2000 HONDA CR-V clutch manual transmission

Symptom-to-Com ponent Chart
Hydraulic System (cont'd)
NOTES
See flushing procedure, page l4-264 and 265,
BSet idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
clf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
Dlf the clutch pack is seized or is excessively worn. inspect the other clutches fot wear, and check the orificecontrol valves, CPC valve, and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed. the transmission will not upshift. lf stuck open, the transmission hasno lst gear.
Hlf the 2nd orifice control valve is stuck, inspect the 2nd and 3rd clutch Dacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
Jlf the clutch pressure control valve is stuck closed. the transmission will not shift out of lst gear.
Klmproper alignment of main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
Llf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Mlf the lst clutch feed pipe guide in the end cover is scored by the mainshaft. inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
N' Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged, lf the 4th feed pipe is darrFaged or out of round. replace the end cover.' Replace the mainshaft if the bushing for the l st feed pipe is loose or damaged. lf the 1st feed pipe is dam-aged or out of round, replace it.
oA worn or damaged sprag clutch is mostly a result of shifting the transmission in E!. E, or E positionwhile the wheels rotate in reverse. such as rocking the vehicle in snow.
PInspect the frame for collision damage.
lnspect for damage and wear:
l. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1, 2, 3. and 4 if worn or damaged. lf transmission makes a clicking, grinding, or whirring noise,also replace mainshaft 4th gear, reverse idler gear, and countershaft 4th gear in addition to 1,2, 3, or 4.lf differential pinion shaft is worn, overhaul differential assembly, replace ATF strainer, and thoroughly cjeantransmission, flush torque converter. cooler, and lines,lf bottom of 3rd clutch is swirled and transmission makes gear noise. replace the countershaft and final drivenoear,
Be very careful not to damage the torque converter housing when replacing the main ball bearing. you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the Drooer tools.
SInstall the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
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Road Test
NOTE: Warm up the engine to normal operating temperature (the radiator tan comes on).
1. Before testing, check the transmission fluid level, see page 14-160.
2. Apply the parking brake and block the wheels. start the engine, then shift to E {'97 - 98) or E {'gg - 00) position
while pressing the brake pedal. Press the accelerator pedal and release it suddenly. The engine should not stall.
3. Repeat same test in E position ('97 - 98 models).
4. Test-drive the vehicle on a flat road in the E or E position. Check that the shift points occur at approximate speeds
shown on a flat road. Also check for abnormal noise and clutch slippage.
Throttle position sensor voltage represents the throttle opening. Monitor it with the Honda PGM Tester or as follows:
a. Unbolt the PCM for road testing; reJer to page 14-58.
b. Set the digital multimeter to check throttle position sensor voltage between these terminals on the PCM:
. '97 Model: Between terminals D'! (+) and A9 (-) or A22 {-}
. '98 - OO Models; Between terminals C27 (+) and 820 (-) or 822 {-)
BACKPROBE ADAPTER
BACKPROBE SETorsAz - 001moA(two roquircdl
STACKING PATCH
CORD
DIGiTAL MULTIMETER
{Comm€rcirllY .vailablc}KS-AHM-32-003,or equival.nt
'97 Model:PCM CONNECTORS
'98 - 0O Models:
A l32Pt
Wire side of female terminals
PCM CONNECTORS
B {25Pt c l31P}
(cont'd)
LGl (BRN/BLK)
'. //B 1 l'o ti , jl. to a 2r / / 11111t1.t nait la t1 t213tr / t6t, tl / / / / 1 3 / 10n v
t-'a:IM-&E -Llfiffi-fl)\"".'E
Wire side ot female termanals14-157
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Road Test
(cont'd)
lgrr or E Position:
Upshift
NOTE:
. Lock-upON:The lock-up control solenoid valve A turns ON.. Lock-up OFF: The lock-up control solenoid valve A turns OFF.
4. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th. then shift from E or E position to E position.The vehicle should immediately begin slowing down from engine braking.
5. Check for abnormal noise and clutch slippage in the following positions.
E {1st Gear) Position
Accelerate from a stop at full throttle, Make sure there is no abnormal noise or clutch slippage.Upshifts should not occur with the shift lever in this position.
E (2nd cear) Position
Accelerate from a stop at fuI throttre. Make sure there is no abnormar noise or crutch srippage.Upshifts and downshifts should not occur with the shift lever in this position.
E (Reverse) Position
Accelerate from a stop at full throttle. and check for abnormal noise and clutch slippage.
6. Test in E (Park) Position
Park the vehicle on slope (approx. 16"), apply the parking brake, and shift into E position. Release the brake; the vehi-cle should not move.
Throftle OpsningUnit of sps€dlsi + 2nd2nd * 3rd3rd + ilthLock-up ON
Throttle position sensor
voltage: 0.75 V
mph9-1220-2328-33
km/h15-1945-5334-40
Throttle position sensor
voltage; 2.25 V
mph22-2643-49oz - ott68-74
km/h35-4169-7999 - 108109 - 118
Fully-opened throttle,
Throttle position sensor
voltage: 4.5 V
mph37-43101 - 11190 - 101
k-/h60-69111 - 124163 - 179145 - 163
Downshift
Throttle OpeningUnit ot speedLock-up OFFi{th + 3rd3rd * 2ndznd + lst
Fully-closed throttle,
Throttle position sensor
voltage; 0.5 V
mpn19-231A - 2'l6 - 10 {3rd - 1st)
km/h5t-5D29-3410 - 15 (3rd * 1st)
Fully-opened throttle,
Throttle position sensor
voltage: 4,5 V
mph88-9986-9657 -6426-32
km/h142 - 't59138 - 15492 - 10342-51
14-158
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Stall Speed
Test
CAUTION:
. To prevent transmission damage, do not te3t stall speed for mors than 10 s€€onds at a time'
. Do not shift the lever while raising th€ engine spsed.
. Be sure to remove tho pressuro gauge bofore testing stall speed,
1. Before testing, check the transmission fluid level, s€e page 14-160.
2. Engage the parking brake and block all four wheels
3. Connect the tachometer, and start the engane.
4. Make sure the Ay'C switch is OFF
5. After the engine haswarmed upto normal operating temperature (the radiator fan comes on),shiftinto@ position.
6. Fully press the brake pedal and accelerator for 6 to 8 seconds, and note engine speed '
j. A|ow 2 minutes for cooling, then repeat the test in E, E ('97 - 98). E {'99 - 00}, and E positions. Stall speed should
be the same in E, E, E, tr. and E positions
Stall Speed rpm:
Specitication: 2,550 rpm
S€rvice Limit: ?,400 - 2.700 rpm
TROUBLEPROBAELE CAUSE
Stall rpm high in El, E, E, E and E
positions
ATF pump output is low
Clogged ATF strainer
Pressure regulator valve stuck closed
Slipping clutch
Stall rpm high in E positionSlippage of 1st clutch, 1st-hold clutch, or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 2nd clutch
stall rpm high in E! or E positionSlippage of 1st clutch or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 4th clutch
Stall rpm low in [dd, E. E, E, ana E
positions
. Engine output low
. Torque converter one-way clutch slipping
14-159
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Pressure Testing
Changing
NOTE: Keep all foreign particles out of the transmis-
sion.
1. Bring the transmission up to operating temperature
(the radiator fan comes on) by driving the vehicle.
Park the vehicle on level ground. turn the engane
off. then remove the drain Plug.
NOTE: lf a cooler flusher is to be used, see page
14-264 and 14-265.
