1999 HONDA CR-V Line

Transmission
Installation (cont'dl
8. Install the transmission housing mounting bolts.
TRANSMISSION HOUSING MOUNTING BOLTS12 x 1.25 mm54 N.m 16,5 kgf.m, a7 lbtftl
9. Remove the transmission jack.
10. Attach the torque convener to the drive plate witheight bolts. Rotate the crankshaft as necessarv totighten the bolts to 'll2 of the specified torque, thento the final torque, in a crisscross pattern. Aftertightening the last bolt. check that the crankshaftrotates freelv.
6x1.0mln12 N.m (1.2 tgt m,8.t lbf.frl
6x1.0mm12 N.m {1.219{.m,8.7 tbtft,
12 x t.25 mm34 N.m 13.5 kgf.rn,25 lbf.ft)
8 x 1.25 mm2a N.m 12.5 kgf'm,18 tbt.ftl
DRIVE PLATE
STIFFENER
44 N.rn (4.5 kgt m, 33 lbtftl
11.
12.
Install the torque convener cover and the rear stiff_ener.
Tighten the crankshaft pulley bolt as necessary (seesection 5).
14-260
13. Connect the ATF cooler hoses to the ATF coolerlines (see page 14-266).
. ATF COOLERLINE
'i 'l'r',:,.) -
10 x 1.25 mm44 N.m (4.5 kgf.m,33 tbtftl
CLAMP
12 x 1.25 mm64 N.m 16.5 kg{.m,a7 tbt.ftlFRotrtT
15.
16.
't 4.
SET RINGReplace.
MOUNT/ARACKET
Install the right front mounvbracket.
Install new set rings on the ends of the intermediateshaft and the driveshaft.
Clean the areas where the intermediate shaft con_tacts the transmission {differential) with solvent orcarburetor cleaner, and dry with compressed air.Then install the intermediate shaft in the differen_tial, While installing the intermediate shaft, be surenot to allow dust or other foreign panicles to enterthe transmission.
l0 x 1.25 mm39 N.m 14.0 kgt.n,29 tbf.ftl
INTERMEDIATE SHAFT
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Transmission
Installation (cont'dl
2WD:
Install the control lever with a new lock washer to thecontrol shaft. Do not bend the shift cable excessivelv.
8 r 1.25 mm22 N.m|'2.2 kgt.m,16 rbf.ft)
SI{IFT CAELECOVER
LOCK WASHER 6 x 1.0 mmReplace. 14 N.m 11.4 kgt.m,10 tbr.frl
lnstallthe shift cable cover.
Install exhaust pipe A.
Connect the primary heated orygen sensor (primary
HO2S) connector.
GASKETSReplace.
22.
23.
10 x 1.25 m.n5r N.m {5.5 kgf.m,40 tbtftlReplace.
SELF.LOCKING
SELF-LOCKING NUT8 ! 1.25 mm16 N.m {1.6 kgf.m,12 lbf.fttReplace.
8 x 1.25 mm22 N.m {2,2 kgt.m, l5 lbt.ftl
SHIFT CABLE
14-262
24. Installthe splash shield and guard bar,
8 x 1.2524 N.m {2.a kgl.m,17 tbt.ftl
SPLASH SHIELD
GUARO BAR
25.
6r1.0|r|m9.8 N.m l1.0lgf.m, 7.2 tbtftl
Connect the mainshaft speed sensor, the shift con-trol solenoid valve, and the linear solenoid connec_tors,
SHIFT CONTROL SOLENOIDVALVE CONNECTOR
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Transmission
Cooler Flushing
@@ To prevent in;ury to face and eyos, atwayswear safety glasses ot a face shield when using thetlansmission flusher.
This procedure should be performed before reinstallingthe transmission.
2.
LCheck equipment for wear and cracks before using.Replace any worn or cracked components.
Using the measuring cup. fill the tank with 21 ounces{approximately 213 lull) ol biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontaaner.
Secure the flusher filler cap, and pressurize theflusher with compressed air to 550 - 829 kpa (5.6 _
8.45 kgf/cm,, 80 - 120psi). The air line should beequipped with a water trap to ensure a dry air sys-tem.
Hang the flusher under the vehicle.
Attach the flusher discharge hose to the return lineof the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-mission cooler using a clamp.
IMPORTANT:
Securely clamp the opposite end ofthe drain hose to abucket or floor drain.
DISCHARGEHOSE
tAirlp Water
TnAI{SrfiSStoN coot"€RFLUSHER{Comm.rcidly.v.il.bt.lK.r -Moor. J38,t{15.Aor aquival.nt
5.
