1999 HONDA CR-V 001

Shift Arm Cover/Shift Arm Shaft Assembly
Disassembly/Reassembly
Shift Arm Cover Ass€mbly
1. Remove the breather cap and set ball screw, washer,
spring. and steel ball.
BREATHER CAP
SPRINGL,25.6 mm (1.01 in.l
T BALL SCREW22 N.m 12.2 kgtm, 16lbf.ftl
Remove the special bolt and conical spring washers.
SHIFTARMCOVER
THRUST WASHER
SHIFI ARM C
WASHER 8x1.0mft
SHIFT LEVER
29 N.m 13.0 kg{.m,z2 tbt.ftl
arm C, and thrustRemove the shift lever, shift
washer from the shift arm cover.
Remove the oil seal.
NOTE: lnstall the thrust washer
face toward shift arm cover.
STEEL BALLD. 5/16 in,
13-18
with the alloy sur-
3. Install in the reverse order of removal.
5. Install the oil seal in to the shift arm cover usino thesDecialtools.
HANOLE07749 - 0010000
ATTACHMENT,32x35mm077a6 - 0010100
OIL SEALReplace.
6. Reassemble the shift arm cover in the reve.se order
of disassembly.
Shift Arm Shaft Assembly
1. Remove the special bolts and conical spring wash-
ers.
SPCCIAL BOLT8x1.0mm29 N.m (3.0 kgf.m,SHIFTARMA 22IbI.ftICONICAL SPRING
SHIFT ARM SHAFT
SPECIAL BOLT8x1.0mm29 N.m {3.0 kgf.m, 22 lbtft}
2. Remove the interlock, shift
from the shift arm shaft.
SPRINGWASHER
arm A, and shift arm B
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Reassembly
NOTE: Refer to page 13-23 for reassembly sequence.
1. Suppon 2nd gear on steel blocks as shown, then
install the 3rd/4th synchro hub using the special
tools and a press as shown.
NOTE: After installing, inspect the operation of the
3rd/ 4th synchro hub set.
PRESS
I
3RD/4THSYNCHRO HUB
DRIVER, ,l(} mm l.O.
07746 - 0030'1 00
2.
2NO GEAR
Install the sth synchro hub using the special tools
and a press.
PRESS
I
DRlvER,40 mm l.D.
077{6 - 00301(x)
ATTACHMENT,35 mm l.D.077i16 - lx)3ollx)
sTH SYNCHBO HUB
3. Install the angular ball bearing using the special
tools and a oress. Note the direction of installation.
PRESS
I
077a6 - 0011x100
HANDLE07749 - 0010000
ATTACHMENT,/Vl x a7 mm
BALL BEARINGNote the dirediono{ installation.
13-27
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Countershaft Assembly
Reassembly (cont'dl
4. Reassembly the friction damper on the spacer using
the sDecialtools and a Dress.
PRESS
t
ATTACHMENT,U2t 47 mfi07716 - 0010300
FRICTION DAMPERInspect for wear anddamage.
Install the 2nd gear by align the
fingers with 2nd gear grooves.
synchro cone the
GROOVE
13-34
6. Support the countershaft on a steel block as shown
and install 3rd gear using the special tools and a
press.
3RO GEAR
7. lnstall 4th gear using the special tools and a press.
PRESS
I
PRESS
t
ATTACHMENT,35 mm LD.07746 - 0030,100
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Differential
Bearing Outer Race Replacement
Note these items:
. The bearing outer race and tapered roller bearingshould be replaced as a set.. lnspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
'1. Remove the oil seals from the transmission housingand clutch housing (see page j3-43).
2. Drive the bearing outer race and thrust shim out ofthe transmission housing, or remove the bearingouter race and 75 mm shim from the clutch housingby heating the clutch housing to about 212"F(100"C) with a heat gun. Do not reuse the thrustshim if the outer race was driven out.
TRANSMISSIONHOUSING:
ATTACHMENT52x55mm07746 - 0010400
THRUST SHIM
BEARINGOUTER RACE
CLUTCHHOUSING:
13-40
4, lnstallthe oil seal (see page 13-43).
3. Install the thrust shim or 75 mm shim and the bear-ing outer race in the transmission housing andclutch housing using the special tools.
Note these items during bearing replacement:. Install the bearing outer race squarely.. Check that there is no clearance between thebearing outer race, thrust shim or 75 mm shimand housing.
