honda cr v 19997 2000 User Manual
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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. (contd) BACK.UP RING 14-245 www.emanualpro.com

Transfer Assembly Reassembly (contd) 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. Install the special tool on the companion flange, then tighten the transfer driven gear shaft locknut while measuring the starting torque of the transfer driven gear shaft. STARTING TOROUE: 0.s8 - 1.39 N.m {10.0 - 14.2 kgf.cm,8.68 - 12.3 lbf.in) TIGHTENING TOROUE: 132 - 216 N.m {13.5 - 22.0 kgf.m, 98 - 159 lbf.ft) NOTE; . Rotate the companion flange several times to seat the tapered roller bearing, then measure the starting torque, . lf the starting torque exceeds 1.39 N.m (14,2 kgf.cm, 12.3 lbf.in), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the locknut loose. . lf the tightening torque exceeds 216 N.m (22.0 kgf.m, 159 lbfft), replace the transfer spacer and reassemble the parts. . Write down the measurement of the starting torque: it is used to measure the total starting rorque. COiPANIOI{ FLANGE HOLDER07MB - TBi(tloA otORAB - TB,.|}IOB TOFOUEWRENCH HOLDER HANDLE07JAB - 001020A 27. 14-246 28. Stake the locknut into the transfer driven gear shaft using a 3,5 mm punch as shown. 0.7 - 1.2 mm{0.03 - 0.05 inl PUNCH3.0 - 3.5 mm10.12 - 0.1{ inl Point to bestaked. 29. Install the transfer shaft in the transfer housing, then install the tapered roller bearing, transfer shaft collar,25 mm thrust shim, transter drive gear, coni- cal spring washer, and transfer shaft locknut on the transfer shaft, NOTE: . Coat the threads of the locknut and transler shaft with ATF before installing the locknut.. Install the conical spring washer in the direction snown. TRANSFER SHAFT TRANSFER HOUSII{G THRUST SHIM. 25 mrt|Selective part CONICAL SPRINGWASHERReplace. \t)t--/./ .,.-,.,\ Replace. www.emanualpro.com

30. 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. {The locknut has left-hand threads,) TOROUE: 118 N.m (12.0 kgf.m, 87 lbt.ft) Stake the locknut on the transfer shaft using a 3.5 mm ounch. al 14 mm ALI-EN WRENGH 0.7 - 1.2.nm{0.0:1- 0.C5 in}PU CH3.0 - 3.5 rnm Total Starting Tolqu€ Insp€ction and Adiustment 32. TemDorarilv install transter cover A without the O- flng. HOUSING TMNSFER COVER A e € v E- 8x1.25mm24 Nm {2.i1kgtm, r? btftl Secure the transfer housing in a bench vise with soft jaws, then rotate the companion flange several times to fit the tapered roller bearing. To prevent damage, always use soft jaws or equivalent materi- als betlveen the transfer housing and the vise. Measure the total starting torque. TOTAL STARTING TOROUE: 1.70 - 2.08 N.m {17.3 - 21.2kgl.cm,15.0 - 18.i1 lbf.in} + Transler Driven Gear Sh8ft Starting Torque Value lwroto down in step 27). (contd) 5J. 34. 14-247 www.emanualpro.com