14-264
7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)
10.
8.
1'I.
Turn on the water valve for 1O seconds. lf waterdoes not flow through the cooler, it is completelyplugged, cannot be flushed, and must be replaced.
Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.
While flushing with the water and flushing fluid fortwo minutes, turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgf/cmr, t20 psi)
Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.
Release the trigger, and rinse the cooler with wate.for one minute.
Turn the water valve off, and the water supply off.
Turn the air valve on for two minutes, or until nomoisture is visible leaving the drain hose. Residualmoisture in the cooler or lines can damage thetransmission.
Remove the flusher from the cooler line. Attach thedrain hose to a container.
Install the transmission, and leave the drain hoseattached to the cooler line.
12.
13.
14.
to.
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17.Make sure the transmission is in E position.
Fill the transmission with ATF, and run the engine
for 30 seconds or until approximately 0.951 {1.0 US
qt., 0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the cooler
return hose to the transmission (see page 14-266).
Refill the transmission with ATF to the proper level
(see page l4'161 ).
18.
19.
TOOL MAINTENANCE
1. €mpty and rinse the flusher after each use. Fill the
flusher with water and pressurize it, then flush the
discharge line to ensure that the unit is clean.
2. lf discharge liquid does not foam, the orifice may be
blocked.
3. To clean, disconnect the large coupling nut from the
flusher.
FILTER
\-0--D
I
IO.RING
Remove the in-line filter from the discharge side and
clean it if necessary.
The fluid orifice is located behind the filter.
Clean it with the pick stored in the bottom of the
tank handle, or blow it clean with air.
Reassemble all parts.
COUPLINGNUT
II
-@q
\ORIFICE
4.
5.
6.
FILLER CAP
14-265
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ATF Cooler Hoses
Gonnection
'1. Connect the ATF cooler hoses to the ATF cooler lines. then secure them with the cliDs.
2. Face the tabs of the clips of the transmission side toward the radiator, and face the tabs of the ATF cooler side down-wa rd.
CLIPFace tabs toward radiator.
ATF COOLER LINEATF COOLER LINE
TRANSMISSION
6-8mm(0.2 - 0.3 inl
ATF COOLER
HOSE CLAMP
CLIPFace tabs downward.
2-rlmm10.1 - 0.2 inl
14-266
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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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DriveshaftsFront Driveshafts
Inspection
Boot Damago
Check the boots on the driveshaft for cracks, damago,
leaking grease, and loose boot bands. lf any damags is
found, replace the boot and boot bands.
Looso Splines
Turn the driveshaft by hand, and make sure th€ splin€s
and joint are not excessively loose. lf damage is found,
replace the inboard joint.
Twisting or Crscking
Make sure the driveshaft is not twisted or crackod.
Replace it if necessary.
DRIVESHAFT
1.
Removal
Loosen the wheel nuts slightly.
Raise the front of the vehicle, and suppon it with
safety stands in the proper locations (see section 1).
Remove the wheel nuts and front wheels.?
SPINDLE NUT24 x 1.5 mmReplace.
lf the right driveshaft is to be removed, drain the
transmission fluid {see s€ction 13 or 14). lt is not nec-
essary to drain the transmission fluid when the left
driveshaft is removed.
Lift up locking tab on the spindle nut, then remove
the nut,
Remove the self-locking nut and flange bolt,
FLANGE BOLT10 x 1.25 mm
FRONT WHEEL
(cont'd)
6.
SELF"LOCKING NUT12 x 1.25 mmReplace.
7. Remove the damper fork,
16-3
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Front Driveshafts
Disassembly (cont'd)
Double Loop
Mark each roller and inboard joint to identify the
locations of the rollers and grooves in the inboardjoint. Thon remove the inboard ioint on the shop
towel. Be careful not to drop the rollers when sepa-
rating them from the inboard joint.
INBOARD JOINTCheck splines for wear or damage.Check inside bore for wear.Inspect for cracks.
16-6
4, Mark the rollers and spider to identify the locstions
of the rollers on the sDider, then remove the rollers.
BEARING REMOVER(Commercially available) DRIVESHAFT
Remove the circlip,
Mark the spider and driveshaft to identify the posi-
tion ofthe spider on the shaft.
Remove the spider using a bearing remover,
Wrap the splines on the driveshaft with vinyl tape to
prevent damage to the boots and dynsmic damper,
7.
q
INBOARD BOOT
DRIVESHAFT
DYNAMIC DAMPER
Rsmove the inboard boot and dvnamic
Take care not to damage the boot and
damDer.
damper.
dynamic
DRIVESHAFT
Mark
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