TRANSMISSIONEND COVER
DRAIN18 x 1.5 mmSEALING WASHEBReplace.49 N.m {5.0 kgt.m, 36 lbf.tl)
Reinstall the drain plug with a new sealing washer,
then refill the transmission with the recommended
fluid to the uDper mark on the dipstick. Always use
Genuine Honda Premium Formula Automatic
Transmission Fluid (ATF) Using a non-Honda ATF
can affect shift quality.
Automatic Transmission Fluid Capacity:
4WD;
2.9 { (3.1 US qt. 2.6 lmp qt) 8t change
5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul
2WD:
2.7 | l2.S US qt,2.1lmp qtl ai change
5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul
2.
a
a
1.
Wlrile testing, be careful of the rotaling wheols.
Mako sure lifts, iacks, and safety stands ar€ placed
properly (see scction 11.
Before testing, be sure the transmission fluid is
filled to the proPer level.
4WD:
Raise the vehicle (see section 11.
2WD:
Raise the front of the vehicle, and make sure it is
securely supported. Set the parking brake, and block
both rear wheels securely.
Allow all four wheels {4WD) or front wheels (2wD}
to rotate freely.
Warm up the engine (the radiator fan comes on),
then stop it and connect the tachometer.
Connect the oil pressure gauges to each inspection
hole securely, and do not allow dust or other foreign
particles to enter the inspection holes.
TOROUE: 18 N'm ll.8 kgf'm, 13 lbf'ft)
5.
A/T PRESSURE HOS€,2210 mm07MAJ - PYiOllA
{4 Requircd}
,4'/"' ,a
W'
A/T PRESSURE HOSEADAPTER07MAJ - PYt0120(il Rcquiledl
6. Measure the following Pressure:. Line Pressure ..........,14-162
. 1st. 1st-hold Clutch Pressure .............'. 14-162
. 2nd,3rd and 4th Clutch Pressure .......... 14-163
7. Install new sealing washers and the sealing bolts in
the inspection holes, and tighten to the specified
toroue.
(cont'd)
A/T OIL PRESSUREGAUGE SET W/PANEL07{06 - 0020400
/4\\-J-- (
+..\.-.\-'-\
A/T LOW PBESSUREGAUGE w/PANEL07406 - 0070300
TOROUE: 18 N'm 11.8 kgf'm, 13 lbf'ft)
14-161
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r] REVERSE IDLER GEAR SHAFT/HOLDER'A N€EDLE BEARING
..] TRANSMISSION HOUSING
al TRANSMISSION HOUSING OIL SEAL Replace.g SET BING.80 mm Selecrive part
O REVERSE GEAR COLLABE couNTERSHAFT REVERSE GEAB
.9,] NEEDLE BEARINGi9 LOCK WASHER Replace..1!i REVERSE SHIFT FORKO REVERSE SELECToRiJ. REVERSE SELECTOR HUBii' COUNTERSHAFT 4TH GEAR.14 NEEDLE BEARINGiD D|STANCE coLLAR,28 mm Selective part(i3 COUNTERSHAFT 2NO GEABi7-] THRUST NEEDLE BEARING(10 COUNTERSHAFT 3RD GEAR(9 NEEDLE BEARINGE9 COUNTERSHAFI3RD GEAB COLLAR.li THRUST NEEDLE BEARING.?) SPLINEO WASHER,,O 3RD CLUTCH ASSEMBLY
€1 O-RING Beplace.i23 COUNTERSHAFT
4i SHIFT CONTROL SOLENOID COVER
?Z] HARNESS CLAMP BRACKET
?9] SHIFT CONTROL SOLENOID VALVE A/B ASSEMBLY
8 HARNESS CLAMP BRACKET
GI SHIFT CONTROL SOLENOID VALVE FILTER/GASKET
(4 MAINSHAFT 2ND GEARi49 NEEDLE BEARING
@ THRUST NEEDLE BEARING(49 MAINSHAFT
@r SEAL|NG R|NG,35 mm
O SEALING RING,29 mm
@ NEEDLE BEARING
.49 SET RING
€) lST.HOLD CLUTCH ASSEMBLY
O o-RING Replace.6E THRUST WASHER
€9 THRUST NEEDLE BEARING
6' NEEDLE EEARING
€ir SUB-SHAFT 4TH GEAR
6 THRUST NEEDLE BEARING
@ SUB.SHAFT 4TH GEAR COLLAR@ sUB-sHAFf
6I NEEDI-E B€ARING STOP
@ NEEDLE BEARING(6t ATF GUIDE CAP Replace.(64 TRANSMISSION HANGEB
@ BREATHER CAP
i@ MAINSHAFT SPEED SENSOR
6i O-RING Replace.