Transfer Assembly 35. Reassembly (contdl 36. Remove taansfer cover A. lf the measurement is out of specification, remove the 68 mm thrust shim from transfer cover A by heating the cover to almost 212F (100C) using a heat gun. Do not heat the cover higher than 212F(100C). Let the cover cool to room temperature before adjusting the starting torque, lf the measurement is within the specification, go to step 40. HEAT GUN 14-248 37. Select the 68 mm thrust shim. THRUST SHIM, 58 mm Shim No.Part NumberThickness zv23974-P1C-O201.41 mm (0.056 in) zw23975-P1C-O201.44 mm (0.057 in) zx23976-P1C-0201.47 mm (0.058 in) ZY23977 - P1C - O201.50 mm (0.059 in) zz23978-P1C-0201.53 mm 10.060 in) 23941 PW5 - 0001.56 mm {0.061 in) B23942-PWs-0001.59 mm 10.063 in) c23943 - PWs 0001.62 mm (0.064 in) D23944-PW5-0001.65 mm {0.065 in} E23945 PWs - 0001.68 mm (0.066 in) F23946 PWs - 0001.71 mm (0.067 in) G23947 PWs - 0001.74 mm (0.069 ini 23948-PW5-0001.77 mm (0.070 ini 23949 PW5 0001.80 mm (0.071 in, J23950-PWs-0001.83 mm {0.072 ini K23951 - PWs - 0001.86 mm (0.073 in L23952 PW5 - 0001.89 mm (0.074 in 23953 PWs - 0001.92 mm (0.076 in N23954 PW5 - 0001.95 mm (0.077 in o23955 PW5 0001.98 mm (0.078 in P23956 - PWs 0002.01 mm (0.079 in o23957-PW5-0002.04 mm (0.080 in R23958, PWs 0002.07 mm (0.081 in s23959-PW5-0002.10 mm (0.083 in T23960 PW5 - 0002.13 mm (0.084 in U23961 PW5 - 0002.16 mm (0.085 in 23962 PWs 0002.19 mm (0.086 in 23963 - PW5 0002.22 mm (0.087 in X23964 - PW5 0002.25 mm (0.089 in 23965 PW5 - 0002.28 mm (0.090 in z23966 PWs 0002.31 mm (0.091 in 23967-PWs-0002.34 mm (0.092 in AB23968-PWs-0002.37 mm (0.093 in) AC23969-PWs-0002.40 mm (0.094 in) AD23970-PW5-0002.43 mm (0.096 in) M23941 PW8 0002.46 mm (0.097 in) BZ23942-PW8-0002.49 mm (0.098 in) cz23943 - PW8 0002.52 mm (0.099 in) DZ23944 PW8 - 0002.55 mm (0.100 in) EZ23945-PW8-0002.58 mm (0.102 in) www.emanualpro.com

38. Install the 68 mm thrust shim using the special tools. PRESSDRIVER07743 - 001 0000 ATTACHMENT,62x68mrr|077a6 - (x)10500 39.After replacing the 68 mm thrust shim. recheck and make sure the total starting torque is within the specification. AEARING OUTER RACE 40. Install the new O-rings on transfer covers A and B, then installthe covers on the transfer housing 6x1.0mm12 N.m 11.2 kgt.D,8.7 rbf.ftlTRANSFEN COVER B O.RINGReplace. 8 r 1.25 rnm24 N.m 12.4 kgl.m, 17 lbfftl Replace. www.emanualpro.com

Transmission Reassembly NOTE: . The illustration shows the 4WD automatic transmission; the 2WD is similar.. Clean all parts with ATF.. Replace the following parts:- O-rings- Lock washers- Gaskets- Sealing washers- Locknuts and conical spring washers of each shaft ATF FEED PIPE / ATF FEED PIPES145 mm SERVO DETENTBASE(37 -98 modeb onlylATF LUBRICATIONPLATE6x1.0mm 2 Bolts99 - 00 models: 1 Bolts LOCK.UP VALVEBODY LOCK.UP SEPARATORPLATE REGULATOR VALVEBODY DOWEL PIN DOWEL PIN VALVE SPRING STATOR SHAFT - 112mmll, rlT ATFSTRAINER 40 mm j coNrRoLI SHAFT COOLER BELIEF VALVE TOROUE CONVERTERCHECK VALVE 6x1.0mm18olts DETENTARMSHAFT 6x1,0mm97 - 98 models:7 Bolts99 - 00 models:8 Bolts SERVO BODY(97 - 98 models) SERVOSEPARATOR PLATE 6x1.0mm3 Bolts STOP SHAFTBRACKET SECONDARYVALVE BODY OOWEL PIN8x40mm O.RING STOP SHAFTCHECK BALLS 18 ATF FEED PIPE112 mm 6x1.0mm5 Eolts ATF PUMP DRIVENGEAR SHAFT ATF PUMP DRIVEN MAIN SEPARATORPLATE MAIN VALVE EOOY SECONDARYSEPARATOR d---.- PLATE--.- CONTROL I.EVER MOUNTING BOLT6x1.0ftm14 N.m (1.4 kgt.m, 10 tbf.ft)(4WD)SERVO BODY(99 - 00 models) ATF PUMP 6x1.0mm ATF FEEO PIPE ) / 105.8 /,,!.,::(./ afF FEEO,/ ptpEs EP,---!ir{+*a r fpffi4 i x*hi _ \zl 14-250 DRIVE GEAR DOWEL PINTOBOUEHOUSING www.emanualpro.com

