honda cr v 19997 2000 User Manual

							
5C.
36.
Install the sub-shaft lst gear on the sub-shaft.
Install the mainshaft 1st gear collar, mainshaft 1st
gear, needle bearing, thrust needle bearing, and the
thrust washer on the mainshaft.
Wrap the shaft splines with tape to prevent O-ring
damage, then install new O-rings on the mainshaft
lnstallthe 1st clutch assemblv on the mainshaft
lST CLUTCHASSEMELY
O.RINGS
,te
SUB.SHAFTlST GEAR
.A/.bwt
THRUST WASHER
IHRUST NEEDLEBEANING
NEEDLE BEARING
MAINSHAFT1ST GEAR
MAINSHAFT
39.
1ST GEARCOLLAB
Align the hole of the sub-shaft lst gear with the
hole of the transmission housing, then insert an 8
mm pin to hold the sub-shaft while tightening the
sub-shaft locknut.
40. Install new conical spring washers and new lock-
nuts on each shaft. Install the washers in the direc-
tion shown.
41. Tighten the locknuts to the specified torque.
Mainshaft and countershaft locknuts have left-hand
threads. Do not use an impact wrench. Always use
a torque wrench to tighten the locknuts.
LOCKNUT TOROUE:
MAINSHAFT: 78 N.m (8.0 kgfm, 58 lbfft)
COUNTERSHAFT: 103 N.m (10.5 kgf.m, 75.9 lbfft)
SUB-SHAFT: 93 N.m {9.5 kgfm, 69 lbfft|
MAINSHAFT
SU8-SHAFT LOCKNUT
LOCXNUT Left-handthreads
CONICAL SPBING WASH€RSlnstall in this direction-
42. Stake each locknut using a 3.5 mm punch.
0.7 - 1.2 mm
{0.03 - 0.05 inl
PIN8 mm pin,
commerciallyavailable
COUNTENSHAFTLOCKNUTLeft-hand threads
PUNCH3.0 - 3.5 mm10.12 - 0.1il inl
LOCKNUTPoint to bestaked.
(contd)
14-255
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Transmission
Reassembly lcontd)
44.
Set the park lever in @ position, then verify that thepark pawl engages the park gear.
lf the pawl does not engage fully, check the distancebetween the park pawl shaft and the park leverroller pin (see page 14-231).
Tighten the lock bolt and bend the lock tab.
1o tbffrl
PARK GEAR
46. Install the end cover with two dowel pins and a newgasket {twelve bolts).
TOROUE: 12 N.m (1.2 kgf.m, 8.7 tbf.ft)
6 r 1.O mm
PARK PAWL
6 x 1.0 mm EOLT HOLE{Used in step 50.)
END COVER
14-256
A/T GEAR FOSMON SWNCH
47. Install the control lever assemblv on the controlshaft. (4WDl
6x1.0mm14 N.m 11.4 kg{.m,10 tbf.ftl
48.
CONTROL LEVERASSEMBLY
Set the A/f gear position switch to E] position.
NOTE: The Aff gear position switch cticks in N]position,
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49. Set the control shaft to E position, and install the
A,/T gear position switch on it.
CONTROL SHAFT
l( ((,,, ,. 
*
$*\.t+-
NN
6x1.0mm12 N.m 11.2 kgt.m,8.7 tbf.ftl
6xl.0mm12 N.m 11.2 kgfm,
8,7
gtt - 00 MoDELS{6 position3}T
Install the A/T gear position switch cover, then
install the harness clamps of the AviT gear position
switch harness on the end cover and the transmis-
sion housing.
50.
CONTROL SHAFT
HARNESS CLAMP
HARNESS CLAMP
Clean the areas where the transfer assembly con-
tacts the transmission with solvent or carburetor
cleaner, dry with compressed air, then coat the con-
tact areas with ATF. (4WD)
Install the transfer assembly with a new O-ring. Do
not allow dust or other foreign particles to enter the
transmission. {4WD)
O.RINGReplace-
10 r 1.25 mma,a Nm 14.5 kgtm, 33 lbfftl
54.
55.
lnstall the cooler lines with the line bolts and new
sealing washers.
TOROUE: 28 N.m 12.9 kgifm. 21 lbfft)
Install the ATF dipstick.
lnstall the breather cap on the breather pipe so its
arrow points to the transmission hanger.
TRANSMISSION
14-257
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Torque Converter/Drive Plate
6 x 1.0 rnin12 N..t| {1.2 kgt.m, 8.7 lbt.frl
DBIVC PTATE
12 x 1.0 mm74 .m (7.5 lgt.m, 54 tbt.ft)Torque in I crisscross oattern.
o
0o
14-258
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Transmission
1.
lnstallation
Flush the ATF cooler as described on page 14-264
and 14-265.
Install the torque converter assembly on the main-
shaft with a new O-ring.
lnstall the starter on the transmission housing, and
install the 14 mm dowel pins in the torque converter
housing.
