honda cr v 19997 2000 User Manual
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![Page 438
Release Bearing
4. Torque the mounting bolts in a crisscross pattern as
shown. Tighten the bolts in several steps to prevent
warping the diaphragm spring.
8 x 1.25 mm25 N.m (2.6 kgf.m, 19lbfft)
Remove the special tools.
Check the diaphragm spring fingers for height (see
page 12-7].
5.
6.
Removal/lnspection
1. Remove the release fork boot from the clutch hous-
Ing.
RELEASEBEABING
RELEASEFORKBOOT
\
RELEASE FORK
Remove the release fork and release bearing from
the clutch housing.
Check the release bearing...](http://img.usermanuals.tech/thumb/34/48204/w64_honda-cr-v-19997-2000-service-manual-437.png "Page 438
Release Bearing
4. Torque the mounting bolts in a crisscross pattern as
shown. Tighten the bolts in several steps to prevent
warping the diaphragm spring.
8 x 1.25 mm25 N.m (2.6 kgf.m, 19lbfft)
Remove the special tools.
Check the diaphragm spring fingers for height (see
page 12-7].
5.
6.
Removal/lnspection
1. Remove the release fork boot from the clutch hous-
Ing.
RELEASEBEABING
RELEASEFORKBOOT
\
RELEASE FORK
Remove the release fork and release bearing from
the clutch housing.
Check the release bearing...")
![Page 439
Release Bearing
lnstallation
NOTE: Use only Super High Temp Urea Grease (P/N
08798 - 9002).
1. With the release fork slid bet\iveen the release bear-
ing pawls. install the release bearing on the main-
shaft while inserting the release tork through the
hole in the clutch housing.
lPlN 08798 - 9002)0.,1- 1.0 I (0.01 - 0 04 ozl
(P/N 087989002)
(P/N 08798 9002)
1.0 - 1.6 g
{0.0,1 - 0,06 ozl
-6.l(P/N 08798 -
r iz]))
| (,4\1t1t
/\[wRELEASEFORKBOOT
Align the detent of the release fork with the release
fork...](http://img.usermanuals.tech/thumb/34/48204/w64_honda-cr-v-19997-2000-service-manual-438.png "Page 439
Release Bearing
lnstallation
NOTE: Use only Super High Temp Urea Grease (P/N
08798 - 9002).
1. With the release fork slid bet\iveen the release bear-
ing pawls. install the release bearing on the main-
shaft while inserting the release tork through the
hole in the clutch housing.
lPlN 08798 - 9002)0.,1- 1.0 I (0.01 - 0 04 ozl
(P/N 087989002)
(P/N 08798 9002)
1.0 - 1.6 g
{0.0,1 - 0,06 ozl
-6.l(P/N 08798 -
r iz]))
| (,4\1t1t
/\[wRELEASEFORKBOOT
Align the detent of the release fork with the release
fork...")
Special Tools ll Ref. No. I Tool NumberDsscriptionOty I Page Roterence o o,6) @-o \9 a @6r @ o @ @ @ @ @ @ @ @ @ 07GAD - PG40100 07GAJ - PG20110 07GAJ - PG20130 07HAJ - PK40201 07JAC - PH80000 07JAD - PH80101 07JAD - PH80400 07LAD - PW50601 07RAB - 0020000 07746 - 0010100 07746 - 0010300 07746 - 0010400 07746 - 0010500 07746 - 0010600 07746 - 0030100 07746 - 0030300 07746 - 0030400 07749 - 0010000 07947 - SD90200 07979 - PJ40001 Driver Attachment Mainshaft Holder Mainshaft Base Preload Inspection Tool Adjustable Bearing Remover Set Driver Attachment Pilot, 28 x 30 mm Attachment, 40 x 50 mm Companion Flange Holder Attachment,32 x 35 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 62 x 68 mm Attachment, 72 x 75 mm Driver, 40 mm l.D. Attachment. 30 mm l.D. Attachment, 35 mm l.D. Handle Attachment Magnet Stand Base 1 1 1l 1 1 1 1 1 1I 1 1 1 1 13-43 13-66 13-66 13-41 13-62. 63 13-43, 53 13-43 13-39, 49 13-48,54,57,58 13-18, 68 13-27,34, 62 13-40. 51t3-40, 50. 51, 61, oz, oJ 13-40 13-27 ,34,35, 49, tJ-5C 13-27,34 13-14,27.34, 40, 43, 49, 50, 51, 53, 61,62,63,6813-49 13-66 * Must be used with commercially available 3/8 - 16 Slide Hammer. o@(9ta\ oG) ,d,(oo@(9(}@o@ .A IAa 5-z Special Tools www.emanualpro.com
MaintenanceBack-up Light Switch
Transmission Fluid
NOTE: Check the fluid with the engine OFF and vehicle
on level ground.