1.Install the suction pipe collar and the ATF magnet {2WD) in the torque converter housing, if necessary. lnstall the main seDarator Dlate and the two dowel pins on the torque converter housing, Install the ATF pump drive gear. ATF pump driven gear, and ATF pump driven gear shaft on the torque converter housing. Installthe ATF pump driven gear with its grooved and chamfered side facing down. ATF PUMPGEAR ATF PUMP D{IVEf{GEAR SHAFT ATF PUiPORIVEN GEAR Grooved and chamteredside faces separatorplate. MAIN S€PAR/ATORPLATE 5. o. Loosely install the main valve body with five bolts. Make sure the ATF pump drive gear rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft moves smoothly in the axial and normal operating directions. Install the secondary valve body, separator plate, and two dowel pins on the main valve body. Do not installthe bolts. Install the control shaft in the housing along with the manual valve. lnstall the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm. SEBVO SEPARATOR PLATE 7. DETENT ARMSHAFT OETENT ARM CONTROLSHAFT MANUAL VAIVE OETENT ARM SPRING onlv on the 98 - 00 models, 14-251 1l. 9. 8. 10. Install the servo body and separator plate on the secondary valve body (97 - 98 models: seven bolts,99 - 00 models: eight bolts). lnstall the servo detent base (97 - 98 models only) and the ATF strainer (97 - 98 models: two bolts,99 - 00 models: one boltl. Tighten the five bolts on the main valve body to 12 Nm (1.2 kgf.m, 8.7 lbf.ft). Make sure the ATF pump drive gear and ATF pump driven gear shaft move smoothly. lf they dont, loosen the bolts on the main valve body, and disas- semble the valve bodies. Realign the ATF pump driv- en gear shaft and reassemble the valve bodies, then retighten the bolts to 12 N.m (1.2 kgim, 8.7 lbf.ft). CAUTION: Failure to align the ATF pump driven gear shaft corroctly will rosult in a seizsd ATF pump drive gear or ATF pump drivon gear shaft. ATF PUMP ATFGEARDRIVE GEAR DBIVEN GEARSHAFT Install the stator shaft and stop shaft Install the bolts and the stop shaft bracket on the secondary valve body, then tighten the bolts (three bolts). Install the torque converter check valve, cooler relief valve, and valve springs in the regulator valve body, then install the regulator valve body on the main valve body {one boltl. Install the lock-up valve body, separator plate, two dowel pins and lubrication plate (eight bolts). Installthe one ATF feed pipe in the main valve body, the three ATF feed pipes in the secondary valve, the three ATF feed pipes in the servo body and the one ATF feed pipe in the lock-up valve body. NOTE: lnstall the 105.8 mm ATF feed pipe with its filter side away from the secondary valve body; the filter is on the 105.8 mm ATF feed pipe, which is(contd) 13. 14. 15. 16. www.emanualpro.com