44 N.m {{.5 kgf.m,33 rbf.f0
Place the transmission on a jack, and raise it to
engine level.
Anach the transmission to the engine, then install
the rear engine mounting bolts and the transmis-
sion housing mounting bolt (rear sidel.
14 mm DOWEL PIN
REAR ENGINE MOUNTING BOLTS
la x 1.5 mm8:l N.m (8.5 kgf.m, 61 lbf.ftl
MOUNTING BOLT {REAR SIDEI12 x 1.25 mm6il N.m 16.5 kgd.m, 47 tbt.ttl
6. Install the transmission housing mounting bolt
(front side).
TRANSMISSION HOUSING MOUNNNG BOLT
{FRONT SIDE)12 x 1.25 mm6,1 N m (6 5 kgl m, 47 lbfftl
Install the transmission mount bracket. Tighten the
bolt loosely, then tighten the nuts to the specified
torque, and tighten the bolt to the specified torque.
7.
12 x 1,25 mm6,a N.ft (6.5 kgtm,47rbf.ft)
t@
TRANSMISSION MOUNTBRACKET
12 x 1 .25 mm74 N.m (7.5 kgf.m,s{ tbtftl
(contd)
TBANSMISSION MOUNT
14-259
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Transmission
Installation (contdl
8. Install the transmission housing mounting bolts.
TRANSMISSION HOUSING MOUNTING BOLTS12 x 1.25 mm54 N.m 16,5 kgf.m, a7 lbtftl
9. Remove the transmission jack.
10. Attach the torque convener to the drive plate witheight bolts. Rotate the crankshaft as necessarv totighten the bolts to ll2 of the specified torque, thento the final torque, in a crisscross pattern. Aftertightening the last bolt. check that the crankshaftrotates freelv.
6x1.0mln12 N.m (1.2 tgt m,8.t lbf.frl
6x1.0mm12 N.m {1.219{.m,8.7 tbtft,
12 x t.25 mm34 N.m 13.5 kgf.rn,25 lbf.ft)
8 x 1.25 mm2a N.m 12.5 kgfm,18 tbt.ftl
DRIVE PLATE
STIFFENER
44 N.rn (4.5 kgt m, 33 lbtftl
11.
12.
Install the torque convener cover and the rear stiff_ener.
Tighten the crankshaft pulley bolt as necessary (seesection 5).
14-260
13. Connect the ATF cooler hoses to the ATF coolerlines (see page 14-266).
. ATF COOLERLINE
i lr,:,.) -
10 x 1.25 mm44 N.m (4.5 kgf.m,33 tbtftl
CLAMP
12 x 1.25 mm64 N.m 16.5 kg{.m,a7 tbt.ftlFRotrtT
15.
16.
t 4.
SET RINGReplace.
MOUNT/ARACKET
Install the right front mounvbracket.
Install new set rings on the ends of the intermediateshaft and the driveshaft.
Clean the areas where the intermediate shaft con_tacts the transmission {differential) with solvent orcarburetor cleaner, and dry with compressed air.Then install the intermediate shaft in the differen_tial, While installing the intermediate shaft, be surenot to allow dust or other foreign panicles to enterthe transmission.
l0 x 1.25 mm39 N.m 14.0 kgt.n,29 tbf.ftl
INTERMEDIATE SHAFT
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17. Install the right and left driveshafts (see section 18).
While installing the right driveshaft in the differen-
tial, be sure not to allow dust or other foreign parti-
cles to enter the transmission.
NOTE:
. Clean the areas where the right driveshaft con-
tacts the transmission (differential) with solvent
or carburetor cleaner, and dry with compressed
air.
. Turn the right and left steering knuckle fully out-
ward, and slide the right driveshaft into the dif-
ferential until you feel its spring clip engage the
side gear. Slide the left driveshaft into the inter-
mediate shaft until you feel the spring clip of the
intermediate shaft engage the left driveshaft,
18. Install right damper fork, then install the right and
left ball joints on each lower arm with the castle
nuts and new cotter pins (see section 18).
DAMPER PINCH BOLT10 x 1 .25 mm43 N.m 14.{ kgf.m,32 rbr.ftl
DAMPERFORX
SELF.LOCKING NUT12 x 1,25 mm6/t N m (6.5 kg{.m, a7 lbtft)Replace.
Replace.
CASTLE12 x 1.25 mm49 - 59 N.m15.0 - 6.0 kgl m, 36 - {3 lbtftl
19, Install the propeller shaft to the transfer assembly
by aligning the reference marks (4WD).
20.
8 x 1.25 mm32 N.m (3.3 kgtm,2ir blft)
Feplace. 
\
@_
PROPELLER SHAFT
lnstall the shift cable.
4WD:
Install the shift cable with the control pin, then
secure it with the snap Din. Do not bend the shift
cable excessivelv.
