honda cr v 19997 2000 User Manual
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![Page 459
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...](http://img.usermanuals.tech/thumb/34/48204/w64_honda-cr-v-19997-2000-service-manual-458.png "Page 459
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...")
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 lndex Note the Iollowing during reassembly: . The 3rd/4th, and 5th synchro hubs, and the ball bearing are installed with a press. . Installthe angular ball bearing with the thin-edged outer race facing the stop ring prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th svnchro hubs, however, should be installed with a press before lubricating them ANGULAR EALL BEARINGCheck for wear and operation.Note the directionof installation.SYNCHRO RINGInspection, page l3 37 SYNCHRO HUBlnspection, page 13-36 SYNCHRO SLEEVEInspection, page 13 36 SPRING SYNCHRO SYOP RING TAPER RING BEARINGCheck Ior wear and operataon. COLLAR RINGInspection, page 13-37 SYNCHRO SPRING SYNCHRO HUBInspection, page 13_36 SYNCHRO SLEEVEInspection, page 13 36 SPFING RINGInspection, page 13_37 GEARInspection, page 13_25, 37 COLLARInspection, page 13-24, 25 GEARInspection, page 13 24, 37 Inspection,page 13-37 3RD GEARInspeclton,page 13 24,37 BEARINGCheck for wearano operalton. Inspection, page 13 26 NEEDLE BEARINGCheck for wear and operat,on. 13-23 www.emanualpro.com
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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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 - 00301 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 Index NOTE: 3 The 3rd, 4th. and sth gear are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd, 4th, and sth gears, however. should be installed with a press before lubricating them. LOCKNUT Replace.127-o-127N.m 113-0- 13kstmi \94-0- 9.trbtft / IST/2ND SYNCHRO HUBInspection, page 13 36 Check lor wear anddamage. THRUST WASHERInspection, page 13-29 DAMPER WASHER AEARINGCheck for wear and ooeration. BEARINGCheck for wear andoperation. GEAR 4TH GEAR 3RD GEAR GEAR SPNING DOUBI.f CONE Inspection, page 13-37 1ST GEARInspection, page 13 29,37 BEARINGCheck tor wear and operation. Inspection, page 13-30, 37 NEEDLE BEARINGCheck for wear and oPeration SPACERSelection, page 13-30 DAMPERCheck for wear and damage. DOUBLE CONE Inspection, page 13-37 SPRING www.emanualpro.com
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.
{contd}
13-29
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Countershaft Assembly Clearance Inspection (contdl 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. www.emanualpro.com
Disassembly 1. 2. Securely clamp the countershaft assembly in a bench vise with wood blocks. SPRIiIG WASHEF BETICHvtsE W(X)D BLOCKS Raise the locknut tab from the groove in the coun- tershaft, then remove the locknut and the spring washer. Remove the ball bearing using a press as shown. CHISEL 4. Remove the Jriction damper from the spacer using a press and a socket. Support lst gear on steel blocks, and press the countershaft out of 3rd gear. PRESS t 5. PRESS I 3RD GEAR 1ST GEAR FRICTION DAMPERInspect lor wear and damage. 13-31 www.emanualpro.com