Transmission Reassembly (contd) TRANSMISSION HANGER 6xl.0mm12 N.m (1.2 kgl.m,8.7 rbt.ft) MAINSHAFT SPEEDSENSOB TRANSMISSION HOUSING MOUNNNG BOLT10 x L254,1 N.m {/4WD: 192WD: 18 t f, llf, l gil / COUNTERSHAFT BEVERSE GEAB LOCK WASHER MAINSHAFTSUB.ASSEMBLY OOWEL PIN14x25mm TRANSMISSION HOUSINGGASKET DOWEL PIN14x25mm REVERSE SHIFTFORK DOWEL PIN14 x 20 rnm NEEDLE BEARING REVERSE SELECTOR COUNTERSHAFTSUB.ASSEMBLY DIFFERENTIAL ASSEMBLY TRANSFES ASSEMBLY(4wDl 14-252 www.emanualpro.com

17. 18. 19. 20. 21. Install the sub-shaft assembly in the transmission housing (see page 14-210 and 14-2111. lnstall the ATF magnet (4WD) in the transmission housing, if necessary. Install the reverse idler gear and gear shaft holder (see page 14-231). Install the differential assembly in the torque con- verter housing. Assemble the mainshaft and countershaft sub- assembly (see page 14-206 and 14 207],, then install them together in the torque converter houslng. COUNTERSHAFTSUB-ASSEMBLY Turn the shift fork so the large chamfered hole is facing the fork bolt hole. then install the shift fork with the reverse selector and torque the lock bolt. Bend the lock tab against the bolt head. SHIFI FORK LOCK WASHERBeplace. 6 r l.O mm4 N.m(1.4 ksl.m. 1O lbt.ft) Large chamfered hole 24. Install the reverse gear with the collar and needle bearing on the countershatt. Align the spring pin on the control shaft with the transmission housing groove by turning the control shaft. SPRING PIN CONTROL SHAFT TRANSMISSION HOUSING 25. Place the transmission housing on the torque con- verter housing with a new gasket and the three dowel pins, Make sure that the mainshaft speed sensor is not installed on the transmission housing before installing the transmission housing on the torque converter housing. 26. Install the transmission housing mounting bolts along with the transmission hanger and the connec- tor bracket, then torque the bolts in two or more steos in the seouence shown. NOTE: The illustration shows the 4WD automatic transmission. The 4WD has 19 transmission hous- ing mounting bolts; the 2WD has 18 bolts. TOROUE: 44 N.m {,[.5 kgf.m, 33 lbfft) {contd) 14-253 SPRING PIN TNANSMISSION www.emanualpro.com

Transmission 28. Reassembly (contd) PARX GEAR ONE.WAY CLUTCH BEARING Install the mainshaft speed ssnsor (with new O-ring) on the transmission housing. Install the park lever on the control shaft, theninstall the lock bolt with a new lock washer. Do notbend the lock tab of the lock washer in this step;bend it after checking the park pawl engagement instep 45. Assemble the one-way clutch and the park gear onthe countershaft 1st gear (see page l4-2Og). Lubricate these pans with ATF:. Countershaft threads. Old locknut threads and flat end. Old conical spring washer. Park gear contact area with conical springwasner Install the countershaft 1st gear collar, needle bear-ing, and the countershaft 1st gear/park gear assem-bly on the countershaft. Install the park pawl shaft. pawl spring, pawl. andpawl stop on the transmission housing, thenengage the pawl with th€ park gear. 31. PAWL I I a STOP LOCK BOLT PAWL SHAFT COUNIERSHAFTCOUNTERSHAFTlST GEAR COLLAR 14-254 33. Install the old locknut and the old conical springwasher on ths countershaft. Tighten the old locknutto seat the park gear to the specified torque, thenremove th€ washer and locknut. The locknut hasleft-hand threads. Do not use an impact wrench.Always use a torque wrench to tighten the locknut. TOROUE: 103 N.m {10.5 kgf.m, 75.9 lbnft) 34. Slip the specialtool ontothe mainshaft. MAINSHAFT07GAB - PF50101 or07GAB - PF501q) PARK GEAR www.emanualpro.com