1999 HONDA CR-V Adjust Ac

Symptom-to-Com ponent Chart
Hydraulic System (cont'd)
NOTES
See flushing procedure, page l4-264 and 265,
BSet idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
clf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
Dlf the clutch pack is seized or is excessively worn. inspect the other clutches fot wear, and check the orificecontrol valves, CPC valve, and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed. the transmission will not upshift. lf stuck open, the transmission hasno lst gear.
Hlf the 2nd orifice control valve is stuck, inspect the 2nd and 3rd clutch Dacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
Jlf the clutch pressure control valve is stuck closed. the transmission will not shift out of lst gear.
Klmproper alignment of main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
Llf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Mlf the lst clutch feed pipe guide in the end cover is scored by the mainshaft. inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
N' Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged, lf the 4th feed pipe is darrFaged or out of round. replace the end cover.' Replace the mainshaft if the bushing for the l st feed pipe is loose or damaged. lf the 1st feed pipe is dam-aged or out of round, replace it.
oA worn or damaged sprag clutch is mostly a result of shifting the transmission in E!. E, or E positionwhile the wheels rotate in reverse. such as rocking the vehicle in snow.
PInspect the frame for collision damage.
lnspect for damage and wear:
l. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1, 2, 3. and 4 if worn or damaged. lf transmission makes a clicking, grinding, or whirring noise,also replace mainshaft 4th gear, reverse idler gear, and countershaft 4th gear in addition to 1,2, 3, or 4.lf differential pinion shaft is worn, overhaul differential assembly, replace ATF strainer, and thoroughly cjeantransmission, flush torque converter. cooler, and lines,lf bottom of 3rd clutch is swirled and transmission makes gear noise. replace the countershaft and final drivenoear,
Be very careful not to damage the torque converter housing when replacing the main ball bearing. you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the Drooer tools.
SInstall the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
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Transfer
4.
Inspection
@E Mako suro lifts, jacks, and safety standsare placod properly lsoe section t).
1. Raise the front of the vehicle, and make sure it issupported securely.
2. Set the parking brake, and block both rear wheelssecurely.
Shift to E position.
Make a reference mark across the propeller shaftand the transfer assembly flanges.
Separate the propeller shaft from the transferassembly.
8 x 1.25 mm32 N.m 13.3 kgl,m,24 lbf.ftlReplace.
14-164
\
6. Set a dial indicator on the transfer assembly flange.then measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.002 - 0.006 inl
7. lf the measurement is out of standard, remove thetransfer assembly and adjust transfer gear backlash{see page '14-232 thru 14-2491.
8. Check for fluid leaks between the mating faces oftransfer cover A and cover B.
9. lf there is a fluid leak, remove the cover, and reDlacethe O-ring.
'10. Check for fluid leaks between the mating face of thetransfer assembly and transmission.
11. lf there is a fluid l€ak, remove the transf€r assem-bly, and replace the O-ring,
12. Check the transfer oil seal for damage and fluidle8ks.
13, lf oil seal replacement is required. remove the trans-fer assembly, replace the oil seal, and adjust thetotal starting torque (see page 1+232 thtu ]'4-249||.
NOTE: Do not replace the oil seal with the transferassembly on the transmission.
COMPANION FLANGE
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Torque Gonverter Housing Bearings
Mainshaft Bearing/Oil Seal Replacement
1. Remove the mainshaft bearing and oil seal using
the soecial tool.
SLIDE HAMMER,3/8" - 16(Commercially available)
ADJUSTABLE EEARINGPULLER,25 - 40 mm07736 - A010008 or07736 - A01000A
ATTACHMENT,62x68mm07746 - 0010500
Install a new mainshaft bearing until it bottoms in
the torque converter housing.
3. Install a new oil seal flush with the torque converter
housing.
ATTACHMENT,
07?46 - 0010m0
07749 - 0010000
14-229
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Torque Gonverter Housing
BearingsGontrol Lever Assembly
Countershaft Bearing Replacement
1. Remove the countershaft bearing using the specialtool.
SLIOE HAMMER,3la" -16(Commercially available)
ADJUSTABLE BEARINGPULLER,25 - 40 mm07736 - A0100OB ol07736 - A01m0A
Install the ATF guide ptate.
Install a new countershaft
converter housing.
COUNTERSHAFTBEARING
bearing in the torque
DRIVER077i19 - 001m00
14-230
ATF GUIDE PLATE
Replacement
Check the condition and movement of the control leverassembly, lf the control lever assembly binds or doesnot move smoothly. replace it.
1. Remove the 6 x 1.0 mm bolt and lock washer.
2. Remove the change shaft trom the torque converterhousing.
3. Remove the control lever assembly from the controlshaft.
4. Install the new control lever assembly in the reverseorder of disassembly, until it bottoms in the torqueconverter housing.
LOCK WASHERReplace.
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Transfer Assembly
Reassembly
NOTE:
. 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 stan-
ing torque.
. Coat all pans with ATF during reassembly.. Replace the tapered roller bearing and the bearing
outer 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 thrusi shim.
Psrtorm this procedute if the transter driven g€ar
shaft or the tapered roller bearing on the transfer
driven gear shaft is replaced.
Prea$emble the parts to check and adiust transtelgear backlash and transfer gear tooth contact.
