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

Transmission
Reassembly
NOTE:
. The illustration shows the 4WD automatic transmission; the 2WD is similar.. Clean all parts with ATF.. Replace the following parts:- O-rings- Lock washers- Gaskets- Sealing washers- Locknuts and conical spring washers of each shaft
ATF FEED PIPE
/
ATF FEED PIPES145 mm
SERVO DETENTBASE(37 -98 modeb onlylATF LUBRICATIONPLATE6x1.0mm
2 Bolts'99 - 00 models: 1 Bolts
LOCK.UP VALVEBODY
LOCK.UP SEPARATORPLATE
REGULATOR VALVEBODY
DOWEL PIN
DOWEL PIN
VALVE SPRING
STATOR SHAFT
'-
'112mmll,
rlT
ATFSTRAINER
40 mm
j coNrRoLI SHAFT
COOLER BELIEF VALVE
TOROUE CONVERTERCHECK VALVE
6x1.0mm18olts
DETENTARMSHAFT
6x1,0mm'97 - 98 models:7 Bolts'99 - 00 models:8 Bolts
SERVO BODY('97 - 98 models)
SERVOSEPARATOR PLATE
6x1.0mm3 Bolts
STOP SHAFTBRACKET
SECONDARYVALVE BODY
OOWEL PIN8x40mm
O.RING
STOP SHAFTCHECK BALLS 18'
ATF FEED PIPE112 mm
6x1.0mm5 Eolts
ATF PUMP DRIVENGEAR SHAFT
ATF PUMP DRIVEN
MAIN SEPARATORPLATE
MAIN VALVE EOOY
SECONDARYSEPARATOR
d---.- PLATE--.- CONTROL I.EVER MOUNTING BOLT6x1.0ftm14 N.m (1.4 kgt.m, 10 tbf.ft)(4WD)SERVO BODY('99 - 00 models)
ATF PUMP
6x1.0mm
ATF FEEO PIPE
) / 105.8
/,,!.,::(./ afF FEEO,/ ptpEs
EP,---!ir{+*a r
fpffi4 i
x*hi
_ \zl
14-250
DRIVE GEAR
DOWEL PINTOBOUEHOUSING
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1.Install the suction pipe collar and the ATF magnet
{2WD) in the torque converter housing, if necessary.
lnstall the main seDarator Dlate and the two dowel
pins on the torque converter housing,
Install the ATF pump drive gear. ATF pump driven
gear, and ATF pump driven gear shaft on the torque
converter housing. Installthe ATF pump driven gear
with its grooved and chamfered side facing down.
ATF PUMPGEAR
ATF PUMP D{IVEf{GEAR SHAFT
ATF PUi'PORIVEN GEAR
Grooved and chamteredside faces separatorplate.
MAIN S€PAR/ATORPLATE
5.
o.
Loosely install the main valve body with five bolts.
Make sure the ATF pump drive gear rotates smoothly
in the normal operating direction, and the ATF pump
driven gear shaft moves smoothly in the axial and
normal operating directions.
Install the secondary valve body, separator plate,
and two dowel pins on the main valve body. Do not
installthe bolts.
Install the control shaft in the housing along with
the manual valve.
lnstall the detent arm and arm shaft in the main
valve body, then hook the detent arm spring to the
detent arm.
SEBVO SEPARATOR PLATE
7.
DETENT ARMSHAFT
OETENT ARM
CONTROLSHAFT
MANUAL VAIVE
OETENT ARM SPRING
onlv on the '98 - 00 models,
14-251
1l.
9.
8.
10.
Install the servo body and separator plate on the
secondary valve body ('97 - 98 models: seven bolts,'99 - 00 models: eight bolts).
lnstall the servo detent base ('97 - 98 models only)
and the ATF strainer ('97 - 98 models: two bolts,'99 -
00 models: one boltl.
Tighten the five bolts on the main valve body to 12
N'm (1.2 kgf.m, 8.7 lbf.ft).
