1998 HONDA CR-V main

20.
2't.
19. Remove the reverse lock cam.
lf necessary, check the clearance of the reverse shift
holder (see page 13-20).
Remove the reverse shift holder.
HOLOER
22. '97 - 99 models: Remove the reverse gear shaft and
the reverse idler gear.'00 model: Remove the reverse gear shaft, reverse
idler gear, thrust washer and the coller.
13-17
23. Remove the mainshaft and countershaft assemblies
with the shift forks from the clutch housing.
NOTE; Before removing the mainshaft and counter-
shaft assemblies, tape the mainshaft spline to pro-
tect it.
ASSEMBLY
Tape the main'
shaft splines.
WASHER
SPRING WASHER
24. Remove the differential asssmbly.
COUNTEBSHAFT
HOUSING
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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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Tapered Roller Bearing Preload Adiustment
lf any oJ the items listed below were replaced, the tapered
roller bearing preload must be adjusted.
. Transmission housing
. Clutch housing
. Differential carrier
o Tapered roller bearing and bearing outer race
. Thrust shim
. 75 mm sham
1. Remove the bearing outer race and thrust shim
from the transmission housing (see page 13-40)'
NOTE:
. Do not reuse the thrust shim if the bearing outer
race was driven out.
. Let the transmission cool to room temperature il
the bearing outer race was removed by heating
the clutch housing.
2. Do not use more than one thrust shim to adjust the
tapered bearing preload. First try the same size
thrust shim that was removed. There are no shims
used on the clutch housing side
SHIMTHRUST
/A
After installing the thrust shim, install the bearing
outer race in the transmission housing (see page
13-40).
With the mainshaft and countershaft removed,
install the differential assembly, and torque the
clutch housing and transmission housing.
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
TOBOUE; 8 x 1.25 mm: 27 N'm(2.8 kgf'm, 20 lbt'ftl
Rotate the differential assembly in both directions
to seat the tapered roller bearings.
Measure the tapered roller bearing preload at nor-
mal room temperature. Measure the starting torque
of the differential assembly in both directions with
the special tool and a torque wrench.
STANDAFD: 1.4 - 2.5 N'm
{1/r - 26 kgf'cm, 12 - 23 lbf in)
(cont'd)
4.
5.
07HAJ - PK4020'1
13-41
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Mainshaft Bearing/Oil Seal
Replacement
1. Remove the ball bearing using the specialtool.
3/8" -16 SLIDE HAMMER(Commercially available)
PULLER.25 - ,10 mm07736 - A01000A
2. Remove the oil seal from the clutch housing.
13-62
BALL BEARING
3. Drive the new oil seal in from the transmission side
using the special tools.
ATTACHMENT,12x 17 .nfi07746 - 0010300
Drive the new bali bearing in from the transmission
side using the special tools.
ATTACHMENT.62x68mm07746 - 0010500
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Mainshaft Thrust Clearance
Adjustment
l. Remove the 78 mm shim
the transmission housing.
4.
and oil guide plate from
Install the 3rd/4th synchro hub, spacer collar, sth
synchro hub, spacer, and ball bearing on the main-
shaft. then install the above assembly in the trans-
mission housing.
lnstallthe washer on the mainshaft.
Measure distance @ between the end of the trans-
mission housing and washer,
NOTE:
. Use a straight edge and vernier caliper.
. Measure at three locations and average the read-
Ing.
END otTRANSMISSION
MAINSHAFT
WASHER
3RD/4TH SYNCHRO HUB
SPACER COLLAR
sTH SYNCHRO HUB
SPACER
78 mm SHIM
13-64
BALL BEARING
5, Measure distance @ between the end of the clutch
housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and avorage the read-
Ings.
END ot CLUTCH HOUSING
BEARING
Select the proper 78 mm shim from the chan by
using the formula below.
Shim S€lection Formula:
From the measurements you made in steps 4 and 5:-1. Add distance @ (step 5) to distance @ (step 4).
-2. From this number. subtract 0.93 (which is the
midpoint of the flex range of the clutch housing
bearing spring washer).
-3. Take this number and compare it to the avail-
able shim sizes in the chart.
(For example)
A: 2.39 2.61
+ Bi O.22 - 0.93
= 2.61= 1.68
Try the 1.68 mm (0.0661 in) shim.
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