 13 24, 37
Inspection,page 13-37
3RD GEARInspeclton,page 13 24,37
BEARINGCheck for wearano operalton.
Inspection, page 13 26
NEEDLE BEARINGCheck for wear and operat,on.
13-23
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Mainshaft Assembly
Clearance Inspection
NOTE; lf replacement is required, always replace the
synchro sleeve and hub as a set.
L Support the bearing inner race with a socket. and
Dush down on the mainshaft.
2. Measure the clearance between 2nd and 3rd oears.
Siandard: 0.06 - 0.21 mm 10.002 - 0.008 in)
Servica Limit: 0.3 mm (0.01 in)
lf the clearance is more than the service limit, mea-
sure the thickness of 3rd gear.
Standard: 34.92 - 34.97 mm {1.375 - 1.377 in)
Service Limit 34.8 mm (1.37 in)
3RD GEAR
lf the thickness of 3rd gear is less than the ser-
vice limit, replace 3rd gear with a new one.
lf the thickness of 3rd gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one.
13-24
+
4. Measure the clearance between 4th gear and the
spacer coIar,
Standard: 0.06 - 0.21 mm {0.002 - 0.008 in)
Servic€ Limit: 0.3 mm {0.01 inl
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer collar,
Standard: 26.03 - 26.08 mm {1.025 - 1.027 inl
Service Limit: 26.01 mm {1.02,[ in]
o[-l:-g;;em
fp-rro.ERcoLLAR
6.tf distance @ is less than the service limit, replace
the sDacer collar with a new one.
lf distance @ is within the service limit. measure
the thickness of 4th gear.
Standard: 31.42 - 31.'17 mm 11.237 - L239 inl
Sarvicc Limit:31.3 mm {1.23 in)
lf the thickness of 4th gear is less than the ser-
vice limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one,
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7. Measure the clearance between the spacer collar
and 5th gear.
Standard: 0.06 - 0.21 mm {0.002 - 0.008 in)
Service Limit: 0.3 mm {0.01 in)
MAINSHAFT
SPACER COLLAR
8.
SOCKET5TH GEAR
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer collar
Standard: 26.03 - 26.08 mm 11.025 - 1.027 in)
S€rvico Limit: 26.01 mm (1.024 in)
9.
SPACERCOLLAR
5TH GEARSIDE
lf distance @ is less than the service limit, replace
the spacer collar with a new one.
lf distance @ is within the service limit, measure
the thickness of sth gear.
Standard: 30.92 - 30.97 mm (1.217 - 1.219 in)
Service Limit: 30.8 mm (1.21 in)
r-- ,,srH GEAR
gt Fq
I .J'-----!--\--J-l
lf the thickness of 5th gear is less than the ser-
vice limit, replace 5th gear with a new one.
li the thickness of sth gear is within the service
limit, replace the sth synchro hub with a new
one.
Disassembly
1. Support 5th gear on steel blocks, and press the
mainshaft out of the 5th synchro hub, as shown. Do
not use a jaw-type puller, because it can damage
the gear teeth.
PRESS
I
ACHMENT
In the same manner as above, support the 3rd gear
on steel blocks. and press the mainshaft out of the
3rd/4th svnchro hub, as shown.
PRESS
I
BLOCKS
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Mainshaft Assembly
Inspection
1.Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, and C.
Standard:
A (Ball bearing surface): 27.987 - 28.000 mm
11.1018 - 1.1024 inl
B (Needle bearing surfacel: 37.984 - 38.000 mm(1.4954 - 1.4961 inl
C {Bafl bearing surfacel: 27.977 -27.990 mm
(1.1015 - 1.1020 inl
Service Limit: A:27.94 mm (1.100 in)
B: 37.93 mm (1.'193 inl
C: 27.94 mm 11.100 inl
Inspect oil passages Ior clogging.
lf anv oart of the mainshaft is less than the service
limit. reolace it with a new one.
2. Inspect for runout.
Standard: 0.02 mm (0.0008 in) max.
Service Limit: 0.05 mm 10.002 inl
NOTE: Support the mainshaft at both ends
sh own.
lf the runout is more than the service limit, reDlace
the mainshaft with a new one.
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Countershaft Assembly
Index
NOTE:
3
The 3rd, 4th. and sth gear are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd,
4th, and sth gears, however. should be installed with a press before lubricating them.
LOCKNUT Replace.127-o-127N.m
113-0- 13kstmi
\94-0- 9.trbtft /
IST/2ND SYNCHRO HUBInspection, page 13 36
Check lor wear anddamage.