Make sure the ATF pump drive gear and ATF pump
driven gear shaft move smoothly. lf they don't,
loosen the bolts on the main valve body, and disas-
semble the valve bodies. Realign the ATF pump driv-
en gear shaft and reassemble the valve bodies, then
retighten the bolts to 12 N.m (1.2 kgim, 8.7 lbf.ft).
CAUTION: Failure to align the ATF pump driven
gear shaft corroctly will rosult in a seizsd ATF pump
drive gear or ATF pump drivon gear shaft.
ATF PUMP ATFGEARDRIVE GEAR DBIVEN GEARSHAFT
Install the stator shaft and stop shaft
Install the bolts and the stop shaft bracket on the
secondary valve body, then tighten the bolts (three
bolts).
Install the torque converter check valve, cooler relief
valve, and valve springs in the regulator valve body,
then install the regulator valve body on the main
valve body {one boltl.
Install the lock-up valve body, separator plate, two
dowel pins and lubrication plate (eight bolts).
Installthe one ATF feed pipe in the main valve body,
the three ATF feed pipes in the secondary valve, the
three ATF feed pipes in the servo body and the one
ATF feed pipe in the lock-up valve body.
NOTE: lnstall the 105.8 mm ATF feed pipe with its
filter side away from the secondary valve body; the
filter is on the 105.8 mm ATF feed pipe, which is(cont'd)
13.
14.
15.
16.
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Description
Rear Differential
Outline
The Real-time 4WD-Dual Pump System model has a hydraulic clutch and a differential mechanism in the rear differential
assembly. Under normal conditions, the vehicle is driven by the front wheels. However, depending on to the driving force
of the front wheels and the road conditions. the system instantly transmits appropriate driving force to the rear wheels
without requiring the driver to switch between 2WD (tront wheel drive) and 4WD (four wheel drive). The switching mecha-
nism between 2WD and 4WD is integrated into the rear differential assembly to make the system light and compact.
ln addition, the dual-pump system switches off the rear-wheel-drive force when braking in a forward gear. This allows the
braking system to work properly on models equipped with an Anti-lock Braking System (ABS).
Construction
The rear differential assembly consists of the torque control differential case assembly and the rear differential carrier
assembly. The torque control differential case assembly consists of the differential clutch assembly, the companion
flange, and the oil pump body assembly. The rear differential carrier assembly consists of the differential mechanism. The
differential drive and driven gears are hypoid gears.
The oil pump body assembly consists of the front oil pump, the rear oil pump, the hydraulic control mechanism, and the
clutch piston. The clutch piston has a disc spring that constantly provides the differential clutch assembly with a preset
torque to Drevent abnormal sound.
The clutch guide in the differential clutch assembly is connected to the propeller shaft via the companion flange, and it
receives the driving force lrom the transfer assembly. The clutch guide rotates the clutch plate and the front oil pump in
the oil pump body.
The clutch hub in the differential clutch assembly has a clutch disc that is splined with the hypoid drive pinion gear. The
hypoid drive gear drives the rear oil pump.
The front and rear oil pumps are trochoidal pumps. The rear oil pump capacity is 2.5 percent larger that the front oil pump
to handle the rotation difference between the front and rear wheels caused by worn front tires and tight corner braking.
The oil pumps are designed so the fluid intake works as a fluid discharge when the oil pumps rotate in reverse. Genuine
Honda CVT fluid is used instead of differential fluid.
Operation
When there is a difference in rotation speed between the front wheels (clutch guide) and rear wheels (hypoid driven gear),
hydraulic pressure from the front and rear oil pumps engages the differential clutch, and drive force from the transler
assembly is applied to the rear wheels.
The hydraulic pressure control mechanism in the oil pump body selects 4WD mode when the vehicle is started abruptly,
or when accelerating in a forward or reverse gear (causing rotation difference between the front and rear wheels). or
when braking in reverse gear {when decelerating). lt switches to 2WD mode when the vehicle is driven at a constant speed
in forwar! or reverse gear (when there is no rotation difference between the front and rear wheels), or when braking in a
fo rwa rd gear (when decelerating).
