Transfer Case: Removal & Installation Honda CR-V IV

Installation

Note. Apply a light coat of clean ATF on all moving parts before reassembly.

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1. Transfer Shaft Assembly Install a new O-ring (A). Install the transfer shaft assembly (A) and the dowel pin (B).
2. Transfer Assembly Install a new O-ring (A) on the transfer assembly (B). Install the transfer assembly and the dowel pin (C).
3. Propeller Shaft Transmission Side - Reconnection Set the No. 1 propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C) you made during the removal procedure. Then install new flange bolts (D) to the specified torque.
4. Under Floor TWC Assembly Install the under-floor TWC.
5. Front Floor Undercover Install the front floor undercover (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
6. Front Splash Shield Install the front splash shield (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
7. ATF - Replacement Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Refill the transmission with the recommended fluid into the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity 2WD: 2.2 L (2.3 US qt) at change 5.85 L (6.18 US qt) at overhaul AWD/4WD: 2.6 L (2.7 US qt) at change 6.4 L (6.8 US qt) at overhaul Insert the dipstick (A) into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick. Make sure the fluid level is between the upper mark (A) and the lower mark (B) on the dipstick. Insert the dipstick into the guide tube aligning the notch with the guide tab.
8. Warm Up The Engine Start the engine. Hold the engine speed at 3, 00 rpm without load in P or N until the radiator fan comes on. Park the vehicle on level ground. Turn the ignition switch to LOCK (0).
9. ATF Level Check NOTE: Keep all foreign particles out of the transmission. Check the fluid level within 60-90 seconds after turning the engine off. Higher fluid level may be indicated if the radiator fan comes on twice or more. Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Insert the dipstick into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick, and check the ATF level. It should be between the upper mark (A) and the lower mark (B). If the ATF level is below the lower mark, check for fluid leaks at the transmission, the hoses, and the line joints. If a problem is found, fix it before filling the transmission with ATF. NOTE: If the vehicle is driven when the ATF level is below the lower mark, one or more of these symptoms may occur: Transmission damage. Vehicle does not move in any gear. Vehicle accelerates poorly, and engine revs up abnormally high when starting off in forward and reverse positions. Engine vibrates at idle. If the ATF level is above the upper mark, drain the ATF to proper level. NOTE: If the vehicle is driven when the ATF level is above the upper mark, the vehicle may creep forward while in N, or have shifting problems. If necessary, fill the transmission with ATF through the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Do not fill the fluid above the upper mark. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Insert the dipstick into the guide tube aligning the notch with the guide tab.
10. HDS DLC - Connection Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard. Turn the ignition switch to ON (II). Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
11. Maintenance Minder Reset «RESET THE MAINTENANCE MINDER»(ref-595380-S34497350472014013100000) .

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1. Vehicle Lift Raise the vehicle on a lift, and make sure it is securely supported.
2. Front Splash Shield Remove the bolts (A), then remove the clips (B) that secure the front inner fender and the front splash shield (C) to the body. From under the front bumper (D), remove the clips (E). From under the body, remove the clips (F), then pull out the front splash shield.
3. Front Floor Undercover Remove the bolts (A) and the clips (B, C) securing the front floor undercover (D), then remove the front floor undercover.
4. ATF - Replacement Remove the drain plug (A), and drain the ATF. Reinstall the drain plug using a new sealing washer (B).
5. Under-Floor TWC Assembly Remove the under-floor TWC.
6. Propeller Shaft Transmission Side - Disconnection Make reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C). Separate the No. 1 propeller shaft from the transfer companion flange. NOTE: Suspend the propeller shaft with an appropriate size nylon strap.
7. Transfer Assembly Remove the transfer assembly (A) and the dowel pin (B). Remove the O-ring (C) from the transfer assembly.

