1999 HONDA CR-V ect

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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Disassembly
1. Remove the transfer covers A and B.
2. Cut the lock tabs of the locknut usino a chisel.
LOCK TAB
5.
Put a 14 mm Allen wrench in the gear side of the
transfer shaft, then secure the Allen wrench in a
bench vise.
Remove the transfer shaft locknut and the conical
spring washer. The transfer shaft locknut has left
hand threads.
Remove the transfer shaft, transfer drive gear, 25
mm thrust shim, transfer shaft collar, and tapered
roller bearing from the transfer housing.
TRANSFER SHAFT
THRUST SHIM,25 mrnSelective part
CONICAL SPRINGWASHERReplace.
(cont'd)
1a mm ALLEN WRENCH
14-235
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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 Gear Bscklash Inspection and Transfer Gear
Tooth Contact Inspection
2. Install the 35 mm thrust shim on the transfer driven
gear shaft, then install the tapered roller bearing
using the special tools and a press.
DRIVER {0 mm LD.077146 - 0030100
TRANSFER DRTVEN ;;.GEAR SHAFT u, 745 - 0O304O0
Place the tapered roller bearing on the bearing outer
race of the companion flange side of the transfer
housrng.
Install the new oil seal on the transfer housing
using the special tools.
OIL SEAL DRIVERATTACHMENT07JAD - PH80101
5. Install the transfer driven gear shaft in the transfer
housing. Do not install the transfer spacer on the
transfer driven gear shaft in this step.
Install the companion flange, conical spring washer,
and locknut on the transfer driven gear shaft. Do
not install the O-ring and the back-up ring on the
transfer gear shaft in this step.
6.
COMPANIONFLANGE
{cont'd)
TRANSFER
TRANSFER HOUSING
14-241
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Transfer Assembly
Reassembly (cont'd)
7.Secure the transfer housing in a bench vise with
soft jaws, then install the special tool on the com-
panion flange. To prevent damage to the transfer
housing, always use soft jaws or equivalent materi-
als between the transfer housing and the vise.
Tighten the locknut while measuring the starting
torque so the starting torque is within 0.98 - '1.39
N.m (10.0 - 14.2 kgf.cm, 8.68 - 12.3 lbnin).
NOTE:
Coat the threads of the locknut, and the shaft
with ATF before installing the locknut.
Do not stake the locknut in this step.
STARTING TOROUE:
0.98 - 1.39 N.m
{10.0 - 14.2 kgrf.cm,8.68 - 12.3 lbf'inl
COMPANION FLANGEHOLDER
07JAB - @1020A
14-242
9. Install the transfer shaft in the transfer housing,
then install the tapered roller bearing, transfer shaft
collar.25 mm thrust shim, transfer drive gear, coni-
cal spring washer, and locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut. and the shaft
with ATF before installing the locknut.
. Do not stake the locknut in this step.
TRANSFER
THRUST SXIM,25 mmSelective pan
TRANSFER DRIVEGEAR
CONICAL SPRINGWASHERReplace.
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10.
11.
Put a 14 mm Allen wrench in the gear side of the
transfer shaft, then secure the Allen wrench in a
bench vise.
Tighten the transfer shaft locknut.
NOTE:
. The transfer shaft locknut has left-hand threads.
. Do not stake the locknut in this step.
TOROUE: 118 N'm 112.0 kgf.m, 87 lbf.ftl
Temporarily install the transfer cover A without
O-ring.
TRANSFER HOUSING
TRANSFER COVER A
the12.
g/FrE24 N.m 12.4 kgt.m, 17 lbf.ftl
TOROUE WRENCH
tt el
g 9-r'r.ru--g 24 N.m 12.4 |
14-243
13.
14.
Rotate the companion flange several times to seat
the tapered roller bearing.
Set a dial indicator on the companion flange, then
measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.02 - 0.06 inl
COMPANION FLANGE
lf the measurement is not within the standard.
remove the transfer shaft locknut and replace the 25
mm thrust shim. Select and install a new 25 mm
thrust shim. then recheck the measurement. Do not
use more than two 25 mm thrust shims to adiust
the transfer gear backlash.
THRUST SHIM, 25 mm
(cont'd)
15.
DIAL INOICATOR
Shim No.Part NumborThickness
I29411-P1C-0001.70 mm (0.067 in)
229412-P1C-0001.73 mm (0.068 in)
29413-P1C-0001.76 mm (0.069 in)
429414-P1C-0001.79 mm (0.070 in)
29415-PlC-0001.82 mm (0.072 in)
629416-P1C-0001.85 mm (0.073 ini
729417-PlC-0001.88 mm (0.074 in)
d29418-P1C-0001.91 mm {0.075 in)
29419-P1C-0001.94 mm (0.076 in)
1029420-PtC-0001.97 mm (0.078 in)
1129421 - P1C - 0002.00 mm (0.079 in)
29422-P1C-0002.03 mm 10.080 in)
29423-P'1C-0002.06 mm (0.081 in)
1429424-P1C-0002.09 mm 10.082 in)
29425-P1C-0002.12 mm (0.083 in)
1629426-P1C-0002.'15 mm (0.085 in)
1729427 - P1C -O002.18 mm (0.086 in)
1829428-PlC-0002.21 mm (0.087 in)
1929429-P1C-0002.24 mm {0.088 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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