To protect the system, the differential clutch assembly is lubricated by hydraulic pressure generated by the oil pumps in
both 4WD and 2WD modes. Also, the thermal switch relieves the hydraulic pressure on the clutch piston and cancels 4WD
mode if the temDerature of the differential fluid rises above normal.
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TOROUE CONTROL OIFFERENTIAL
REAR DIFFERENTIAL ASSEMBLY
OIL PUMP BODY
OIFFERENTIAL CLUTCHHYPOID DRIVEPINION GEAR
OIFFERENTIAL CARRIER
DIFFERENTIAL
HYPOID RING GEAR
DIFFERENTIAI- HOUSING
REAR OII- PUMP
ASSEMBLY
CLUTCH GUIDE
COMPANION FLANG€
CLUTCH HUB
CLUTCH PLATE
HYDRAULIC CONTROL SYSTEM
CLUTCH PISTON
CLUTCH DISC
REAR OIL PUMP
FRONT OIL PUMP
DISC SPRINGFRONT OIL PUMP
DIFFEREMT|AL CLUTCHASSEMBI-Y
THERMAL SWITCHRELIEF VALVEOIL STRAINER
15-5
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Rear Differential Assembly
Disassembly (cont'dl
9. Remove the shim and the clutch quide.
d"HIM'30mm
CLUTCH GUIDE
Remove the clutch hub/plates/discs and the pressure
prare.
10.
CLUTCH HUB/PLATES/OISCS
k
ffi-:*
_zz PRESSURE PLArE
@-
15-22
11. Remove the thrust needle bearing and the oil pump
driveshaft.
Remove the oil pump body assembly, the oil pump
pin, the magnet, and the oil strainer.
OIL PUMP BODY ASSEMBLY
MAGNET
OIL PUMP PIN
12.
OIL STRAINERInspect for damageor clogging.
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Reassembly
1. Apply CVT fluid to the rubber of the oil strainer, then
install the oil strainer, the magnet, and the oil pump
pin to the differential carrier.
OIL PUMP PIN
DIFFERE]TTIAL CARRIERASSEMBLY
Align the oil pump pin with the groove of the rear oil
pump in the pump body assembly, then install the oil
pump body assembly to the differential carrier assem-
oty.
-n
CWfluid
2.
MAGNET
OIL PUMP BODY ASSEMBLY
3. Tighten the oil pump body assembly mounting
bolts.
4. Install the oil pump driveshaft by aligning the pro-
jection of the oil pump driveshaft with the groove of
the front oil pump in the oil pump body assembly.
lnstall in this direction.
Projection
6x1.0mm12 N.m 11.2 kg{.m,8.7 lbl.ft}
Install the thrust needle bearing.
Install the pressure plate assembly by aligning the
projection of the pressure plate with the groove of
the oil pump driveshaft.
5.
OIL PUMPDRIVESHAFT
(cont'd )
15-23
THRUST NEEDLE BEABING
PRESSURE PLATE
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Component Locations
lndex
Note these items during disassembly:' lf an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged dur-ing transit, storage or service. it should be deployed (see section 24),a Before removing the gearbox, remove the driver.s airbag assembly and steering wheel.. After installing the gearbox, check the wheel alignment and adjust if necessary.
SRS components are located in this area. Review the SRS component locations, precautions, and procedures an the SRssection (24) before performing repairs or servrce.
STEERING WHEELRemoval, page 17,18Disassembly/Reassembly, page 1?,18Installation, page 17-19DRIVER'S AIRBAG ASSEMBLYRemoval/lnstallation, see section 24
STEERING GEARBOXRack Guide Adjustment, page 17-15Removal, page 17-31Disassembly, page 17-34Reassembly, page 17,40Installation, page 17,51VALVE BODY UNITOverhaul, page 17-38
STEERING COLUMNRemoval/lnstallation. page 17-20Inspection, page l7 21Steering Lock Replacement, page 17 22CABLE REELRemoval/lnstallation, see section 24tcNrnoN swtTcHSee s€ction 23
STEERING HOSES, LINESReplacement. page l7-23
Pump Belt Inspection andAdjustment, pag€ t7-14Pump Pressure Check, page 17-16 ot 17-1jReplacemont, page 17-24Disassembly, pa96 17,25Inspection, page 17-26Reassembly. page17-28
RESERVOIRFluid R6placement. page 17 15Fluid Leakage lnspection, page 17-23
END BALL JOINTBallJoint Boot Replacement, page 17-50
17-3
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Troubleshooting
General Troubleshootin g
Check the following before you begin:
. Has the suspension been modified in a way that would affect steering?