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1. Transfer Assembly Install a new O-ring (A) on the transfer assembly (B). Install the transfer assembly and the dowel pin (C).
2. Propeller Shaft Transmission Side - Reconnection Set the No. 1 propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C) you made during the removal procedure. Then install new flange bolts (D) to the specified torque.
3. Under Floor TWC Assembly Install the under-floor TWC.
4. Front Floor Undercover Install the front floor undercover (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
5. Front Splash Shield Install the front splash shield (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
6. ATF - Replacement Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Refill the transmission with the recommended fluid into the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity 2WD: 2.2 L (2.3 US qt) at change 5.85 L (6.18 US qt) at overhaul AWD/4WD: 2.6 L (2.7 US qt) at change 6.4 L (6.8 US qt) at overhaul Insert the dipstick (A) into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick. Make sure the fluid level is between the upper mark (A) and the lower mark (B) on the dipstick. Insert the dipstick into the guide tube aligning the notch with the guide tab.
7. Warm Up The Engine Start the engine. Hold the engine speed at 3, 00 rpm without load in P or N until the radiator fan comes on. Park the vehicle on level ground. Turn the ignition switch to LOCK (0).
8. ATF Level Check NOTE: Keep all foreign particles out of the transmission. Check the fluid level within 60-90 seconds after turning the engine off. Higher fluid level may be indicated if the radiator fan comes on twice or more. Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Insert the dipstick into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick, and check the ATF level. It should be between the upper mark (A) and the lower mark (B). If the ATF level is below the lower mark, check for fluid leaks at the transmission, the hoses, and the line joints. If a problem is found, fix it before filling the transmission with ATF. NOTE: If the vehicle is driven when the ATF level is below the lower mark, one or more of these symptoms may occur: Transmission damage. Vehicle does not move in any gear. Vehicle accelerates poorly, and engine revs up abnormally high when starting off in forward and reverse positions. Engine vibrates at idle. If the ATF level is above the upper mark, drain the ATF to proper level. NOTE: If the vehicle is driven when the ATF level is above the upper mark, the vehicle may creep forward while in N, or have shifting problems. If necessary, fill the transmission with ATF through the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Do not fill the fluid above the upper mark. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Insert the dipstick into the guide tube aligning the notch with the guide tab.
9. HDS DLC - Connection Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard. Turn the ignition switch to ON (II). Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
10. Maintenance Minder Reset «RESET THE MAINTENANCE MINDER»(ref-595380-S34497350472014013100000) .

Transfer Oil Seal Replacement

SPECIAL TOOL DESCRIPTION Image Description/Tool Number Companion Flange Holder 07RAB-TB4010B Holder Handle 07JAB-001020B Driver Handle, 15 x 135L 07749-0010000 Oil Seal Driver Attachment, 58 mm 07JAD-PH80101

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1. Vehicle Lift Raise the vehicle on a lift, and make sure it is securely supported.
2. Front Splash Shield Remove the bolts (A), then remove the clips (B) that secure the front inner fender and the front splash shield (C) to the body. From under the front bumper (D), remove the clips (E). From under the body, remove the clips (F), then pull out the front splash shield.
3. Front Floor Undercover Remove the bolts (A) and the clips (B, C) securing the front floor undercover (D), then remove the front floor undercover.
4. ATF - Replacement Remove the drain plug (A), and drain the ATF. Reinstall the drain plug using a new sealing washer (B).
5. Under-Floor TWC Assembly Remove the under-floor TWC.
6. Propeller Shaft Transmission Side - Disconnection Make reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C). Separate the No. 1 propeller shaft from the transfer companion flange. NOTE: Suspend the propeller shaft with an appropriate size nylon strap.
7. Transfer Assembly Remove the transfer assembly (A) and the dowel pin (B). Remove the O-ring (C) from the transfer assembly.
8. Transfer Shaft Assembly Remove the transfer shaft assembly (A) and the dowel pin (B). Remove the O-ring (A).
9. Companion Flange Using a chisel, cut the lock tab (A) on the locknut (B) of the transfer output shaft (hypoid gear). NOTE: Be careful not to damage the transfer output shaft (hypoid gear). Secure the transfer housing (A) in a bench vise (B) with soft jaws. NOTE: To prevent damaging the transfer housing, always use wood blocks or equivalent materials between the transfer housing and the bench vise. Install the companion flange holder and the holder handle, then loosen the locknut. Remove the companion flange holder and the holder handle. Remove the locknut (A), the conical spring washer (B), the backup ring (C), the O-ring (D), and the companion flange (E).
10. Transfer Output Shaft (Hypoid Gear) Remove the transfer output shaft (hypoid gear) (A) and the transfer spacer (B).
11. Transfer Output Shaft Oil Seal Remove the oil seal (A).