1. Remove the filler plug. then check the level and
condition of the fluid.
FILLER PLUG44 N.m {4.5 kgf.m. 33 lbf ftl
ll
Ptopet Level
\--ril /
HllllllTl /
Hllllrlll /_rf-F{--rno..
ll| | Replaco.
The fluid level must be up to the filler hole. lf it is
below the hole, add fluid until it runs out. then rein-
stall the tiller plug with a new washer.
lf the transmission fluid is diny, remove the drain
plug and drain the fluid.
FILLEB PLUGa,a N.m 14.5 kgf..n. 33 lbtftl
DRAIN PLUG39 N m (4.0 kgf.m, 29 lbfft)WASHERReplace.
Reinstall the drain plug with a new washer. and
refill the transmission fluid to the proper level.
NOTE: The drain plug washer should be replaced at
every fluid change.
Reinstall the filler plug with a new washer.
Fluid Capacity
1.7 / {1.8 US qt, 1.5 lmp qtl at oil change
2.1 ! 12.2 US qt, 1.A lmp qtl at overhaul
Alwavs use Genuine Honda Manual Transmission
Fluid (MTF). Using motor oil can cause stiffer shift-
ind because it does not contain the proper additives.
Test/Replacement
1. Disconnect the connectors from the switch.
Terminal side oImale lerminals
BACK.UP LIGHT SWTTCHr 25 N.m 12.5 kgt m, 18 lbf.ftl
WASHERReplace.
Check for continuity between the No. 1 and No. 2
terminals.
. There should be continuity when the shift lever
tnto reverse.
. There should be no continuity when the shift
lever in position except reverse,
lf necessary, replace the switch.
13-3
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Transfer Assembly
lnspection
@ Make sure tifts, iacks, and satety stands
are placed properly (see section 1).
L Raise the front of the vehicle, and support it with
safety stands (see section 1).
2. Set the parking brake, and block both rear wheels
securely.
3. Shift to neutral oosition.
4. Make a reference mark across the DroDeller shaft
and the transfer assembly flanges,
REFERENCE
8 x 1.25 mm32 N.m (3.3 kg{.m.24 rbf.ftlReplace.
Separate the propeller shaft from the transfer
assemDty.
5.
13-4
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 in)
COMPAf{ION FI-ANGE
1.lf the measurement is out of specification, remove
the transfer assembly and adjust transfer gear back-
lash (see page 13-44 thru 13-61).
Check the transfer oil seal for damage and fluid
teaKs.
lf oil seal replacement is required, remove the trans-
fer assembly, replace the oil seal, and adjust the
total starting torque (see page 13-44 thru 13-61).
NOTE: Do not replace the oil seal when the transfer
assembly is installed on the transmission.
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Removal
!@@ Make sure the lifts, i8cks. and safety stands
are placed properly {see section 1}.
1. Raise the front of the vehicle, and support it with
safety stands (see section 1).
2. Set the parking brake, and block both rear wheels
securely.
3. Drain the manual transmission fluid Reinstall the
drain plug with a new sealing washer.
4. Disconnect the heated oxygen sensor (HO2S) con-
nector.
SELF.L(rcKNGNUTReplace.
SELF-LOCKI{GNUTReplac€.
5. Remove exhaust oipe A.
6. Make reference marks across the propeller shaft
and the transfer assembly flanges
Separate the propeller shaft from the transfer
assembly flanges,
Remove the rear stiffener, then remove the transfer
assembly.
NOTE: While servicing the transfer assembly, do
not allow dust or other foreign particles to enter the
transmission.
7.
REFEREI{CE iARKS
Replace.
Replace.
13-5
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Transfer Assembly
lnstallation
1. Install a new O-ring on the transfer assembly.
8 x 1.25 mm24 N.m (2.4 kgt m,17 rbt.ftl
10 x 1.25 mm44 N.m (4.5 kgJ.m,
2.
DOWEL PIN
Replace.TRANSFEBASSEMBLY
Clean the areas where the transfer assembly con
tacts the transmission with solvent or carburetor
cleaner, and dry with compressed air. Then apply
MTF to the contact areas.