. Are tire sizes, tire variety and air pressure correct?
. ls the steering wheel original equipment or equivalent?
. ls the power steering pump belt properly adjusted?
. ls steering fluid reservoir filled to proper level?
. ls the engine idle speed correct and steady?
Hard Steering (Check the power assist, see page 17-12. lf the force is over 29 N (3.0 kgl 6.6 lbfl, proceed with this troubleshooting.i
Abnormalthiidpressure (Iluidpressure is toohigh)
Relief pressuretoo low
Faulty valve body unit
Abnormal
Check the teed and return circuit lines and hosebetween the gearbox and pump for clogging anddeformation.
Normal line and hose
Check the pump fluid pressure(see page 17-16 or 17-17).Measure steady state lluid pres-
sure at idle with the pressure con-trol valve and the shut-off valve (it
so equipped) fully open.The fluid pressure should be 1,500kPa (15 kgf/cm,,213 psi)or less.
Normal
Check the flow control valve (see page 17 26).. Check the valv€ lor smooth movement in the hous-ing.. Check the relief valve for leaks.
Check the pump fluid pressure(see page 17-16 or l7-17).Measure pump relief pressure atidle with the pressure controlvalve and the shut'off valve lil soequipped) fully closed.The fluid pressure should be 6,9007,800 kPa (70 - 80 kgflcm,, 1,000- 1,140 psi).
Normal relief pressure
17-4
Go to page 17 5Faulty pump assemblyFaulty flow control valve
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Troubleshooting
Noise and Vibration
NOTE: Pump noise in first 2 - 3 minutes after starting in cold weather is normal.
Humming
Rattle or chattering
Humming due to pulsation of fluid is normal, particularly when the wheel isturned with the vehicle stooDed.
lf equipped with automatic trans-mission, the hum could be thetorque converter or pump noase.
Confirm by temporarily removingthe pump belt.
Feed hose (high-pressure) touch-ing the frame.Beposition the feed hose.
Loose steering shaft connector,tie-rod, or balljoint.Check and tighten, or replaceparts as necessary,
Column shaft wobbling.Roplace the column assembly.
Check the rack guide for properadjustment (see page 17-15).Adjust, if necessary.
Rattling sound and feeling when turning the steering wheel right and left with th€engine OFF is normal.
Pump noise, though not loud, from the valve body unit can be heard when turn-ing the steering wheel to full lock in either direction. This is normal. Do not holdthe steering wheel at full lock lor more than five seconds when inspecting.
17-8
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Troubleshooting
Fluid Leaks
Check the gearbox assembly for oil leaks carefully. Oil can leak out ot various points, depending on location of the faulty
oil seals/seal rings. Check the following before removing the gearbox from the frame.
Steering GearboxLeaking from the oil seal on thetop of the valve housing.Replace the valve oil seal fromthe valve housing.
Leaking from cylinder end intoleft tie rod boot.Replace the valve oil seal fromthe pinion shaft.
Replace the cylinder end seal onthe valve body unit side.
Leaking from cylinder end intoright tie-rod boot.Replace the cylinder end seal onthe cylinder end side.
Leaking lrom the shaft upper endsection or pin engagement sec-tion of the pinion shaft.Replace the valve body unit.
Tighten the connector. It it's stillleaking, replace the line, cylinderor valve housing.
Leaking from cylinder line A or Bconnections (at tlare nut).
Leaking caused by a damagedcylinder line A or B.Replace cylinder line A or B.
Leaking from pump outlet hoseand return line joint fitting on thevalve body unit {at tlare nut}.
Tighten the connector. ll it's stillleaking, replace the line, joint fit-ting or valve housing,
17-10
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