Automatic Transmission: Overhaul Honda Element I

Clutch Disassembly

Special Tools Required

1. Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
2. Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

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1. Remove the snap ring with a screwdriver.
2. Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (5), and waved spring (D) from the 1st clutch drum (E).
3. 2003-2004 models: Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (3), clutch flat-plates (D) (2), and waved spring (E) from the 2nd clutch drum (F).
4. 2003-2004 models: Make reference marks on the clutch flat-plates (D).
5. 2005-2006 models: Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (3), 2.0 mm-thick flat-plate (D), 4.0 mm-thick plate (E), and waved spring (F) from the 2nd clutch drum (G).
6. 2005-2006 models: Make reference mark on 2.0 mm-thick flat-plate (D).
7. 2003-2004 models: Remove the clutch end-plate (A), clutch discs (B) (3), clutch waved-plates (C) (3), and waved spring (D) from the 3rd clutch drum (E).
8. 2003-2004 models: Remove the clutch end-plate (A), clutch discs (B) (3), clutch waved-plates (C) (3), and waved spring (D) from the 4th clutch drum (E).
9. 2005-2006 models: Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 3rd clutch drum (E).
10. 2005-2006 models: Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 4th clutch drum (E).
11. Install the special tools.
12. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.
13. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).
14. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
15. Compress the return spring until the snap ring can be removed.
16. Remove the snap ring with snap ring pliers.
17. Remove the special tools.
18. Remove the snap ring (A), spring retainer (B), and return spring (C).
19. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other passage while applying air pressure.
20. Remove the piston, then remove the O-rings from the 3rd and 4th clutch pistons.
21. Remove the piston, then remove the O-ring from the 1st and 2nd clutch drum, and remove the O-ring from each clutch piston.

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1. Inspect the 3rd and 4th clutch pistons and clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. Check the oil seal (A) on the spring retainer of the 1st and 2nd clutches for wear, damage, and peeling.
5. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
6. Inspect the clutch discs, clutch plates, and clutch end-plate for wear, damage, and discoloration. Standard Thickness Clutch Discs: 1.94 mm (0.076 in.) Clutch Plates 2003-2004 models 1st clutch (waved-plates): 1.6 mm (0.063 in.) 2nd clutch: Waved-plates: 2.0 mm (0.079 in.) Flat-plate: 2.0 mm (0.079 in.) 3rd clutch (waved-plates): 2.3 mm (0.091 in.) 4th clutch (waved-plates): 2.3 mm (0.091 in.) 2005-2006 models 1st clutch (waved-plates): 1.6 mm (0.063 in.) 2nd clutch: Waved-plates: 2.0 mm (0.079 in.) 2.0 mm-thick flat-plate: 2.0 mm (0.079 in.) 4.0 mm-thick plate: 4.0 mm (0.157 in.) 3rd clutch (waved-plates): 2.0 mm (0.079 in.) 4th clutch (waved-plates): 2.0 mm (0.079 in.)
7. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clutch end-plate-to-top-disc clearance.
8. If any plate is worn, damaged, or discolored, replace the damaged plate with the new plate, and inspect the other waved-plates for a phase difference. If the clutch plate is replaced, inspect the clutch end-plate-to-top-disc clearance.
9. If the clutch end-plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.

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1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (D) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the clutch waved-plate about 60 degrees (except 2003-2004 models 3rd and 4th) or 72 or 54 degrees (2003-2004 models 3rd and 4th) by holding its circumference. The dial indicator should be at top (E) of a phase difference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top. Standard: 0.07-0.20 mm (0.003-0.008 in.) Minimum: 0.05 mm (0.002 in.)
5. Rotate the clutch waved-plate about 60 degrees (except 2003-2004 models 3rd and 4th) or 72 or 54 degrees (2003-2004 models 3rd and 4th) from the top position. The dial indicator should be at bottom (F) of a phase difference. Zero the dial indicator.
6. Measure the phase difference between other two bottoms (F, H) and tops (G, I) of the clutch waved-plate by following steps 3 through 5.
7. If the two values of the three measurements are within the standard, the waved-plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.