Note. Apply a light coat of clean ATF on all moving parts before reassembly.

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1. Transfer Output Shaft Oil Seal Install a new oil seal (A) flush with the transfer housing surface (B) using the driver handle and the 58 mm oil seal driver attachment. NOTE: Apply a light coat of clean ATF on oil seal before installation.
2. Transfer Output Shaft (Hypoid Gear) Install a new transfer spacer (A) on the transfer output shaft (hypoid gear) (B) in the direction shown, and install them in the transfer housing.
3. Companion Flange Install the companion flange (A), a new O-ring (B), the back-up ring (C), a new conical spring washer (D), and a new locknut (E). Install the conical spring washer in the direction shown. Secure the transfer housing (A) in a bench vise (B) with soft jaws. NOTE: To prevent damaging the transfer housing, always use wood blocks or equivalent materials between the transfer housing and the bench vise. Install the companion flange holder and the holder handle. Tighten the locknut to the specified torque. Tightening torque: AWD: 213 N.m (21.7 kgf.cm, 157 lbf.ft) 4WD: 196 N.m (20.0 kgf.cm, 145 lbf.ft) Stake the locknut to a depth (A) of at least 0.7 mm (0.028 in) using a 3.5 mm punch (B). Be careful not to make a crack on the locknut when staking.
4. Transfer Shaft Assembly Install a new O-ring (A). Install the transfer shaft assembly (A) and the dowel pin (B).
5. Transfer Assembly Install a new O-ring (A) on the transfer assembly (B). Install the transfer assembly and the dowel pin (C).
6. Propeller Shaft Transmission Side - Reconnection Set the No. 1 propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C) you made during the removal procedure. Then install new flange bolts (D) to the specified torque.
7. Under Floor TWC Assembly Install the under-floor TWC.
8. Front Floor Undercover Install the front floor undercover (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
9. Front Splash Shield Install the front splash shield (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
10. ATF - Replacement Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Refill the transmission with the recommended fluid into the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity 2WD: 2.2 L (2.3 US qt) at change 5.85 L (6.18 US qt) at overhaul AWD/4WD: 2.6 L (2.7 US qt) at change 6.4 L (6.8 US qt) at overhaul Insert the dipstick (A) into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick. Make sure the fluid level is between the upper mark (A) and the lower mark (B) on the dipstick. Insert the dipstick into the guide tube aligning the notch with the guide tab.
11. Warm Up The Engine Start the engine. Hold the engine speed at 3, 00 rpm without load in P or N until the radiator fan comes on. Park the vehicle on level ground. Turn the ignition switch to LOCK (0).
12. ATF Level Check NOTE: Keep all foreign particles out of the transmission. Check the fluid level within 60-90 seconds after turning the engine off. Higher fluid level may be indicated if the radiator fan comes on twice or more. Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Insert the dipstick into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick, and check the ATF level. It should be between the upper mark (A) and the lower mark (B). If the ATF level is below the lower mark, check for fluid leaks at the transmission, the hoses, and the line joints. If a problem is found, fix it before filling the transmission with ATF. NOTE: If the vehicle is driven when the ATF level is below the lower mark, one or more of these symptoms may occur: Transmission damage. Vehicle does not move in any gear. Vehicle accelerates poorly, and engine revs up abnormally high when starting off in forward and reverse positions. Engine vibrates at idle. If the ATF level is above the upper mark, drain the ATF to proper level. NOTE: If the vehicle is driven when the ATF level is above the upper mark, the vehicle may creep forward while in N, or have shifting problems. If necessary, fill the transmission with ATF through the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Do not fill the fluid above the upper mark. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Insert the dipstick into the guide tube aligning the notch with the guide tab.
13. HDS DLC - Connection Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard. Turn the ignition switch to ON (II). Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
14. Maintenance Minder Reset «RESET THE MAINTENANCE MINDER»(ref-595380-S34497350472014013100000) .

