honda cr v 19997 2000 User Manual

							
Countershaft Assembly
Inspection
1. Inspect the gear surface and bearing surface Ior
wear and damage, then measure the countershaft
at points A, B, and C.
Standa.d:A: 36.000 - 36.015 mm
11.,1173 - f.ill79 inl
B: 36.98/t - 37.000 mm
{r.4561 - 1.4567 inl
C: 24.987 - 25.000 mm
{0.98:17 - 0.9843 inl
Servics Limit: A:35,95 mm (1.115 in)
B: 36.93 mm (1.454 in)
C: 24.94 mm (0.982 in)
lf anv part of the countershaft is less than the ser-
vice limit. reolace it with a new one.
lnspect for wear and damage.
13-32
2. Inspect for runout.
Standard: 0.02 mm 10.0008 inl max.
Service Limit: 0.05 mm {0.002 inl
NOTE: Support the countershaft at both ends as
shown.
Rotate two complete revolutions.
lf the runout exceeds the service limit, reDlace the
countershaft with a new one.
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Reassembly
Note these items during reassembly:
. Press the 3rd, 4th, and sth gear on the countershaft
without lubrication.
. When installing the 3rd, 4th. and sth gears, suppon
the shaft on steel blocks and install the gears using a
press.
. Refer to page 13-28 for reassembly sequence.
1. Install the thrust shim, needle bearing, 1st gear, and
friction damper.
NOTE: Reassembly the friction damper on the lst
gear before installation.
rnrcrroru orn,leen ----.-4O)
lST GEAR
NEEDLE BEARING
THRUST SHIM
2. Install the double cone synchro.
3. Install the 1sv2nd synchro hub by align the friction
damper fingers with 1svznd synchro hub grooves.
(contd)
OUTER
lST/2ND
13-33
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Countershaft Assembly
Reassembly (contdl
4. Reassembly the friction damper on the spacer using
the sDecialtools and a Dress.
PRESS
t
ATTACHMENT,U2t 47 mfi07716 - 0010300
FRICTION DAMPERInspect for wear anddamage.
Install the 2nd gear by align the
fingers with 2nd gear grooves.
synchro cone the
GROOVE
13-34
6. Support the countershaft on a steel block as shown
and install 3rd gear using the special tools and a
press.
3RO GEAR
7. lnstall 4th gear using the special tools and a press.
PRESS
I
PRESS
t
ATTACHMENT,35 mm LD.07746 - 0030,100
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8. Install sth gear using the special tools and a press.
PRESS
I
DRIVER, 40 mm l.D.
07715 - 0030300
ATTACHMENT,30 mm LD.077,16 - 0030300
LInstall the needle bearing using the special tools
and a press, then installthe bearing outer race
PRESS
I
DRIVER. 40 mm l.D.077{6 - 0030100
ATTACHMENT,30 mm l.D.07746 - 0030300
NEEDLEBEASING
10. Install the ball bearing using the special tools and a
press.
PRESS
I
DRIVER. 40 mm LD.07746 - 0030100
ATTACHMENT,30 mm LD.077a6 - 0030300
11.Securely clamp the countershaft assembly in
bench vise with wood blocks.
LOCKNUTReplace.
Install the spring washer.
Install the new locknut to the correct torque, then
stake the locknut tab into the groove.
Torque: 127 + 0 + 127 N.m 113 - 0 +13 kgf.m,
94+0-94|bf.ft)
12.
wooD slocKs
13-35
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Synchro Sleeve, Synchro Hub
Inspection
1.Inspect gear teeth on all synchro hubs and synchro
sleeves for rounded off corners, which indicate
Install each synchro hub in its mating synchro
sleeve, and check for freedom of movement.
NOTE: lf replacement is required, always replace
the synchro sleeve and synchro hub as a set.
SYNCHROSLEEVE
SYNCHBOHUB
13-36
LONGER ?EETH
Installation
When assembling the synchro sleeve and synchro hub,
be sure to match the three sets of longer teeth (120
degrees apart) on the synchro sleeve with the three sets
of deeper grooves in the synchro hub. Do not installthe
synchro sleeve with its longer teeth in the lsv2nd syn-
chro hub slots because it will damage the spring ring.
SYNCHRO
SYNCHBOSI.EEVE
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Synchro Ring, Gear
Inspection
Inspect the synchro ring and gear.
Ar lnspect the inside of the synchro ring for wear.
B: lnspect the synchro sleeve teeth and matching
teeth on the synchro ring for wear (rounded of0.
CCGOOO WORN
Cr Inspect the synchro sleeve teeth and matching
teeth on the gear tor wear (rounded off).
,,

u (-l
GOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface lor wear and roughness.
F: Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks.
2. Coat the cone surface of the gear with oil, and place
the synchro ring on the matching gear. Rotate the
synchro ring, making sure that it does not slip.
Measure the clearance between the synchro ring
and gear allthe way around.
NOTE: Hold the synchro ring against the gear even-
ly while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.85 - 1.10 mm (0.033 - 0.0,lil in)
Service Limit: 0.,1 mm 10.02 inl
Double Cone Synchro-lo-Goar Clearance
Standard:
@: {Outer Synchro Ring to Synchto Conel
0.5 - 1.0 mm (0.02 - 0.04 in)
€): {synchro cone to Geal)
0.5 - 1.0 mm (0.02 - 0.0i1inl
@: louter Synchro Ring to Gearl
0.95 - 1.68 mm (0.037 - 0.056 inl
Service Limit:
@: 0.3 mm (0.01 inl
@: 0.3 mm {0.01 in}
@: 0.6 mm {0.02 in)
lf the clearance is less than the service limit, replace
the synchro ring and synchro cone.
