1999 HONDA CR-V service

2.
Clearance InsPection
1. Measure the clearance between the shift arm A and
select arm.
Standard: 0.05 - 0 25 mm (0.002 - 0'01 inl
Service Limit:0.5 mm (0.02 in)
lf the clearance are more than the service limit,
measure the diameter of the select arm pln
Standard: 7.9 - 8.0 mm (0.311 - 0.315 in)
SELECTARM
lf the diameter of the select arm pin is less than
the service limit, replace the select arm wrtn a
new one.
lf the diameter of the select arm pin is within the
service limit, replace the shift arm A with a new
one.
SELECT ARM
SHIFT ARM A
SHIFT ARM C
SHIFT ARM B
3. Measure the clearance between the shift arm B and
shift arm c.
Standard: 0.05 - 0.25 mm (0.002 - 0.01 inl
Seryice Limit:0,5 mm (0.02 inl
lf the clearance are more than the service limit,
measure the diameter of the shift arm C.
Standard: 12.9 - 13.0 mm (0 508 - 0.512 in)
SHIFT ARM C
lf the diameter of the shift arm C is less than the
service limit, replace the shift arm C with a new
one.
lf the diameter of rhe shift arm C is within the
service limit, replace the shift arm B with a new
o ne.
13-19
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Reverse Shift Holder
Clearance Inspection
1.Measure the clearances between the reverse shift
holder and sth/reverse shift Diece Din.
Standard:A: 0.05 - 0.35 mm (0.002 - 0.014 in)
8: 0.4 - 0.8 mm 10.02 - 0.03 inl
Service Limit: A: 0.5 mm (0.02 in)
B: 1.0 mm 10.0,[ in]
2.lf the clearances are more than the service limit.
measure the widths of the groove in the reverse
shift holder.
Standard: A: 7.05 - 7.25 mm {0.278 - 0.285 inl
B: 7.4 - 7.7 mm (0.29 - 0.30 inl
lf the widths of the grooves are not within thestandard, replace the reverse shift holder with a
new one.
lf the widths of the grooves are within the stan-
dard, replace the sth/reverse shift piece with anew one.
PIECE PIN
REVERSE SHIFT HOLDER
13-20
3. Measure the clearance between the reverse idler
gear and reverse shift holder.
Standard: 0.5 - 1.1 mm {0.02 - 0.0i1 in}
Service Limit: 1.8 mm (0.07 in)
REVERSEIDLERGEAR
lf the clearance is more than the service limit. mea-
sure the width ot the reverse shift holder.
Standard: 13.0 - 13.3 mm (0.512-0521inl
It the width is not within the standard, replace
the reverse shift holder with a new one.
lf the width is within the standard, reolace the
reverse idler gear with a new one.
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Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and synchro hub should be
reolaced as a set.
1. Measure the clearance between each shift fork and
its matching synchro sleeve.
Standard: 0.35 - 0.65 mm 10.01/t - 0.026 inl
Service Limit: 1,0 mm {0.039 inl
SHIFT FORK
2. lf the clearance exceeds the service limit. measure
the thickness of the shift fork fingers.
Standard:
lf the thickness of the shift fork finger is less than
the standard, replace the shift fork with a new
one.
lf the thickness of the shift fork tinger is within
the standard, replace the synchro sleeve with a
new one.
3rd/4th shift fork7.4 - 7.6 mm
(0.29 - 0.30 in)
1sv2nd shift fork
5th shift fork
6.2 - 6.4 mm(0.24 - 0.25 in)
3. Measure the clearance between the shift fork and
the shift arm A.
Standard; 0.2 - 0.5 mm (0.008-0.020 in)
Service Limit: 0.6 mm (0.02i1 in)
sTH/REVERSESHIFT PIECE ran,rru
lST/2NDSI{IFT FORK
lf the clearance exceeds the service limit, measure
the width of the shift arm A.
Standard: 12.9 - 13.0 mm 10.508 - 0.512 inl
lf the width of the shift arm A is less than the
standard, reDlace the shift arm A with a new one.
lf the width of the shift arm A is within the stan-
dard, replace the shift fork or shift piece with a
new ones.
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Mainshaft Assembly
Clearance Inspection
NOTE; lf replacement is required, always replace the
synchro sleeve and hub as a set.
L Support the bearing inner race with a socket. and
Dush down on the mainshaft.
2. Measure the clearance between 2nd and 3rd oears.
Siandard: 0.06 - 0.21 mm 10.002 - 0.008 in)
Servica Limit: 0.3 mm (0.01 in)
lf the clearance is more than the service limit, mea-
sure the thickness of 3rd gear.
Standard: 34.92 - 34.97 mm {1.375 - 1.377 in)
Service Limit 34.8 mm (1.37 in)
3RD GEAR
lf the thickness of 3rd gear is less than the ser-
vice limit, replace 3rd gear with a new one.
lf the thickness of 3rd gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one.
