1999 HONDA CR-V 001

10.
11.
Put a 14 mm Allen wrench in the gear side of the
transfer shaft, then secure the Allen wrench in a
bench vise.
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 112.0 kgf.m, 87 lbf.ftl
Temporarily install the transfer cover A without
O-ring.
TRANSFER HOUSING
TRANSFER COVER A
the12.
g/FrE24 N.m 12.4 kgt.m, 17 lbf.ftl
TOROUE WRENCH
tt el
g 9-r'r.ru--g 24 N.m 12.4 |
14-243
13.
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 - 0.16 mm {0.02 - 0.06 inl
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 two 25 mm thrust shims to adiust
the transfer gear backlash.
THRUST SHIM, 25 mm
(cont'd)
15.
DIAL INOICATOR
Shim No.Part NumborThickness
I29411-P1C-0001.70 mm (0.067 in)
229412-P1C-0001.73 mm (0.068 in)
29413-P1C-0001.76 mm (0.069 in)
429414-P1C-0001.79 mm (0.070 in)
29415-PlC-0001.82 mm (0.072 in)
629416-P1C-0001.85 mm (0.073 ini
729417-PlC-0001.88 mm (0.074 in)
d29418-P1C-0001.91 mm {0.075 in)
29419-P1C-0001.94 mm (0.076 in)
1029420-PtC-0001.97 mm (0.078 in)
1129421 - P1C - 0002.00 mm (0.079 in)
29422-P1C-0002.03 mm 10.080 in)
29423-P'1C-0002.06 mm (0.081 in)
1429424-P1C-0002.09 mm 10.082 in)
29425-P1C-0002.12 mm (0.083 in)
1629426-P1C-0002.'15 mm (0.085 in)
1729427 - P1C -O002.18 mm (0.086 in)
1829428-PlC-0002.21 mm (0.087 in)
1929429-P1C-0002.24 mm {0.088 in)
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Transfer Assembly
Reassembly (cont'd)
Secure the transfer housing in a bench vise with
soft jaws. To prevent damage, always use soft jaws
or equivalent materials between the transfer hous-
ing and the vise.
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.s8 - 1.39 N.m
{10.0 - 14.2 kgf.cm,8.68 - 12.3 lbf.in)
TIGHTENING TOROUE:
132 - 216 N.m
{13.5 - 22.0 kgf.m, 98 - 159 lbf.ft)
NOTE;
. Rotate the companion flange several times to
seat the tapered roller bearing, then measure the
starting torque,
. lf the starting torque exceeds 1.39 N.m (14,2
kgf.cm, 12.3 lbf.in), replace 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
rorque.
COi'PANIOI{ FLANGE HOLDER07MB - TBi(tloA otO'RAB - TB,.|}IOB
TOFOUEWRENCH
HOLDER HANDLE07JAB - 001020A
27.
14-246
28. Stake the locknut into the transfer driven gear shaft
using a 3,5 mm punch as shown.
0.7 - 1.2 mm{0.03 - 0.05 inl
PUNCH3.0 - 3.5 mm10.12 - 0.1{ inl
Point to bestaked.
29. Install the transfer shaft in the transfer housing,
then install the tapered roller bearing, transfer shaft
collar,25 mm thrust shim, transter drive gear, coni-
cal spring washer, and transfer shaft locknut on the
transfer shaft,
NOTE:
. Coat the threads of the locknut and transler shaft
with ATF before installing the locknut.. Install the conical spring washer in the direction
snown.
TRANSFER SHAFT
TRANSFER HOUSII{G
THRUST SHIM. 25 mrt|Selective part
CONICAL SPRINGWASHERReplace.
\t)t--/./
.,.-,.,\
Replace.
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Transfer Assembly
35.
Reassembly (cont'dl
36.
Remove taansfer 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 212"F(100'C). Let the cover cool to room temperature
before adjusting the starting torque,
lf the measurement is within the specification, go to
step 40.
HEAT GUN
14-248
37. Select the 68 mm thrust shim.
THRUST SHIM, 58 mm
Shim No.Part NumberThickness
zv23974-P1C-O201.41 mm (0.056 in)
zw23975-P1C-O201.44 mm (0.057 in)
zx23976-P1C-020'1.47 mm (0.058 in)
ZY23977 - P1C - O201.50 mm (0.059 in)
zz23978-P1C-0201.53 mm 10.060 in)
23941 PW5 - 000'1.56 mm {0.061 in)
B23942-PWs-0001.59 mm 10.063 in)
c23943 - PWs 0001.62 mm (0.064 in)
D23944-PW5-0001.65 mm {0.065 in}
E23945 PWs - 0001.68 mm (0.066 in)
F23946 PWs - 0001.71 mm (0.067 in)
G23947 PWs - 0001.74 mm (0.069 ini
23948-PW5-0001.77 mm (0.070 ini
23949 PW5 0001.80 mm (0.071 in,
J23950-PWs-0001.83 mm {0.072 ini
K23951 - PWs - 0001.86 mm (0.073 in
L23952 PW5 - 0001.89 mm (0.074 in
23953 PWs - 0001.92 mm (0.076 in
N23954 PW5 - 0001.95 mm (0.077 in
o23955 PW5 0001.98 mm (0.078 in
P23956 - PWs 0002.01 mm (0.079 in
o23957-PW5-0002.04 mm (0.080 in
R23958, PWs 0002.07 mm (0.081 in
s23959-PW5-0002.10 mm (0.083 in
T23960 PW5 - 0002.13 mm (0.084 in
U2396'1 PW5 - 0002.16 mm (0.085 in
23962 PWs 0002.19 mm (0.086 in
23963 - PW5 0002.22 mm (0.087 in
X23964 - PW5 0002.25 mm (0.089 in
23965 PW5 - 0002.28 mm (0.090 in
z23966 PWs 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 in)
BZ23942-PW8-0002.49 mm (0.098 in)
cz23943 - PW8 0002.52 mm (0.099 in)
DZ23944 PW8 - 0002.55 mm (0.100 in)
EZ23945-PW8-0002.58 mm (0.102 in)
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38. Install the 68 mm thrust shim using the special
tools.