THRUST WASHERInspection, page 13-29
DAMPER
WASHER
AEARINGCheck for wear and ooeration.
BEARINGCheck for wear andoperation.
GEAR
4TH GEAR
3RD GEAR
GEAR
SPNING
DOUBI.f CONE
Inspection, page 13-37
1ST GEARInspection, page 13 29,37
BEARINGCheck tor wear and operation.
Inspection, page 13-30, 37
NEEDLE BEARINGCheck for wear and oPeration
SPACERSelection, page 13-30
DAMPERCheck for wear and damage.
DOUBLE CONE
Inspection, page 13-37
SPRING
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Countershaft Assembly
Clearance Inspection (cont'dl
4. Measure the clearance between the 2nd qear and
3rd gear.
Standard: 0.07 - 0.1,1 mm (0.003 - 0.006 inl
Service Limit:0.18 mm (0.007 inl
FEET.ERGAUGE
!t .-]
lf the clearance is more than the service limit. mea-
sure the thickness of the spacer.
Standard: 29.07 - 29.09 mm (l.14il - 1.145 inl
13-30
6. lf the thickness is less than the standard, reDlace the
spacer wrln a new one.
lf the thickness is within the standard, measure the
thickness of the 2nd gear.
Standald: 28.92 - 28.97 mm (1.139 - 1.141 in)
lf the thickness of 2nd gear is less than the stan-
dard, replace 2nd gear with a new one.
lf the thickness of lst gear is within the standard,
replace 1sv2nd synchro hub with a new one.
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Disassembly
1.
2.
Securely clamp the countershaft assembly in a
bench vise with wood blocks.
SPRIiIG WASHEF
BETICHvtsE
W(X)D BLOCKS
Raise the locknut tab from the groove in the coun-
tershaft, then remove the locknut and the spring
washer.
Remove the ball bearing using a press as shown.
CHISEL
4. Remove the Jriction damper from the spacer using a
press and a socket.
Support lst gear on steel blocks, and press the
countershaft out of 3rd gear.
PRESS
t
5.
PRESS
I
3RD GEAR
1ST GEAR
FRICTION DAMPERInspect lor wear and damage.
13-31
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Countershaft Assembly
Inspection
1. Inspect the gear surface and bearing surface Ior
wear and damage, then measure the countershaft
at points A, B, and C.
Standa.d:A: 36.000 - 36.015 mm
11.,1173 - f.ill79 inl
B: 36.98/t - 37.000 mm
{r.4561 - 1.4567 inl
C: 24.987 - 25.000 mm
{0.98:17 - 0.9843 inl
Servics Limit: A:35,95 mm (1.'115 in)
B: 36.93 mm (1.454 in)
C: 24.94 mm (0.982 in)
lf anv part of the countershaft is less than the ser-
vice limit. reolace it with a new one.
lnspect for wear and damage.
13-32
2. Inspect for runout.
Standard: 0.02 mm 10.0008 inl max.
Service Limit: 0.05 mm {0.002 inl
NOTE: Support the countershaft at both ends as
shown.
Rotate two complete revolutions.
lf the runout exceeds the service limit, reDlace the
countershaft with a new one.
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Reassembly
Note these items during reassembly:
. Press the 3rd, 4th, and sth gear on the countershaft
without lubrication.
. When installing the 3rd, 4th. and sth gears, suppon
the shaft on steel blocks and install the gears using a
press.
. Refer to page 13-28 for reassembly sequence.
1. Install the thrust shim, needle bearing, 1st gear, and
friction damper.
NOTE: Reassembly the friction damper on the lst
gear before installation.
rnrcrroru orn,leen ----.-4O)
lST GEAR
NEEDLE BEARING
THRUST SHIM
2. Install the double cone synchro.
3. Install the 1sv2nd synchro hub by align the friction
damper fingers with 1svznd synchro hub grooves.
(cont'd)
OUTER
lST/2ND
13-33
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Countershaft Assembly
Reassembly (cont'dl
4. Reassembly the friction damper on the spacer using
the sDecialtools and a Dress.
PRESS
t
ATTACHMENT,U2t 47 mfi07716 - 0010300
FRICTION DAMPERInspect for wear anddamage.
Install the 2nd gear by align the
fingers with 2nd gear grooves.
synchro cone the
GROOVE
13-34
6. Support the countershaft on a steel block as shown
and install 3rd gear using the special tools and a
press.
3RO GEAR
7. lnstall 4th gear using the special tools and a press.
PRESS
I
PRESS
t
ATTACHMENT,35 mm LD.07746 - 0030,100
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