1999 HONDA CR-V Starting

Transfer Assembly
Reassembly (cont'd)
Remove transfer 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 212F
(100"C). Let the cover cool to room temperature
before adjusting the starting torque.
lI the measurement is within the specification, go to
step 40.
COVER A
BEARING OUTER RACE
35.
36.
HEAT GUN
13-60
37. Select the 68 mm thrust shim.
THRUST SHIM, 68 mm
Shim No.Part NumberThickne3s
zv23914-P1C-0201.41 mm (0.056 in)
zw23975-P1C-020'1.44 mm 10.057 in)
zx23916 PlC -020'1.47 mm (0.058 in)
ZI23917 -P1C-O201.50 mm (0.059 in)
zz23978-PlC-0201.53 mm (0.060 in)
23941 - PW5 0001.56 mm {0.061 in)
23942-PWs-0001.59 mm (0.063 in)
c23943-PW5-000't.62 mm (0.064 in)
D23944 PW5 - 0001.65 mm (0.065 in)
E23945-PWs-0001.68 mm (0.066 in)
F23946-PW5-0001.71 mm 10.067 in)
G23947-PW5-000'1.74 mm 10.069 in)
23948-PWs-0001.77 mm (0.070 in)
23949-PWs-0001.80 mm (0.071 in)
239s0-PW5-0001.83 mm (0.072 in)
K23951 - PW5 - 0001.86 mm (0.073 in)
L23952-PWs-0001.89 mm {0.074 in)
239s3-PWs-0001.92 mm {0.076 ini
N23954-PW5-0001.95 mm (0.077 in)
o23955-PW5-0001.98 mm (0.078 in)
P23956 - PW5 , 0002.01 mm (0.079 in)
o23957-PWs-0002.04 mm (0.080 in)
R23958-PWs-0002.07 mm (0.081 in)
23959-PW5-0002.10 mm (0.083 in)
T23960-PW5-0002.13 mm (0.084 in)
U23961 - PW5 - 0002.16 mm (0.085 in)
23962-PW5-0002.19 mm (0.086n)
23963-PWs-0002.22 mm (0.087n)
X23964-PWs-0002.25 mm (0.089n)
23965,PWs-0002.28 mm 10.090n)
23966-PW5-0002.31 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 'n}
BZ23942-PW8-0002.49 mm (0.098 in)
cz23943-PW8-0002.52 mm {0.099 ini
DZ23944-PW8-0002.55 mm (0.100 in)
EZ23945-PW8-0002.58 mm (0.102 ini
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38. Install the 68 mm thrust shim using the special
tools.
DRIVER077€ - 001(xno
THRUST S1{IM,68 mmSelective part
BEARING OUTER BACE
ATTACHMENT.62x68mm077a6 - (x)10500
39.After replacing the 68 mm thrust shim, recheck and
make sure the total starting torque is within the
soecification.
40. Coat the new O-rings with MTF, install them on
transfer covers A and B, then install the covers on
the transfer housing.
6x1.0mm12 N.m 11.2 kgf.m,8.7 tbt.ft)TRANSFER COVER B
TRANSFER
O.RINGReplace.
O.BINGReplace.
TRANSFERCOVER A
8 r 1.25 mm2,r N.m (2.4 kgl.m. 17 lbtft)
13-61
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Description
General Operation (cont'dl
Gsar Selection'97 - 98 Models
The shift lever has seven positions; El PARK, ts REVERSE, N NEUTRAL, Ell 1st through 4th ranges, lpq 1st th.ough 3rdranges, P 2nd gear, and [ 1st gear
'99 - 00 Models
The shitt lever has six positions; El PARK, E REVERSE, E NEUTRAL. E ,lst through 4th ranges, and 1st through 3rd(when Over-Drive (O/D) is OFF) ranges. @ 2nd gear, and E 1st gear.
Starting is possible only in @ and @ positions. using a slide-type. neutral-safety switch.
Automatic Transaxle (A/T) Gear Position IndicatorThis indicator in the instrument panel shows which gear has been selected.
Transler Mochanism {4WD}
The transfer mechanism consists of the transfer shaft drive gear. the transfer shaft. the transfer drive gear, the transfer driv-en gear shaft, and the companion flange, The transfer mechanism assembly is on the rear side ot the transmission. besidethe differential. The transfer shaft drive gear on the final driven gear drives the transfer shaft driven qear. power is transmit-ted to the rear differential via the transfer shaft and the Drooeller shaft.
