1999 HONDA CR-V front end

Transfer Assembly
Removal
@ Make sure the lifts, iacks, and safety
stands are placed properly (see section 11.
1. Raise the front of the vehicle, and make sure it is
supported securely.
2. Set the parking brake, and block both rear wheels
securelv.
3 Drain the automatic transmission fluid (ATF).
Reinstall the drain plug with a new sealing washer'
DRAIN PLUG'18 x'1.5 rnm49 N.m 15.0 kgf.m, 36 lbl.ftl
4. Remove the guard bar and the splash shield.
GUARD 8AR
14-165
5.Disconnect the primary heated oxygen sensor
{Primary HO2S) connector.
Remove exhaust pipe A.
SELF-LOCKINGNUTBeplace.
7.
SEI-F.LOCKINGNUTReplace.
NUTReplace
Remove the shift cable cover.
Remove the snap pin and control pin, then separate
the shift cable from the control lever. Do not bend
the shift cable excessively.
(cont'd)
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Transmission
21.
Removal (cont'dl
Make reference marks across the transfer assemblv
and propeller shaft flanges. (4WD)
Separate the propeller shaft from the transfer
assembly. (4WD)
I x 1.25 mmReplace.
Remove the intermediate shaft,
Tie plastic bags over the both ends of the intermedi-
ate shaft. Coat all precision finished surfaces with
clean engine oil.
22.
REFERENCE MARKS
14-172
24.Remove the right front mounvbracket.
Remove the ATF cooler hoses at the ATF cooler
lines. Turn the ends of the cooler hoses uo to ore-
vent ATF from flowing out, then plug the lines and
hoses. Check for any sign of leakage at the hose
ioints.
RIGHT FRONTMOUNT/BRACKET
Remove the rear stiffener and torque converter
cover.
Remove the eight drive plate bolts, one at a time.
while rotating the crankshaft pulley.
27.
COVER
DRIVE PLATE
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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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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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Front Driveshafts
Removal (cont'd)
Remove the cotter pin from the lower arm ball ioint
castle nut, and remove the nut.
Install a 12 mm hex nut on the ball joint. Make sure
the hex nut is flush with the ball joint pin end, or the
threaded section of the ball joint pin might be dam-
aged by the special tool.
Use the special tool as shown in section '18 to sepa-
rate the ball joint and lower arm, Be caretul not to
damage the ball joint boot, lf necessary, apply pen-
etrating type lubricant to loosen the ball joint,
Pry out the driveshaft assembly with a pry bar, as
shown, to force the set ring at the driveshaft end
past the groove. Be careful not to damage the oil
seals when prying.
i0.
1l.
07MAC - SLm2m
PRY BAR
16-4
12. Pull on the inboard joint, and remove the driveshaft
from the differential case or bearing support as an
assembly. Do not pull on the driveshaft, the inboardjoint may come apart. Pull the driveshaft straight
out to avoid damaging the differential oil seal or the
intermediate shaft outer seal.
Left driveshaft:
Remove the left driveshaft from the bearing suppon
by tapping on the inboard joint of the driveshaft
with a olastic hammer.
BEARING SUPPORT
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13, Pull the knuckle outward, and remove the driveshaft
inboard joint from the differential case or bearing
suoDort.
KNUCKLE
Remove the driveshaft outboard joint from the front
wheel hub using a plastic hammer.
PLASTIC HAMMER
14.
DRIVESHAFT
DRIVESHAFT
Disassembly
Inboard Joint Sid€:
1, Carefully clamp the driveshaft in a vise with softjaws, then remove the set ring from the inboardjoint.
2. Remove the boot bands. Take care not to damage
the boot,
. lf the boot band is a locking tab type, pry up the
locking tabs with a screwdriver, and lift up the
end of the band.
. lf the boot band isawelded typeora low profile
type, carefully cut the boot band with a pair of
diagonal cutters.
. lf the boot band is a double loop type. lift up the
band bend.
Locking Tab
SET BINGReplace.
Welded
{cont'd)
16-5
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Front Driveshafts
Reassembly {cont'd)
7. Fit the inboard joint onto the driveshaft, and note
these items:
Reinstall the inboard joint onto the driveshaft by
aligning ths marks on the inboard joint with the
marks on the rollers.
Hold the driveshaft so the inboard joint points up
to prevent it from falling off.
Adjust the length of the driveshafts to the specifica-
tions shown. then adjust the boots to halfway
between full compression and full e)dension. Make
sure the ends of the boots seat in the grooves of the
driveshaft and Ioint.
/€\
/,?:..{ \
t Sptine airection
lffi
tYl:\
ROLLER HOLDER
16-10
Left: 508 - 513 mm 120 - 2O.2 inl
Right: AT model 520 - 525 mm {20.5 - 20.7 in)
MT mod6l 515 - 520 mm (20.3 - 20.5 inl
II
-flm+dm@
9. Position the dynamic damper to the specifications
as snown.
Left: 299.5 t 2 mm 111.8 r O.l inl
Right: 299.5 t 2 mm 111.810.1 inl
OUTBOARO JOINT
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10. Set the double loop band onto the boot or dynamic
damper with the band end toward the front of the
vehicle.
11. Pull up the slack in the band by hand.
12. Make a mark on the band 10 - 14 mm (0.4 - 0.6 in)
from the clip.
OOUBLE LOOP BAND
CLIP
13.
'14.
Thread the free end of the band through the nose
section of a commercially available boot band tool(KD-3191 or equivalent). and into the slot on the
winding mandrel.
Place a wrench on the winding mandrel of the boot
band tool. and tighten the band until the marked
spot on the band meets the edge of the clip.
BOOT BAND TOOL(KD-3191
or equivalentlMark on band.
15.
WINDINGMANDREL
Lift up the boot band tool to bend the free end of
the band 90 degrees to the clip, Center-punch the
clip, then fold over the remaining tail onto the clip.
(cont'd)
16-1 1
HAMMER
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