TRANSMISSIONHOUSING:
HANDI-E07749 - 00 xxto
ATTACHMENT,62x68mm077ir6 - 0010500
BEARINGOUIER RACETHRUST SHIM
CLUTCHHOUSING:HANDLE07749 - 001tXX)o
ATTACHMENT.72xt5mm07745 - 00106{x)
OUTER RACE
75 mm SHIM
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Differential
Tapered Roller Bearing Preload Adjustment (cont'd)
7. lf the tapered roller bearing preload is not within
the standard, select the thrust shim which will give
the correct tapered roller bearing preload from the
following table.
NOTE: Changing the thrust shim to the nexl size
will increase or decrease tapered roller bearingpreload about 0.3 - 0.4 N.m (3 - 4 kgf.cm, 2.6 -
3.5 lbf.in).
THRUST SHIM
8. Recheck the tapered roller bearing preload.
Part Numbe.Thickness
41381 - PX5 0001.90 mm (0.0748 in)
B41382 - PX5 0001.93 mm {0.0760 in)
c41383-PX5-000'1.96 mm (0.0772 in)
n41384-PX5-0001.99 mm (0.0783 in)
E41385-PX5-0002.02 mm (0.0795 in)
F41386-PXs-0002.05 mm (0.0807 in)
G41387-PXs-0002.08 mm (0.0819 in)
n41388-PX5-0002.11 mm (0.0831 in)
41389-PX5-0002.14 mm (0.0843 in)
J41390-PXs-0002.'17 mm (0,0854 in)
K41391 - PX5 - 0002.20 mm (0.0866 in)
4'1392-PX5-0002.23 mm (0.0878 in)
M41393-PX5-0002.26 mm (0.0890 in)
N41394-PX5-0002.29 mm (0.0902 in)
o41395, PXs - 0002.32 mm (0.09'13 in)
P41396-PX5-0002.35 mm (0.0925 in)
o41397-PX5-0002.38 mm (0.0937 in)
4't398-PXs-0002.41 mm (0.0949 in)
S41399-PXs-0002.44 mm (0.0961 in)
T41400-PXs-0002.47 mm (0.0972 in)
41873-P16-0001.66 mm (0.0654 in)
AB41874-Pl6-0001.69 mm (0,0665 in)
AC41875 P16 - 000'1.72 mm (0.0677 in)
AD41876-P16-0001.75 mm (0.0689 in)
AE41877-P16-0001.78 mm (0.0701 in)
AF41878-P16-0001.81 mm (0.07'13 in)
41879-P16-000'1.84 mm (0.0724in)
AH41880-P16-0001.87 mm {0.0736 in)
13-42
9. How to select the correct thrust shim:-1) Compare the tapered roller bearing preload
you get with the thrust shim that was removed,
with the specified preload of 1.4 - 2.5 N.m(14 -- 26 kgfcm, 12-23lbtinl.-2) lf your measured tapered roller bearing preload
is less than specified. subtract yours from the
specified,
lf yours is more than specified, subtract the
specified from your measurement.
For example with a 2.17 mm (0.0854 in) thrust
shiml
@ specified 2.5 N.m (26 kgf.cm,23 lbiin)- you measure 0.6 N.m (6 kgf.cm,5 lbf.in)
1.9 N.m (20 kgicm, 18 tbt.in) tess
@ you measure 3.3 N.m (34 kgf.cm,30 lbf.in)- specified 2.5 N.m (26 kgncm,23 lbf.in)
0.8 N.m (8 kgf.cm,7lbt.in) more
Each shim size up or down from standard
makes about 0.3 - 0.4 N.. (3 - 4 kgf'cm,
2.6 - 3.5 lbf.in) difference in tapered roller bear-
ing preload.
In example @, your measured tapered roller
bearing preload was 1.9 N.m (20 kgf.cm,
18 lbf.in) less than standard so you need a
thrust shim five sizes thicker than standard {trythe 2.32 mm (0.0913 in) thrusr shim. and
recheck).
ln example @, your measurement was 0,8 N.m
{8 kgf.cm, 7 lbf.in) more than standard, so you
need a thrust shim two sizes thinner (try the
2.1'l mm {0.0831 in) thrust shim, and recheck).