6D REVERSE IDLER GEAR
@r DOWEL PlN, 14 x 25 mm.6d SNAP RINGS
QlI SUB.SHAFT TRANSMISSION HOUSING BEARING
E) MAINSHAFT TRANSMISSION HOUSING BEABING.2, COUNTERSHAFI TRANSMISSION HOUSINGBEARING
@[E
t,n9t0@)@),lD
04
@
@@:.ro)
ai
Replace-SNAP RINGTHRUST WASHEBTHRUST NEEDLE BEARINGMAINSHAFT 4TH GEARNEEDLE BEARINGSTHRUST NEEDLE BEARINGMAINSHAFT 4TH GEAB COLLAR2NO/4TH CLUTCH ASSEMBLYO-RING Replace.THRUST WASHER,36.5 x 55 mm Selective partTHRUST NEEOLE BEARING
DOWEL PlN, 14 x 25 mmCONNECTOR BRACKETATF MAGNETDOWEL PlN, 14 x 20 mmTRANSMISSION HOUSING GASKET Replace.DIFFERENTIAL ASSEMBLYDOWEL PlN, 10 x 12 mmO-RING Replace.TRANSFER ASSEMBLYTOROUE CONVERTER HOUSING OIL SEAL Replace.TOROUE CONVERTER HOUSING
TOROUE SPECIFICATIONS
Bolt/Nut No.Torque ValueSizeRgmarks
6A
6B
10A
12 N.m (1.2 kgf.m,8.7 lbf.ft)
14 N.m (1.4 kgf.m, 10 lbift)
44 N.m (4.5 kgf.m,33 lbf.ft)
6x 1.0 mm
6x 1.0 mm
10 x 1.25 mm
14-177
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oatl,6
@!.,
ao6l
@o@@@@@o@@@)@@@@@@@@@@)
@@@@)@@@@@@@
REVERSE IDLER GEAR SHAFT,/HOLDERNEEOLE BEARINGTRANSMISSION HOUSINGTRANSMISSION HOUSING OIL SEAL R€place.SET RING,80 mm Selective part
REVERSE GEAR COLLARCOUNTERSHAFT REVERSE GEARNEEDLE BEARINGLOCK WASHER Replace.REVERSE SHIFT FORKREVERSE SELECTORREVERSE SELECTOR HUBCOUNTERSHAFT 4TH GEARNEEDLE BEARINGDISTANCE COLLAR,28 mm Selective pan
COUNTERSIIAFT 2ND GEARTHRUST NEEDLE BEARINGCOUNTERSHAFT 3RD GEARNEEDLE AEARINGCOUNTERSHAFT 3RD GEAR COLLARTHRUST NEEOLE BEARINGSPLINEO WASHER3RD CLUTCH ASSEMBLYO-RINGS Replace.COUNTERSHAFTSHIFT CONTROL SOLENOID COVERHARNESS CLAMP BRACKETSHIFT CONTROL SOLENOID VALVE A/B ASSEMBLYHARNESS CLAMP BRACKETSHIFT CONTROL SOLENOID VALVE FILTER/GASKETReplace.SNAP RINGTHRUST WASHERTHRUST NEEDLE BEARINGMAINSHAF ,ITH GEARNEEDLE BEARINGSTHRUST NEEDLE BEARINGMAINSHAFT 4TH GEAR COLLAR2ND/4TH CLUTCH ASSEMBLYO-RINGS ReDlace.THRUST WASHER,36.5 x 55 mm Selective part
THRUST NEEDLE BEARING