Disassemble the parts, then assemble the translerdriven gsar shaft and its related pans.
2.
3.
4. Measure and adjust the starting torque oI the
transfer driven gear shaft tapered roller bearing.
5. Assemble the transfer shaft and its related parts.
6. Measure and adiust the total starting torque.
35 mm Thrust Shim Selection
L 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.
FoRMULA:+ -*-+c=x
A: Number on the existing transfer driven gear shaft
B; 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 oear
shaft is shown in 'll100 mm.
14-240
EXAMPLE:
C: EXISTING 35 mmTHRUST SHIMThickness: C=1.05 mm
X: REPLACEMENT 35 mmTHRUST SHIMThickness: X=?? mm
Number: A=+2Numbe.: B=-'l
Ar EXISTING TRANSFERDRIVEN GEAR SHAFT
x= A - B .c" 100 100 -
2-1
100 100 '-
= 0.02 + 0.0'l + 1.05=1.08 {mm)
B: REPLACEMENT TRANSFERDRIVEN GEAR SHAFT
Select 35 mm thrust shim thickness of l08 mm(0.043 in). lf the tapered roller bearing on the transfer
driven gear shaft is replaced.
Measure the thickness of the replacement bearingand the existing bearing, and calculate the difference
of the bearjng thickness. Adjust the thickness of the
existing 35 mm thrust shim by the amount of differ-
ence in bearing thickness, and select the replacement
35 mm thrust shim.
THRUST SHIM, 35 mm
Shim No.Part NumberThickness
41361 - PS3 - 0000.72 mm (0.028 in)
41362-PS3-0000.75 mm {0.030 in}
c41363-PS3-0000.78 mm (0.03'1 in)
D41364-PS3-0000.81 mm (0.032 in)
41365-PS3-0000.84 mm (0.033 an)
F41366-PS3-0000.87 mm (0.034 in)
41367-PS3-0000.90 mm (0.035 in)
H41368-PS3-0000.93 mm (0.037 in)
41369-PS3-0000.96 mm 10.038 in)
41370-PS3-0000.99 mm (0.039 in)
K4 r371 - PS3 - 0001.02 mm (0.040 in
41372-PS3-0001.05 mm (0.041 in
M41373-PS3-0001.08 mm (0.043 in
N41374-PS3-000'1.11 mm 10.044 in
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Transfer Assembly
18.
Reassembly (cont'dl
16. Apply Prussian Blue to both sides of the transfergear teeth lightly and evenly.
17.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.
CORRECT TOOTH CONTACT PATTERN
NCONRECT TOOTH CONTACT PATTERN
TOE CONTACT
HEEL CONTACT
FLANK CONTACT
14-244
FACE CONTACT
19. lf the transfer gear tooth contact is incorrect, adjust
the transfer gear tooth contact with a 35 mm or 25
mm th rust shim.
NOTE:
. To select a 35 mm thrust shim, refer to page 14,240.
. Do not use more than two 35 mm shims to
adjust the transfer gear tooth contact.. To select the 25 mm thrust shim, refer to page
14-243.
. Do not use more than two 25 mm shims 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 drivegear. Because this movement causes the transfergear backlash to change, move the transfer drivegear away from the transfer driven gear shaft to
adjust the transfer gear backlash as follows:. Increase the thickness of the 25 mm thrust
shrm.
. Reduce the thickness of the 68 mm thrust
shim by the amount of increased thickness of
the 25 mm thrust shim.
Heel Contact
Use a thinner 35 mm thrust shim to move the
transfer driven gear shaft away from the transfer
drive gear. Because thjs 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
shim.
. Increase the thickness of the 68 mm thrust
shim by the amount of reduced thickness ofthe 25 mm thrust shim.
Flank Contaqt
Use a thinner thrust shim to move the transfer
drive gear toward the transfer driven gear shaft.Flank contact must be adjusted within the limits
of the transfer gear backlash. lf the backlash
exceeds the limits, adjust as described underHeel Contact.
Face Contaqt
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 transfer gear backlash. lf the back-
lash exceeds the limits, adjust as described
under Toe Contact.
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20. Remove the parts on the transfer shaft, and remove
the transfer shaft from the transfer housinq.
TRANSFER SHAFT
TRANSFER HOUSINGTAPEFED ROLLERBEARNG
TRANSFERCOLLAR
TRANSFER DRIVEGEAR
THRUST SHIM, 25 mmSelective pan
CONICAL SPRINGWASHERReplace.
Transf€r Driven Gear Shaft Starting Torque Inspsction
and Adjustment
21. 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.
22. Install the special tool on the companion flange,
then remove the transfer driven oear shaft locknut
and the conical spring washer.
COMPANION FLANGE HOLDER07RAB - TB,010A ol07RAB - TB,010B
Replace.
23. Remove the transter driven gear shaft and the com-
panion flange,
24. Install the new transfer spacer on the transfer dri-
ven gear shaft, then install them in the transfer
housrng.
TRANSFER DRIVENGEAR SHAFTTFANSFER SPACERlnstall in this direction.Replace.
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, and transfer
shaft with ATF before installing the locknut.
. Install the conical spring washer in the direction
shown,
TRANSFER HOUSING
O.RINGReplace.
CONICAL SPRINGWASHERReplace.
LOCKNUTReplace.
(cont'd)
BACK.UP RING
14-245
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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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