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Home >> Honda >> 2003 >> CR-V 4WD L4-2.4L >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Transmission Overhaul >> End Cover and Idler Gear Removal/Installation

End Cover and Idler Gear Removal/Installation

End Cover Removal





4WD





2WD

Special Tools Required
Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Remove the ATF cooler lines.
2. Remove the A/T clutch pressure control solenoid valve A, then remove the ATF pipe, ATF joint pipes, and gasket.
3. Remove A/T clutch pressure control solenoid valves B and C, then remove the ATF joint pipes and gasket.
4. Remove the transmission range switch cover.
5. Remove the transmission range switch harness clamps from the clamp brackets, then remove the transmission range switch.
6. Remove the end cover.





7. Slip the special tool onto the mainshaft.
8. Engage the park pawl with the park gear.





9. Cut the lock tab (A) of each shaft locknut (B) using a chisel (C). Then remove the locknuts and conical spring washers from each shaft.

NOTE:
^ Countershaft and secondary shaft locknuts have left-hand threads.
^ Keep all of the chiseled particles out of the transmission.
^ Clean the old mainshaft and countershaft locknuts; they are used to install the press fit idler gear on the mainshaft, and park gear on the countershaft.

10. Remove the special tool from the mainshaft.





11. Set a two-jaw (or three-jaw) puller (A) on the countershaft (B) by putting a spacer (C) between the puller and countershaft, then remove the park gear (D).





12. Install 6 x 1.0 mm bolts (A) on the mainshaft idler gear (B). Set a puller (C) on the mainshaft (D) with putting a spacer (E) between the puller and mainshaft, then remove the mainshaft idler gear.
13. Remove the park pawl, park pawl spring, park pawl shaft, and stop shaft.
14. Remove the park lever from the control shaft.

Park Lever Stop Inspection and Adjustment
1. Set the park lever in the P position.





2. Measure the distance (A) between the park pawl shaft (B) and the park lever roller pin (C).
STANDARD: 57.7 - 58.7 mm (2.27 - 2.31 inch)





3. If the measurement is out of standard, select and install the appropriate park lever stop (A) from the table.





PARK LEVER STOP

4. After replacing the park lever stop, make sure the distance is within tolerance.

Idler Gear Shaft Bearing Replacement

Special Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 52 x 55 mm 07746-0010400





1. Remove the idler gear shaft bearing (A) from the end cover (B) with the special tool.





2. Install the new bearing in the end cover with the special tools.

Control Shaft Oil Seal Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 22 x 24 mm 07746-0010800





1. Remove the oil seal (A) from the end cover (B).





2. Install the new oil seal flush to the end cover with the special tools.

Control Shaft Bearing Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 22 x 24 mm 07746-0010800





1. Remove the oil seal from the end cover, then remove the bearing.





2. Install the new bearing flush to the end cover with the special tools.
3. Install the new oil seal.

ATF Feed Pipes Replacement





1. Remove the snap rings (A), ATF feed pipes (B), and feed pipe flanges (C) from the end cover (D).
2. Install the new O-ring (E) over the ATF feed pipe.
3. Install the ATF feed pipe in the end cover by aligning the feed pipe tabs with the indentations in the end cover.
4. Install the new O-ring (F) in the end cover, then install the feed pipe flange over the ATF feed pipe and O-ring.
5. Secure the ATF feed pipe and feed pipe flange with the snap ring.

End Cover Installation

Special Tools Required
Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100





1. Install the special tool onto the mainshaft.
2. Lubricate the following parts with ATF:
^ Splines and threads of the mainshaft.
^ Splines of the mainshaft idler gear.
^ Old conical spring washer and old locknut.





3. Install the mainshaft idler gear (A), old conical spring washer (B), and old locknut (C) on the mainshaft (D), and tighten the locknut to 226 Nm (23.0 kgf-cm, 166 ft. lbs.).

NOTE:
^ Do not tap the idler gear to install.
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.





