Transfer HONDA CR-V 2000 RD1-RD3 / 1.G Owner's Manual

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)
www.emanualpro.com

Transter Gear Backlash Inspection and Transfer Gear
Tooth Contaqt Inspection
2. lnstall the 35 mm thrust shim on the transfer driven
gear shaft, then install the tapered roller bearing
using the special tools and a press.
NOTE: Use old lransfer spacer for bearing installa-
tion, then discard it.
TRANSFER DRIVENG€AR SHAFT
Install the bearing outer race, then the tapered bear-
ing on the companion flange side ot the transfer
housing.
3.
OIL SEAL DRIVERATTACHMENT07JAD - PH80101DRIVER077/tg - 001qt00
Replace.TAPERED ROLLERBEARING
Install the new oil seal on the transfer housing
using the special tools.
5. Install the transfer driven gear shaft in the transfer
housing. Do not install the transfer spacer on the
transfer driven gear shaft in this step.
TRANSFERHOUSING
Installthe companion flange. conical spring washer,
and locknut on the transfer driven gear shaft. Do
not install the O-ring and the back-up ring on the
transfer gear shaft in this step.
6,
COMPANIONFLANGE
CONICAL SPRING
direction.
(cont'd)
13-53
TRANSFER HOUSING
WASHER
www.emanualpro.com

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.
www.emanualpro.com

TOROUE WRENCH
10. Hold the transfer shaft with a 14 mm Allen wrench
clamped in a bench vise.
lil mm ALLEN WRENCH
Tighten the transfer shaft locknut.
NOTE:
. The transfer shaft locknut has left-hand threads,
. Do not stake the locknut in this step.
TOROUE: 118 N.m (12.0 kgf.m,86.8 lbf.ft)
Temporarily install the transfer cover A without the
O-ring.
11.
rl0ustNG
TRANSFER COVER A
8xL25mm24 N.m (2.4 kgt.m. 17 lbnftl
'14.
Rotate the companion flange several times to seat
the tapered roller bearing.
Set a dial indicator on the companion flange, then
measure the transfer gear backlash.
STANDARD: 0.06 - 0.15 mm 10.002 - 0.006 in)
COMPANION FLANGE
lf the measurement is not within the standard,
remove the transfer shaft locknut and replace the 25
mm thrust shim. Select and install a new 25 mm
thrust shim. then recheck the measurement. Do not
use more than one 25 mm thrust shim to adjust the
transfer gear backlash,
THRUST SHlM,25 mm
DIAL INDICATOR
Shim No.Part NumbelThickness
I2941r - P1C - 0001.70 mm 10.067 in
229412-PlC-000'L73 mm (0.068 in
329413-P1C-0001.76 mm (0.069 in
29414-PlC-0001.79 mm (0.070 in
529415-P1C-0001.82 mm (0.072 in
629416-PlC-0001.85 mm (0.073 in
7294'17-PrC-0001.88 mm (0.074 in
8294'18-P1C-0001.91 mm (0.075 in)
29419-PlC-0001.94 mm (0.076 in)'1029420-P1C-0001.97 mm 10.078 in)
1129421 - P1C - 0002.00 mm (0.079 in)
1229422 -P1C - 0002.03 mm (0.080 in)
1329423-P1C-0002.06 mm (0.081 in)
l429424-P1C-0002.09 mm (0.082 in)
29425-P'tC-0002.12 mm (0.083 in)
1629426-P1C-0002.15 mm (0.085 in)
1729427 -P1C-0002.18 mm {0.086 in)'1829428-P1C-0002.21 mm {0.087 in)
1929429-P1C-0002.24 mm 10.088 in)
(cont'd)
13-55
www.emanualpro.com

Transfer Assembly
Reassembly (cont'dl
16. Apply Prussian Blue to both sides of the transfer
gear teeth lightly and evenly.
Rotate the companion flange in both directions until
the transfer gear rotates one full turn in both direc-
tions.
Check the transfer gear tooth contact pattern.
CORREST TOOTH CONTACT PATTERN
INCORRECT IOOTH CONTACT PATTERN
TOE CONTACT
HEEL CONTACT
FLANK CONTACT
17.
18.
TRANSFER DRIVE GEAR
13-56
FACE CONTACT
19. lf the transfer gear tooth contact is incorrect, adjust
the transfer gear tooth contact with a 35 mm or 25
mm thrust shim.
NOTE:
. To select a 35 mm thrust shim, refer to page '13-
. Do not use more than one 35 mm shim to adjust
the transfer gear tooth contact.
. To select the 25 mm thrust shim, refer to page
13-55.
a Do not use more than one 25 mm shim to adjust
the transfer gear tooth contact.
Toe Contact
Use a thicker 35 mm thrust shim to move the
transfer driven gear shaft toward the transfer drive
gear. Because this movement causes the transfer
gear backlash to change, move the transfer drive
gear away from the transfer driven gear shaft to
adjust the transfer gear backlash as iollows;
. Increase the thickness of the 25 mm thrust
shim.
. Reduce the thickness of the 68 mm thrust
shim bv the amount of increased thickness of
the 25 mm thrust shim.
Heol Contact
Use a thinner 35 mm thrust shim to move the
transfer driven gear shaft away from the transfer
drive gear. Because this movement causes the
transfer gear backlash to change, move the trans-
fer drive gear toward the transfer driven gear shaft
to adjust the transfer gear backlash as follows:
. Reduce the thickness of the 25 mm thrust
sh im.
a Increase the thickness of the 68 mm thrust
shim by the amount of reduced thickness of
the 25 mm thrust shim.
Flank Contact
Use a thinner thrust shim to move the transfer
drive gear toward the transfer driven gear shaft.
Flank contact must be adtusted within the limits
of the transfer gear backlash. lf the backlash
exceeds the limits, adjust as described under
Heel Contact.
Face Contsct
Use a thicker thrust shim to move the transfer
drive gear away from the transfer driven gear
shaft. Face contact must be adjusted within the
limits of the transjer gear backlash. lf the back-
lash exceeds the limits, adjust as described
under Toe Contact.
www.emanualpro.com

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
www.emanualpro.com

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.
www.emanualpro.com

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
www.emanualpro.com

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
www.emanualpro.com

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
www.emanualpro.com