Clutches
The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears.When the hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction discs andsteel plates together, locking them so they don't slip. Power is then transmifted through the engaged clutch pack to its hu$mounted gear. When hydraulic pressure is bled from the clutch pack, the piston releases the friction discs and steel plates, andthey are free to slide past each other. This allows the gearto spin independently on its shaft, transmitting no power.
lst Clutch
The 1st clutch engages/disengages lst gear, and is located at the end ofthe mainshaft, just behind the end cover.The 1st clutch is supplied hydraulic pressure by its ATF feed pipe within the mainshaft.
lst-hold Clutch
The 1st-hold clutch engages/disengages 1st-hold or E position, and is located at the middle of the sub-shaft. The 1st-holdclutch is supplied hydraulic pressure by its ATF feed pipe within the sub-shaft.
2nd Clutch
The znd ciutch engages/disengages 2nd gear, and is located at the middle of the mainshaft. The 2nd clutch is joined back-to-back to the 4th clutch. The 2nd clutch is supplied hydraulic pressure through the mainshaft by a circuit connected to theinternal hydraulic circuit.
PositionDescription
Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch locked.
Allclutches released.
General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehicle speedand throftle position. Downshifts through 3rd,2nd, and lst on deceleration to stop.The lock-up mechanism operates;n 3rd and 4th gear.
used for rapid €cceleration at highway speeds and general driving; stans off in 1st, shifts automatically to2nd_then 3rd, dejending on vehicle speed and throttle position. Downshifts through lower gears on decel-eration to stop. The lock-up mechanism comes into operation in 3rd gear.
Driving in 2nd_gear; stays in 2nd gear, does not shift up and down. For engine braking or better trac_tion starting off on loose or slippery surfaces.
Driving in 1st gear; stays in 1st gear, does not shift up. For engine braking.
tll PARK
t!!l l|EvEn>E
E NEUTRAL
Ell DRrvE ('97 - sB)E DRrvE ('ss - oo)(1st through 4th )
E DRrvE {'97 - s8)O DRTVE with over-Drive (O/D) is OFF('99 - 00)(1st through 3rd)
E SECOND
E FIRST
14-4
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Symptom-to-Component Chart
Hydraulic System
Before troubleshooting a problem on Hydraulic system, check the self-diagnosis Dl ('97 - 98) or Lq ('99 - 00) indicator
light indication. lf the El or E indicator light indicates a trouble code, perform the electrical troubleshooting according to
the Electrical System-to-Component Chart. lf the Ol or E indicator light does not indicate a trouble code and failure is not
found on the electrical troubleshooting, perform the hydraulic troubleshooting following the chart.
SYMPTOMCheck these items on the
PROBABLE CAUSE List
Check these items on
the NOTES List
Engine runs, but vehicle does not move in any gear.1r2FAt?82?K,L.R,S
Vehicle moves in El. @, but not in lE. E, E, or E, position6, 8, 9, 10, 29, 52c,M,o
Vehicle moves in [D!. E, E. E, E, but not in E] position.al
Vehicle moves in .&1, E. E, E, E, but not in E position4,6, 14, 15c,L.o
Vehicle moves in E position.10 , 12, 13, 'l4, '16, 2A, 32, 33, 34
Excessive idle vibration1,2, 18,3'1,35, 44, 46, 41B,K,L
Poor acceleration; flares on starting off in E, Di position
or E position
Stall rpm hish in El, El, E, E, E Position
Stall rpm hiqh in E, E, E, E position
1,2,3,6,37, 40K,L,R
6, 8, 10C,D
Stall rpm high in E positionc,D
Stall rpm high in hl position14N
Stall rpm low17,31, 44, 46, 47R
No shift18, 19, 39, 47, 48G,L
Fails to shift in Pr, E position or E position; from 1st to
3rd gear
21, 48
Fails to shift in EJ, E position or E position; from 1st to
4th gear
21,22, 47
Erratic upshifting
fz upshlft. ,3 ripshlft, 3r. up+ilft57
ffi20, 47
il21, 4A
3-4 upshift22, 47
Harsh upshift ('l-2)12, 18, 19,2A,49, 50, 56, 57
Harsh upshift (2-3)13, 1A, 19,23,26,28, 49, 50, 56, 57C,D.E,H,L
Harsh upshift {3-4)14,1A, 19,24,27,28, 49, 50, 56. 57C, D, E, I,L
Harsh downshitt (2-1)18, 19,23, 42,53,56,51o
Harsh downshift (3-2)12, 18,19,24,41,42, 54. 56, 57, 58
Harsh downshift (4-3)13,'1A, 19, 25, 41, 42, 55, 56, 57C, D, E, I
Flares on 2-3 upshift13,1A,19,23,26,50FI
Flares on 3-4 upshift14, 1A, 19,24,27,50E,L,N
Excessive shock on 2-3 upshift13. '18, 19 , 23, 26, 42, 49 , 50, 51E.L.N
Excessive shock on 3-4 upshift14, 1A, 19,24,27 , 42, 49,50,51E,L,N
Late shift from N position to ld or Erl position. or to E
position
10, 29M
Late shift from E position to E position4, 14,20,51o
Noise from transmission in all shift lever positions2,36K,L.O
Vehicle does not accelerate more than 3l mph (50 km/h).11
(cont'd)
14-153
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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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Clutch
Installthe snap ring.