PRESSDRIVER07743 - 001 0000
ATTACHMENT,62x68mrr|077a6 - (x)10500
39.After replacing the 68 mm thrust shim. recheck and
make sure the total starting torque is within the
specification.
AEARING OUTER RACE
40. Install the new O-rings on transfer covers A and B,
then installthe covers on the transfer housing
6x1.0mm12 N.m 11.2 kgt.D,8.7 rbf.ftlTRANSFEN COVER B
O.RINGReplace.
8 r 1.25 rnm24 N.m 12.4 kgl.m, 17 lbf'ftl
Replace.
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Special Tools
Ret. No.Tool NumberOescriptionotvPage Reler€nce
o
@aa
@/il
tol
J - 38592
07GAD - PH7020'1
07JAB - 0010204
OTRAB _TB40lOB
07749 - 0010000
07965 - 6920101
Transfer Case Oil Seal lnstaller
Seal Driver
Holder Handle
Flange Holder
Driver
Hub Dis/Assembly Tool
1
1
1
1
1
1
15-20
15-19
tc-zt, z9
15-21,25
15-19
15-19
6\
@
15-2
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Rear Differential Assembly
Reassembly (cont'dl
7. Install the clutch hub/plates/discs, then align the pro-
jection of the plates with the discs.
M, 30 mm
CLUTCH GUIDE
sHl
,/
.A-\,/r\-7
8.
9.
CLUTCH HUA/PLATES/Dtscs
Installthe clutch guide and the 30 mm shim.
Apply liquid gasket to the sealing surface of the
torque control differential case, and note these
rlems:
. Use liquid gasket (P/N 08718 - 0001).
. Remove any dirt or fluid from the sealing sur-
face.
. lf 20 minutes have passed after applying liquid
gasket, reapply it before you assemble the hous-
ings. Allow it to cure at least 30 minutes after
assembly before filling differential with fluid.
TOBOUE CONTROLDIFFERENNAL
--- Apply liquid gaskot
15-24
6x1.0mm12 N.m 11.2 tgf m,8.7lbt.ftl
10. lnstall the dowel pins and toroue control differential
case.
TOROUE CONTNOL
11. Install the companion flange, O-ring, back-up ring,
disc spring washer, and the locknut.
NOTE: Apply CW fluid to the O-ring.
,24mm
DISC SPRING WASHER,2a mm
lnstall in this direction.
@+-_alcr-upnwc
COMPANION FLAI{GE
/r-
K@#/
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T
R€f. No. Tool NumberD€scriptionOtv Page Rolsrenca
o
@
\D'
o
@
@
07JAF - SH20400
07LAD - PW50601
07MAC - S100200
07746 - 0010300
07746 - 0010400
07746 - 0030400
07749 - 0010000
07965 - SD90100
07xAc - 0010200
Attach ment
Attachment,40 x 50 mm LD.
Ball Joint Remover,28 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Attachment, 35 mm l.D.
Driver
Suppon Base
Threaded Adapter,24 x 1.5 mm
1'l
1
1
1
1,l
'I
1
16-16
16-18
16-4
16-16
16-17,
16-17
16-16
16-7
18
17,18
oarl
!.,
o)
16-2
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Outboard Joint Side:
1. Lift up the three tabs with a screwdriver, then
remove the boot bands, Take care not to damage
the boot.
NOTE:
. lf the boot band is a double loop type, lift up the
band bend.
. lf the boot band is a welded type, cut the boot
band.
. lf the bootband isa lockingtabstype. pry upthe
tabs with a screwdriver, and lift up the end of the
oano.
Ear Clamp
EAR CLAMP BANDReplace.
2. Slide the outboard boot to the inboard ioint side.
Wipe off the grease to expose the driveshaft andthe outboard joint inner race.
Mark the driveshaft at the same position of the out-
board joint end with paint.
TAB
DRIVESHAFT
PAINT MARK
5, Carefullv clamD the driveshaft in a vise.
THREADED AOAPTER,2iI x 1.5 mm07xAc - 0010200
Remove the outboard joint using a special tool asshown.
Remove the driveshatt trom the vise
Remove the stop ring from the driveshaft.
o.
7.
8.
STOP RINGReplace.
Slide hammc..5/8'x lS Throad(Commerically, available)
DRIVESHAFT
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