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1. Vehicle Lift Raise the vehicle on a lift, and make sure it is securely supported.
2. Front Splash Shield Remove the bolts (A), then remove the clips (B) that secure the front inner fender and the front splash shield (C) to the body. From under the front bumper (D), remove the clips (E). From under the body, remove the clips (F), then pull out the front splash shield.
3. Front Floor Undercover Remove the bolts (A) and the clips (B, C) securing the front floor undercover (D), then remove the front floor undercover.
4. ATF - Replacement Remove the drain plug (A), and drain the ATF. Reinstall the drain plug using a new sealing washer (B).
5. Under-Floor TWC Assembly Remove the under-floor TWC.
6. Propeller Shaft Transmission Side - Disconnection Make reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C). Separate the No. 1 propeller shaft from the transfer companion flange. NOTE: Suspend the propeller shaft with an appropriate size nylon strap.
7. Transfer Assembly Remove the transfer assembly (A) and the dowel pin (B). Remove the O-ring (C) from the transfer assembly.
8. Transfer Shaft O-Ring Remove the transfer shaft assembly (A) and the dowel pin (B). Remove the O-ring (A).

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1. Transfer Shaft O-Ring Install a new O-ring (A). Install the transfer shaft assembly (A) and the dowel pin (B).
2. Transfer Assembly Install a new O-ring (A) on the transfer assembly (B). Install the transfer assembly and the dowel pin (C).
3. Propeller Shaft Transmission Side - Reconnection Set the No. 1 propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C) you made during the removal procedure. Then install new flange bolts (D) to the specified torque.
4. Under Floor TWC Assembly Install the under-floor TWC.
5. Front Floor Undercover Install the front floor undercover (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
6. Front Splash Shield Install the front splash shield (A), then install the bolts (B) and the clips (C, D). Make sure the clips snap into place securely.
7. ATF - Replacement Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Refill the transmission with the recommended fluid into the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity 2WD: 2.2 L (2.3 US qt) at change 5.85 L (6.18 US qt) at overhaul AWD/4WD: 2.6 L (2.7 US qt) at change 6.4 L (6.8 US qt) at overhaul Insert the dipstick (A) into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick. Make sure the fluid level is between the upper mark (A) and the lower mark (B) on the dipstick. Insert the dipstick into the guide tube aligning the notch with the guide tab.
8. Warm Up The Engine Start the engine. Hold the engine speed at 3, 00 rpm without load in P or N until the radiator fan comes on. Park the vehicle on level ground. Turn the ignition switch to LOCK (0).
9. ATF Level Check NOTE: Keep all foreign particles out of the transmission. Check the fluid level within 60-90 seconds after turning the engine off. Higher fluid level may be indicated if the radiator fan comes on twice or more. Remove the ATF dipstick (yellow loop) (A), and wipe it with a clean cloth. Insert the dipstick into the guide tube aligning the notch (B) with the guide tab (C). Remove the dipstick, and check the ATF level. It should be between the upper mark (A) and the lower mark (B). If the ATF level is below the lower mark, check for fluid leaks at the transmission, the hoses, and the line joints. If a problem is found, fix it before filling the transmission with ATF. NOTE: If the vehicle is driven when the ATF level is below the lower mark, one or more of these symptoms may occur: Transmission damage. Vehicle does not move in any gear. Vehicle accelerates poorly, and engine revs up abnormally high when starting off in forward and reverse positions. Engine vibrates at idle. If the ATF level is above the upper mark, drain the ATF to proper level. NOTE: If the vehicle is driven when the ATF level is above the upper mark, the vehicle may creep forward while in N, or have shifting problems. If necessary, fill the transmission with ATF through the dipstick guide tube opening (A) to bring the fluid level between the upper mark and the lower mark of the dipstick. Do not fill the fluid above the upper mark. Always use ATF DW-1 (genuine Honda automatic transmission fluid). Using a non-Honda ATF can affect shift quality. Insert the dipstick into the guide tube aligning the notch with the guide tab.
10. HDS DLC - Connection Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard. Turn the ignition switch to ON (II). Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
11. Maintenance Minder Reset «RESET THE MAINTENANCE MINDER»(ref-595380-S34497350472014013100000) .