Reassembly (cont'd)
7.
S AP RIIG
8. Remove the special tools.
9, Install the disc spring in the direction shown.
1ST, 2ND, 4TH, lST-HOLD CLUTCH:
3RD CLUTCH:
Dlsc sPRrrtc
CIUTCH ORUM
otsc sPfitl{c
14-220
10.Soak the clutch discs thoroughly in ATF for a mini_mum of 30 minutes. Before installing the platesand discs, make sure the inside of the clutch drumis free of din or other foreign matter
Starting with a clutch plate, alternatelv install theclutch plates and discs. Install the clutch end platewith its flat side toward the disc.
CLUTCH EI{D PI.ATEInstall in this directior.
CLUTCHCLUTCH EI{D PLATE
12. Install the snap ring.
SCREWDRIVER
't1.
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O TRANSFER HOUSING
O o-RING Replace.
O TRANSFER HOUSING ROLLER BEARING
@ TRANSFER SHAFT
O TAPERED ROLLER BEARING OUTER RACE
@ TAPERED ROLLER BEARING
O TRANSFER SHAFT COLLAR
@ THRUST SHIM, 25 mm Selective part
€) TRANSFER DRtvE GEAR (HYPoID GEAR}
@ coNtcAL SPRtNG WASHER Reptace,
@ TRANSFER SHAFT LOCKNUT,22 x 1.25 mm Left-hand rhreads, replace.
(D TAPERED ROLLER EEARING
@ TAPERED ROLLER EEARING OUTER RACE(} THRUST SHIM, 68 mm Selective part
@ O-RING Replace.
@ TRANSFER coVER A
(} TRANSFER COVER B
@ o-RING Replace.
(9 TRANSFER DRIVEN GEAR SHAFT (HYPOID GEAR)
@ THRUST SHIM, 35 mm Selective part
@ TAPERED ROLLER BEARING
@ TRANSFER SPACER Reptace.
@ TAPERED RoLLER BEARTNG OUTER RACE
@ TAPERED ROLLER BEARING OUTER RACE
@ TAPERED BOLLER BEARTNG
@ olL SEAL Replace.
@ COMPANION FLANGE
@ o-RING Replace.
@ BACK-UP RING
@ coNtcAL SPRtNG WASHER Reptace.
@ TRANSFER DRIVEN GEAR SHAFT LOCKNUT,22 x 1.25 mm Replace.
TOROUE SPECIFICATIONS
Boh/Nut No.Torque ValueSizeRemarks
6A
8C
22L
22H
12 N'm (1.2 kgf.m,8.7 lbf.ft)
24 N.m (2.4 kgf.m, 17 lbnft)
118 N.m (12.0 kgim,87 Ibift)
132 216 N.m (13.5 22.0 kgf.m,
98 - 159 lbift)
6x1.0mm
8 x 1.25 mm
22 x 'l.25 mm
22 x 1.25 mm
Transfer shaft locknut:
Left hand threads
Transfer driven gear shaft locknut
Tightening torque: depending on
Total Starting Torque value
14-233
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Transfer Assembly
Inspection
NOTE: To prevent damage to the transfer housing,
always use soft jaws or equivalent materials between
the transfer housing and the vise.
Trsnsfer Gear (Hypoid gear) Backl8sh M€asurem€nt
1. Set a dial indicator on the companion flange as
snown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.02 - 0.06 in)
Total Starting Torque Meagurgm€nt
3, Rotate the companion flange several times to seat
the tapered roller bearing.
4. Measure the starting torque (companion flange
side) using a torque wrench as shown,
STANDARD:
2.68 - 3.,17 N.m(27.3 - 35.,1 kgf.cm, 23.7 - 30.7 lbf.inl
TRANSFER SHAFT
DIAL INDICATOR
COMPANION FLANGE
14-234
Transfer Gear (Hypoid gear) Tooth Contact Inspection
5, Remove transfer cover B, then apply Prussian Blue
to both sides of the transfer gear teeth lightly and
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. Thepattern should be centered on the gear tseth as
snown.
6.
7.
8.lf the statrting torque measurement or the tooth
contact pattern are not correct, disassemble the
transfer assembly, replace worn or damaged parts,
and reassemble it.
TRANSFER DRIVE G€AR
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