SYNCHRO SPRING
SYNCHRO
1.
OUTER SYNCHRO RING
13-37
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Differential
lndex
NOTE: lf the * mark parts were replaced, the tapered
roller bearing preload must be adjusted (see page 13-
41).
*THRUST SHIMAdiustment, Page 1341
+BEARING OUTER RACEBeplacement, page 13 40Inspect for wear and damage.
*TAPERED ROLLERBEARINGReplacement, page l3-39Inspect for wear and damage.
10 x 1.0 mm103 N.m {10.5 kgf m, 75.9 lbf.ft}Left-hand threads
CARRIERBacklash inspection, page 13 38lnspect for cracks.
FINAL DRIVEN GEARReplacement, page 13-39Inspect for wear and damage
TRANSFER DRIVEN GEARReplacement, page 13-39Inspect {or wear and damage.
,,4\
W-
*TAPERED ROLLER BEARINGBeplacement, page 1339Inspect for wear and damage.
IEEARING OUTER RACEReplacement, page 13-40Inspect for wear and damage.
.75 mm SHIM
13-38
Backlash Inspection
1. Place the differential
install both axles.
assembly on V-blocks and
PINION GEARS
V-BLOCK
2. Measure the backlash ot both pinion gears.
Standard (Newl: 0.05 - 0.15 mm (0.002 - 0.006 inl
lf the backlash is not within the standard, reolace
the differential carrier.
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Final Driven Gear RePlacement
LRemove the bolts in a crisscross pattern in several
steps, and remove the final driven gear from the dif-
ferential carrier.
NOTE: The final driven gear bolts have left-hand
threads.
10 x 1.0 mm103 N.m (10.5 kgf m,75.9lbfftlLefthand threads
FINAL DRIVEN GEAR
lnsoect {or weal and damage
TRANSFER ORIVEN GEARInspect for wear and damage.
Install the final driven gear by tightening the bolts
in a crisscross pattern in several steps.
Tapered Roller Bearing
Replacement
Note these items:
. The tapered roller bearing and bearing outer race
should be replaced as a set.
. Inspect and adiust the tapered roller bearing preload
whenever the tapered roller bearing is replaced
. Check the tapered roller bearings for wear and rough
rotation. lf the tapered roller bearings are OK, remov-
al is not necessary.
1. Remove the tapered roller bearings using a bearing
puller and a bearing separator as shown.
Install new tapered roller bearings using the special
tool as shown.
NOTE: Drive the tapered roller bearings on until
they bottom against the differential carrter.
PRESS
IJ
BEARINGSEPAFATOB{Commercially
ATTACHMENT,,10 x 50 mm07LAD - PWs060 l
BEARING
13-39
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Differential
Bearing Outer Race Replacement
Note these items:
. The bearing outer race and tapered roller bearingshould be replaced as a set.. lnspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
1. Remove the oil seals from the transmission housingand clutch housing (see page j3-43).
2. Drive the bearing outer race and thrust shim out ofthe transmission housing, or remove the bearingouter race and 75 mm shim from the clutch housingby heating the clutch housing to about 212F(100C) with a heat gun. Do not reuse the thrustshim if the outer race was driven out.
TRANSMISSIONHOUSING:
ATTACHMENT52x55mm07746 - 0010400
THRUST SHIM
BEARINGOUTER RACE
CLUTCHHOUSING:
13-40
4, lnstallthe oil seal (see page 13-43).
3. Install the thrust shim or 75 mm shim and the bear-ing outer race in the transmission housing andclutch housing using the special tools.
Note these items during bearing replacement:. Install the bearing outer race squarely.. Check that there is no clearance between thebearing outer race, thrust shim or 75 mm shimand housing.
TRANSMISSIONHOUSING:
HANDI-E07749 - 00  xxto
ATTACHMENT,62x68mm077ir6 - 0010500
BEARINGOUIER RACETHRUST SHIM
CLUTCHHOUSING:HANDLE07749 - 001tXX)o
ATTACHMENT.72xt5mm07745 - 00106{x)
OUTER RACE
75 mm SHIM
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Tapered Roller Bearing Preload Adiustment
lf any oJ the items listed below were replaced, the tapered
roller bearing preload must be adjusted.
. Transmission housing
. Clutch housing
. Differential carrier
o Tapered roller bearing and bearing outer race
. Thrust shim
. 75 mm sham
1. Remove the bearing outer race and thrust shim
from the transmission housing (see page 13-40)
NOTE:
. Do not reuse the thrust shim if the bearing outer
race was driven out.
. Let the transmission cool to room temperature il
the bearing outer race was removed by heating
the clutch housing.
2. Do not use more than one thrust shim to adjust the
tapered bearing preload. First try the same size
thrust shim that was removed. There are no shims
used on the clutch housing side
SHIMTHRUST
/A
After installing the thrust shim, install the bearing
outer race in the transmission housing (see page
13-40).
With the mainshaft and countershaft removed,
install the differential assembly, and torque the
clutch housing and transmission housing.
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
TOBOUE; 8 x 1.25 mm: 27 Nm(2.8 kgfm, 20 lbtftl
Rotate the differential assembly in both directions
to seat the tapered roller bearings.
Measure the tapered roller bearing preload at nor-
mal room temperature. Measure the starting torque
of the differential assembly in both directions with
the special tool and a torque wrench.
STANDAFD: 1.4 - 2.5 Nm
{1/r - 26 kgfcm, 12 - 23 lbf in)
(contd)
4.
5.
07HAJ - PK40201
13-41
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