4. Install the park lever (A) and park lever stop (B) on the control shaft (C), then install the lock bolt with the new lock washer (D). Do not bend the lock tab of the lock washer until step 18.
5. Install the park pawl shaft (E), park pawl spring (F), park pawl (G), and stop shaft (H) on the transmission housing.
6. Lubricate the following parts with ATF:
^ Threads and splines of the countershaft.
^ Old conical spring washer and old locknut.
^ Areas where the park gear contacts the conical spring washer.
7. Install the park gear (I), old conical spring washer (J), and old locknut (K) on the countershaft.
8. Lift the park pawl up, and engage it with the park gear, then tighten the locknut to 226 Nm (23.0 kgf-cm, 166 ft. lbs.).

NOTE:
^ Do not tap the park gear to install.
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ Countershaft locknut has left-hand threads.

9. Remove the locknuts and conical spring washers from the mainshaft and countershaft.
10. Lubricate the threads of the shafts, the new locknuts, and the new conical spring washers with ATF.





11. Install the new conical spring washers (A) in the direction shown, and install the new mainshaft locknut (B), the new countershaft locknut (C), and the new secondary shaft locknut (D).
12. Tighten the locknuts to 167 Nm (17.0 kgf-cm, 123 ft. lbs.).

NOTE:
^ Be sure to install the conical spring washers in the direction shown.
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ Countershaft and secondary shaft locknuts have left-hand threads.

13. Remove the special tool from the mainshaft.





14. Stake the locknuts into the shafts with a punch.





15. Install the control lever (A) on the control shaft (B), and install the bolt with the new lock washer (C), then bend the lock tab of the lock washer against the bolt head.





16. Set the park lever in the P position, then verify that the park pawl (A) engages the park gear (B).
17. If the park pawl does not engage fully, check the distance (C) between the pawl shaft (D) and the park lever roller pin (E).
18. Tighten the lock bolt, and bend the lock tab of the lock washer (F) against the bolt head.





19. Install the ATF feed pipe (A) into the idler gear shaft, and install the ATF lubrication pipe (B) into the transmission housing.





20. Install the end cover (A) with the two dowel pins, new O-rings, and new gasket. Tighten the 6 x 1.0 mm bolts (12) (B) and 8 x 1.0 mm bolts (3) (C).
21. Install the harness clamp bracket (D).





22. Set the control shaft (A) to the [N] position by turning the control lever on the torque converter side.

NOTE: Do not squeeze the end of the control shaft tips together when turning the shaft. If the tips are squeezed together it could cause a faulty signal or position due to the play between the control shaft and the switch.





23. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold in the N position.

NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the R position.





24. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C).





25. Tighten the bolts on the transmission range switch while you continue to hold the E1 position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge.





26. Connect the transmission range switch connector (A) securely, then install the harness clamps (B) on the clams bracket (C).
27. Install the transmission range switch cover (D).





28. Install the new gasket (A) on the transmission housing, and install the ATF pipe (B) and ATF joint pipes (C).
29. Install the new O-rings (D) over the ATF joint pipes.
30. Install the A/T clutch pressure control solenoid valve A (E).





31. Install the new gasket (A) on the transmission housing, and install the ATF joint pipes (B).
32. Install the new O-rings (C) over the ATF joint pipes.
33. Install the A/T clutch pressure control solenoid valves B and C (D) and harness clamp brackets (E).





34. Install the ATF cooler inlet line (A) with the new sealing washers (B), and install the bracket (C) of the ATF cooler inlet line on the shift solenoid valve cover hole (D) (described in step 22 in Shaft Assemblies and ATF Strainer Installation.
35. Install the ATF cooler outlet line (E) with the new sealing washers (F).





36. Install the breather tube (A) with the dot (B) on the tube facing rearward, then install the other end (C) in the slot (D) of the transmission hanger (E).





37. 4WD model: Install the transfer assembly (A) with the new O-ring (B) and dowel pin (C).
38. Install the ATF dipstick.





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