CONTROLLEVER
SHIFT CAALECOVER
8 x 1.25 mm22 N.m 12.2lgl m,16 rbt.ftl
(contd)
REFERENCE MARKS
14-261
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Transmission
Installation (contdl
2WD:
Install the control lever with a new lock washer to thecontrol shaft. Do not bend the shift cable excessivelv.
8 r 1.25 mm22 N.m|2.2 kgt.m,16 rbf.ft)
SI{IFT CAELECOVER
LOCK WASHER 6 x 1.0 mmReplace. 14 N.m 11.4 kgt.m,10 tbr.frl
lnstallthe shift cable cover.
Install exhaust pipe A.
Connect the primary heated orygen sensor (primary
HO2S) connector.
GASKETSReplace.
22.
23.
10 x 1.25 m.n5r N.m {5.5 kgf.m,40 tbtftlReplace.
SELF.LOCKING
SELF-LOCKING NUT8 ! 1.25 mm16 N.m {1.6 kgf.m,12 lbf.fttReplace.
8 x 1.25 mm22 N.m {2,2 kgt.m, l5 lbt.ftl
SHIFT CABLE
14-262
24. Installthe splash shield and guard bar,
8 x 1.2524 N.m {2.a kgl.m,17 tbt.ftl
SPLASH SHIELD
GUARO BAR
25.
6r1.0|r|m9.8 N.m l1.0lgf.m, 7.2 tbtftl
Connect the mainshaft speed sensor, the shift con-trol solenoid valve, and the linear solenoid connec_tors,
SHIFT CONTROL SOLENOIDVALVE CONNECTOR
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26. Connect the vehicle speed sensor (VSS). the coun-
tershaft speed sensor. and the A,/T gear position
switch connectors,
VEHICLE SPEEO
SPEED SENSOACO{NECTOR
Connect the lock-up control solenoid valve connec-
tor, then install the harness clamp on the clamp
bracket.
HARNESS CI-AMP
27.
RADIATOR HOSECLAMP
TRANSMISSIONGROUND CAB1ITERMINAL
LOCK-UP OONTROLSOLENOID VALVECONNECTOR
6x1.0mm12 Nm (1.2 kgi.m,8.? tbtftl
28.
29.
Instail the transmission ground cable terminal on
the transmission hanger, and install the radiator
hose clamp on the transmission hanger,
Connect the starter cables to the starter, and install
the harness clamD on the clamD bracket. Make sure
the crimped side of the starter cable ring terminal is
facing out.
STARTEBCABLE
STARTER CAAtf,
Install the air cleaner housing assembly and the
intake air duct.
Refill the transmission with ATF (see page 14-161).
Connect the battery positive terminal and negative
terminal.
Set the parking brake, Start the engine, and shift the
transmission through all gears three times.
Check the shift cable adjustment (see page 14-271]-.
Check the tront wheel alignment and adjust it if
needed (see section 18).
Let the engine reach normal operating temperature
(the radiator fan comes on) with the transmission in
E or N position, then turn it off and check the ATF
level {see page 14-160).
Perform a road test (see page 14-157 and 14-158).
30.
31.
34.
CLAMP BRACKET
37.
14-263
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Transmission
Cooler Flushing
@@ To prevent in;ury to face and eyos, atwayswear safety glasses ot a face shield when using thetlansmission flusher.
This procedure should be performed before reinstallingthe transmission.
2.
LCheck equipment for wear and cracks before using.Replace any worn or cracked components.
Using the measuring cup. fill the tank with 21 ounces{approximately 213 lull) ol biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontaaner.
Secure the flusher filler cap, and pressurize theflusher with compressed air to 550 - 829 kpa (5.6 _
8.45 kgf/cm,, 80 - 120psi). The air line should beequipped with a water trap to ensure a dry air sys-tem.
Hang the flusher under the vehicle.
Attach the flusher discharge hose to the return lineof the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-mission cooler using a clamp.
IMPORTANT:
Securely clamp the opposite end ofthe drain hose to abucket or floor drain.
DISCHARGEHOSE
tAirlp Water
TnAI{SrfiSStoN coot€RFLUSHER{Comm.rcidly.v.il.bt.lK.r -Moor. J38,t{15.Aor aquival.nt
5.
14-264
7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)
10.
8.
1I.
Turn on the water valve for 1O seconds. lf waterdoes not flow through the cooler, it is completelyplugged, cannot be flushed, and must be replaced.
Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.
While flushing with the water and flushing fluid fortwo minutes, turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgf/cmr, t20 psi)
Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.
Release the trigger, and rinse the cooler with wate.for one minute.
Turn the water valve off, and the water supply off.
Turn the air valve on for two minutes, or until nomoisture is visible leaving the drain hose. Residualmoisture in the cooler or lines can damage thetransmission.
Remove the flusher from the cooler line. Attach thedrain hose to a container.
Install the transmission, and leave the drain hoseattached to the cooler line.
12.
13.
14.
to.
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