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Transfer Drive Gear Bearing
Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the tapered roller bearing from the transfer
drive gear using the special tools and a press.
BEARING SEPARATOR, GEARo - 1112"
{Commercially available)
Install the new tapered roller bearing in the transfer
drive gear using the special tools and a press
ATTACHMENT,40x50mm07LAD - PW5lr601
ATTACHMENT,37x/Omm07746 - 0010200
Transfer Driven Gear Shaft
Bearing Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the taDered roller bearing from the transfer
driven gear shaft using a press and a collar.
BEARING SEPARATOR,0 - 1112'
lCommercially available)
lnstall the 35 mm thrust shim on the transter driven
gear shaft.
Install the new tapered roller bearing on the transfer
driven gear shaft using the special tools and a press.
NOTE: Use old transfer spacer for bearing installa-
tion, then discard it.
DRIVER 40 mm l.D.07746 - 0030r00
13-49
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Transfer Housing Bearing Outer Race Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the tapered roller bearing outer race from
the transfer housing.
TBANSFER HOUSING
Install the new tapered roller bearing outer race
using the special tools and a press
DRIVER07749 - 0o1(xD0
TRANSFER HOUSINGBEARING OUTERRACE
J
i=
\l
DRIVER ATTACHMENT
13-51
Bealing Outer Race Locations
and Special Tool APP|ications
TRANSFER HOUSINGSectionalViewATTACHMENT,62x68mm07746 - 0010500
ATTACHMENT,62x68mm07?a6 - 0010500
ATTACHMENT,52x55mm07715 - 0010400
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Transfer Assembly
Reassembly
Note these items during reassembly:. 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 start-Ing rorque.
. Coat all parts with MTF during reassembly.. Replace the tapered roller bearing and the bearingouter 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 thrust shim.
Perform this procedure if the transler driven gear
shaft or the tapered roller bearing on the transferdriven gear shaft is replaced.
Preassemble the parts to check and adjust transfergear backlash and transfer gear tooth contact.
Disassemble the parts, then assemble the transferdriven gear shaft and its related parts.
4. Measure and adjust the staning torque of the trans-fer driven gear shaft tapered roller bearing.
5. Assemble the transfer shaft and jts related parts.
6. Measure and adjust the total starting torque.
35 mm Thrust Shim Seleqtion
1. 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.
ronrvruu:fi--fr-+c=x
A: Number on the existing transfer driven gear shaftB: 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 gear
shaft is shown in 1/100 mm.
2.
3.
13-52
EXAMPLE:
C: EXISTING 35 mmTHRUST SHIMThicknoss: C=1.05 mm
X: REPLACEMET{T35 mmTHRUST SHIMThickness: X=?? mm
Number: A=+2Number: B-l
A: EXISTING TRANSFERDRIVEN GEAR SHAFT
x= A - B -.'- 100 100 -
2-1
100 100 '-
= 0.02 + 0.01 + 1.05-'1.08 (mm)
B: REPLACEMENT TRANSFERDRIVEN GEAF SHAFT
Select 35 mm thrust shim thickness ot '1.08 mm(0.043 in). lf the tapered roller bearing on the transferdriven gear shaft is replaced.
Measure the thickness of the replacement bearingand the existing bearing, and calculate the differenceof the bearing thickness. Adjust the thickness of theexisting 35 mm thrust shim by the amount of differ-ence in bearing thickness. and select the replacement
35 mm thrust shim. Do not use more than one 35 mmthrust shim to adjust the transfer gear backlash,
THRUST SHIM. 35 mm
Shim No.Part NumberThickness
41361 - PS3 - 0000.72 mm (0.028 in)
B41362-PS3-0000.75 mm (0.030 in)
c41363-PS3-0000.78 mm (0.031 in)
41364-PS3-0000.81 mm (0.032 in)
E41365-PS3-0000.84 mm (0.033 in)
F4r366-PS3-0000.87 mm (0.034 in)
41367-PS3-0000.90 mm (0.035 in)
n41368-PS3-0000.93 mm (0.037 in)
41369-PS3-0000.96 mm {0.038 in)
41370-PS3-0000.99 mm (0.039 in)
41371 - PS3 - 0001.02 mm (0.040 in)
L41372-PS3-0001.05 mm (0.041 in)
41373-PS3-0001.08 mm (0.043 in)
N41374-PS3-0001.11 mm (0.044 in)
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