Installthe transfer assembly on the transmission.
NOTE: While installing the transfer assembly on
the transmission, do not allow dust or other foreign
particles to enter the transmission.
lnstall the rear stiffener.
Install the propeller shaft to the transfer assembly
by aligning the reference marks,
8 x1.25 mm32 N.m 13.3 kg{.m,24 tbf.ftl
REFERENCE MARKS
6. Install the exhaust pipe A,
GASKETEXHAUST PIPE A
HO2S CONNECTOR
10 x 1 .25 mm54 N.m (5.5 kgt m,40 tbtfttReplace.
SELF.LOCKING
NUT8 x 1.25 mm16 N.m {1.6 kgf.m,12 tbt.ft)Replace.8 x 1.25 mmzzN.m l2.2kg!-m,16 rbf.trtReplace.
7.Connect the heated oxygen sensor (HO2S) connector.
Relill the transmission with MTF (see page 13-3).
Start the engine, and run it to normal operating tem-
perature (the radiator tan comes on). Turn the
engine off. and check fluid level.
8.
9.
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Transmission AssemblY
Removal
@FMak. sw. iack and safety stands are placed propel-
ly, and hoist brackets are attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the batterY.
2. Remove the intake air duct and air cleaner houslng
(see section 5).
3. Remove the slave cylinder and clutch hose bracket
NOTE:
. Do not operate the clutch pedal once lhe slave
cvlinder has been removed.
. Take care not to bend the clutch line.
4. Disconnect the
ground cable.
starter cables and transmission
TRANSMISSIONGROUND CABLE
Disconnect the back-up light switch connector and
wire harness clamP.
(contd)
13-7
WIRE HARNESS CLAMP
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Transmission Assembly Removal (contdl 6. Remove the cotter pins, washers, plastic washers. cable from the levers. then remove the steel shift cable, and select 1. 8. Remove the cable bracket from the clutch housing. Disconnect the vehicle speed sensor (VSS) connec-tor. -------------.2 13-8 9. Remove the bolts. four upper transmission mou nting 10. 11. Drain transmission fluid (see page 13-3). Remove the guard bar and the splash shield. MOUNNNG BOLTS www.emanualpro.com
12. Disconnect the heated oxygen sensor (HO2S) con-
nector, then remove the exhaust pipe A.
GASKETReplace.
HO2S CONNECTOR
NUTReplace.
EXHAUST
SELF.LOCKINGReplace.
GASKETReplace.
Mark reference marks on the joint of the transfer
and the propeller shaft.
8 x 1.25 mmReplace.
Separate the propeller shaft from the transfer
assemDly.
REFERENCE MABKS
14.
15. Remove the cotter pins, and castle nuts. then sepa-
rate the ball ioints from the lower arm (see sectlon
18).
OAMPER PINCH BOLT
CASTLE NUTNUTReplace.
17.
16.
DAMPER FORKFOFKEOLTReplace.
Remove the right damper tork bolt, then separate
right damper fork and damPer.
Pry the right driveshaft out of the differential, and
pry the left driveshaft out of the intermediate shaft
(see section 18).
Pull out the inboard ioint, and remove the right and
left driveshaft (see section 18).
Tie plastic bags over the driveshatt ends. Coat all
precision finished surfaces with clean engine oil
18.
19.
\
{contd}
13-9
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Transmission Assembly Removal (contd) 20. Remove the intermediate shaft. 21.Tie plastic bags over the both ends of the intermedi- ate shaft. Coat all precision finished surfaces withclean engine oil. Remove the rear engine stiffene. and clutch hous-Ing cover. 13-10 23. Remove the right front mounvbracket. RIGHT FRONTMOUNT/BRACKET Place a jack under the transmission, raise it just enough to take it off of the mounts, then remove the transmission mount bracket and transmission mount. TRANSMISSION MOUNT MOUNT BRACKET www.emanualpro.com
25. Remove the transmission mounting bolts and the rear engine mounting bolts. REAR ENGINE MOUNTING BOLTSReplace. TRANSMISSION Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmis- sion jack. NOTE: Take care not to bend the clutch line. Remove the starter motor and hose clamp from the transmission housing. STARTERMOTOR 28. Remove the release tork boot. release bearing, and release fork from the clutch housing RELEASEBEANING 13-1 1 www.emanualpro.com