MAINSHAFT 2ND GEARNEEDLE BEARINGTHRUST NEEOLE BEARINGMAINSHAFTSEALING RINGS,35 mmSEALING RING. 29 mmNEEDLE BEARINGSET RINGlST-HOLD CLUTCH ASSEMSLYO-RINGS Replace.THRUST WASHERTHRUST NEEDLE BEARINGNEEDLE BEARINGSUB.SHAFT 4TH GEARTHRUST NEEDLE BEARINGSU&SHAFT,ITH GEAR COLLARSUB.SHAFTNEEDLE BEARING STOPNEEDLE BEARINGATF GUIDE CAP Replace.TRANSMISSION HANGERBREATHER CAPMAINSHAFT SPEED SENSORO-RING Reolace.REVERSE IDI.fR GEARDOWEL PlN, lil x 25 mmSNAP RINGSSU&SHAFT TRANSMISSION HOUSING AEARINGMAINSHAFT TRANSMISSION HOUSING BEARINGCOUNTERSHAFT TNANSMISSION HOUSINGBEABINGDOWEL PlN, 14 x 25 mrnCONNECTOR BRACKETDOWEL PlN, 14 x 20 mmTRANSMISSION HOUSING GASKET Replace.DIFFERENTIAL ASSEMBLYTOROUE OONVERTER HOUSING OIL SEAL Replace.TOROUE CONVERTER HOUSING
@@@@@@@@@@@@@@@@@@@@@@@)@@@@@@@
@@@@@@@
TOROUE SPECIFICATIONS
Boli/Nut No.Torque ValueSizeRemarks
6B
10A
12 N.m (1.2 kgf.m,8.7 lbf.ft)'14 N.m (1.4 kgim, 10 lbf'ft)
44 N.m (4.5 kgim, 33 lbf.ft)
6x 1.0 mm
6x1.0mm
10 x '1.25 mm
14-1A3
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End Cover
Removal
NOTE:
o The illustration shows the 4WD automatic transmission; the 2WD is similar.. cleanall parts thoroughly in solvent or carburetor cleaner, and drythem with compressed air.. Blow out all passages.
. When removing the transmission end cover, replace the following:- End cover gasket- Lock washer- O-rings- Shaft locknuts- Conical spring washers- Sealing washers
END COVER GASKET
MAINSHAFT LOCKNUT
CONICAL SPRING WASHER
6 x 1 .0 rhm EOLTS
PARK PAWL
A/T GEAR POSMONSwlTCH COVER
NEEDI.T BEARING
SUB.SHAFT LOCKNUT
CONICAL SPRINGWASHER
LINE AOLT
ATF COOI.f B LINES
14-186
PAwL 7// Locx wASHER
'sHAFr 9/ ?ARK srop
o-- Ay' couNTERsHAFr
G-€ LocKNUr!€ / ..t,"o, "oo
A/T GEAR POSMONSW|TCH HARNESS CLAMP
CONICAL SPRINGWASHCR
A/T GEAR POSITION
PARK GEAR
Y CLUTCH
lST GEAR
NEEDLE BEARING
1ST CLUTCH ASSEMBLY
THRUST WASHER
THRUST NEEDLE AEARING
O.RINGS
\\
SUB.SHAFT 1ST GEAR
MAINSHAF? 'ST GEAR
MAINSHAFT 1STGEAR COLLAR
SEALING WASHERS
!€'-l
I"EVERSPRING
COUNTERSHAFTlST GEAR COLLAR
PAWL
lt1/ sroe
Y plwl f
L/'SPRING
LOCKNUT
LINE BOLTSEALING WASHERS
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