13-24
+
4. Measure the clearance between 4th gear and the
spacer coIar,
Standard: 0.06 - 0.21 mm {0.002 - 0.008 in)
Servic€ Limit: 0.3 mm {0.01 inl
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer collar,
Standard: 26.03 - 26.08 mm {1.025 - 1.027 inl
Service Limit: 26.01 mm {1.02,[ in]
o[-l:-g;;em
fp-rro.ERcoLLAR
6.tf distance @ is less than the service limit, replace
the sDacer collar with a new one.
lf distance @ is within the service limit. measure
the thickness of 4th gear.
Standard: 31.42 - 31.'17 mm 11.237 - L239 inl
Sarvicc Limit:31.3 mm {1.23 in)
lf the thickness of 4th gear is less than the ser-
vice limit, replace 4th gear with a new one.
lf the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one,
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7. Measure the clearance between the spacer collar
and 5th gear.
Standard: 0.06 - 0.21 mm {0.002 - 0.008 in)
Service Limit: 0.3 mm {0.01 in)
MAINSHAFT
SPACER COLLAR
8.
SOCKET5TH GEAR
lf the clearance is more than the service limit, mea-
sure distance @ on the spacer collar
Standard: 26.03 - 26.08 mm 11.025 - 1.027 in)
S€rvico Limit: 26.01 mm (1.024 in)
9.
SPACERCOLLAR
5TH GEARSIDE
lf distance @ is less than the service limit, replace
the spacer collar with a new one.
lf distance @ is within the service limit, measure
the thickness of sth gear.
Standard: 30.92 - 30.97 mm (1.217 - 1.219 in)
Service Limit: 30.8 mm (1.21 in)
r-- ,,srH GEAR
gt Fq
I .J'-----!--\--J-l
lf the thickness of 5th gear is less than the ser-
vice limit, replace 5th gear with a new one.
li the thickness of sth gear is within the service
limit, replace the sth synchro hub with a new
one.
Disassembly
1. Support 5th gear on steel blocks, and press the
mainshaft out of the 5th synchro hub, as shown. Do
not use a jaw-type puller, because it can damage
the gear teeth.
PRESS
I
ACHMENT
In the same manner as above, support the 3rd gear
on steel blocks. and press the mainshaft out of the
3rd/4th svnchro hub, as shown.
PRESS
I
BLOCKS
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Mainshaft Assembly
Inspection
1.Inspect the gear surface and bearing surface for
wear and damage, then measure the mainshaft at
points A, B, and C.
Standard:
A (Ball bearing surface): 27.987 - 28.000 mm
11.1018 - 1.1024 inl
B (Needle bearing surfacel: 37.984 - 38.000 mm(1.4954 - 1.4961 inl
C {Bafl bearing surfacel: 27.977 -27.990 mm
(1.1015 - 1.1020 inl
Service Limit: A:27.94 mm (1.100 in)
B: 37.93 mm (1.'193 inl
C: 27.94 mm 11.100 inl
Inspect oil passages Ior clogging.
lf anv oart of the mainshaft is less than the service
limit. reolace it with a new one.
2. Inspect for runout.
Standard: 0.02 mm (0.0008 in) max.
Service Limit: 0.05 mm 10.002 inl
NOTE: Support the mainshaft at both ends
sh own.
lf the runout is more than the service limit, reDlace
the mainshaft with a new one.
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Clearance Inspection
NOTE: lf replacement us required, always replace the
synchro sleeve and hub as a set.
1. Measure the clearance between the lst oear and
thrust washer.
Standard: 0.06 - 0.18 mm (0.@2 - 0.007 in)
Servica Limit:0.23 mm {0.009 in)
THRUST WASHER
2.lf the clearance is more than the service limit, mea-
sure the thickness of the thrust washer.
Standsrd: 1.95 - 1.97 mm (0.077 - 0.078 in)
3. lf the thickness is less than the standard, reDlace the
thrust washer with a new one. lf the thickness is
within the service limit, measure the thickness of
the 1st gear.
Standard: 26.95 - 27.00 mm (1.061 - 1.063 inl
lf the thickness of 1st gear is less than the stan-
dard, replace 1st gear with a new one.
lf the thickness of lst gear is within the standard.
replace 1sv2nd synchro hub with a new one.
{cont'd}
13-29
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Countershaft Assembly
Clearance Inspection (cont'dl
4. Measure the clearance between the 2nd qear and
3rd gear.
Standard: 0.07 - 0.1,1 mm (0.003 - 0.006 inl
Service Limit:0.18 mm (0.007 inl
FEET.ERGAUGE
!t .-]
lf the clearance is more than the service limit. mea-
sure the thickness of the spacer.
Standard: 29.07 - 29.09 mm (l.14il - 1.145 inl
13-30
6. lf the thickness is less than the standard, reDlace the
spacer wrln a new one.
lf the thickness is within the standard, measure the
thickness of the 2nd gear.
Standald: 28.92 - 28.97 mm (1.139 - 1.141 in)
lf the thickness of 2nd gear is less than the stan-
dard, replace 2nd gear with a new one.
lf the thickness of lst gear is within the standard,
replace 1sv2nd synchro hub with a new one.
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