Clutch Reassembly

Special Tools Required

1. Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
2. Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

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1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install the new O-rings (A) on the 3rd and 4th clutch pistons (B).
3. Install the new O-ring (A) in the 1st and 2nd clutch pistons (B), and install the new O-ring (C) on the clutch drums (D).
4. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate it to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.
5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.
6. Install the special tools.
7. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.
8. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).
9. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
10. Compress the return spring.
11. Install the snap ring with snap ring pliers.
12. Remove the special tools.
13. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (5) and discs (D) (5), then install the clutch end-plate (E) with the flat side toward the disc.
14. 2003-2004 models: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (F) (4) and clutch waved-plates (G) (3), then install the clutch end-plate (H) with the flat side toward the disc.
15. 2005-2006 models: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, clutch disc (E), and 2.0 mm-thick flat-plate (F), then starting with the clutch disc, alternately install the clutch discs (G) (4) and clutch waved-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the disc.
16. 2003-2004 models: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3), then install the clutch end-plate (E) with the flat side toward the disc.
17. 2003-2004 models: Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (3) and discs (D) (3), then install the clutch end-plate (E) with the flat side toward the disc.
18. 2005-2006 models: Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.
19. 2005-2006 models: install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (C) (4) and discs (D) (4), then install the clutch end-plate (E) with the flat side toward the disc.
20. Install the snap ring with a screwdriver to secure the clutch end-plate.
21. Check that the clutch piston moves by applying air pressure into fluid passage.

Reassembly

Special Tools Required

1. Driver, 40 mm I.D. 07746-0030100
2. Attachment, 35 mm I.D. 07746-0030400
3. Driver 07749-0010000
4. Oil seal driver attachment 07JAD-PH80101
5. Companion flange holder 07RAB-TB4010A or 07RAB-TB4010B
6. Holder handle 07JAB-001020A
7. Attachment, 62 x 68 mm 07746-0010500

Note. While reassembling the transfer assembly: Check and adjust the transfer gear tooth contact. Measure and adjust the transfer gear backlash. Check and adjust the tapered roller bearing starting torque. Coat all parts with ATF during reassembly. Replace the tapered roller bearing and the bearing outer race as a set if either part is replaced. Replace the transfer drive gear and the transfer output shaft as a set if either part is replaced.

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1. Select the 35 mm thrust shim if the transfer output shaft is replaced. Calculate the thickness of the 35 mm thrust shim using the formula, and select the shim from the table. NOTE: The number on the transfer output shaft is shown in 1/100 mm. THRUST SHIM, 35 mm THRUST SHIM, 35 mm Shim No. Part Number Thickness A 41361-PS3-000 0.72 mm (0.028 in.) B 41362-PS3-000 0.75 mm (0.030 in.) C 41363-PS3-000 0.78 mm (0.031 in.) D 41364-PS3-000 0.81 mm (0.032 in.) E 41365-PS3-000 0.84 mm (0.033 in.) F 41366-PS3-000 0.87 mm (0.034 in.) G 41367-PS3-000 0.90 mm (0.035 in.) H 41368-PS3-000 0.93 mm (0.037 in.) I 41369-PS3-000 0.96 mm (0.038 in.) J 41370-PS3-000 0.99 mm (0.039 in.) K 41371-PS3-000 1.02 mm (0.040 in.) L 41372-PS3-000 1.05 mm (0.041 in.) M 41373-PS3-000 1.08 mm (0.043 in.) N 41374-PS3-000 1.11 mm (0.044 in.)
2. Select the 35 mm thrust shim if the tapered roller bearing on the transfer output shaft is replaced. Measure the thickness of the replacement bearing and the existing bearing, and calculate the difference of the bearing thickness. Adjust the thickness of the existing 35 mm thrust shim by the amount of the difference in bearing thickness, and select the replacement 35 mm thrust shim from the table.
3. Install the 35 mm thrust shim (A) on the transfer output shaft (B), then install the tapered roller bearing (C) with the special tools and a press.
4. Place the tapered roller bearing (A) on the bearing outer race of the companion flange side of the transfer housing.
5. Install the new oil seal (B) on the transfer housing with the special tools and a press.
6. Install the transfer output shaft (A) in the transfer housing (B). Do not install the transfer spacer on the transfer output shaft.
7. Install the companion flange (A), conical spring washer (B), and locknut (C) on the transfer output shaft (D). Do not install the O-ring and back-up ring.
8. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
9. Install the special tool on the companion flange.
10. Tighten the locknut while measuring the starting torque so the starting torque is within 0.98-1.39 N.m (10.0-14.2 kgf.cm, 8.7-12.3 lbf.in.). Do not stake the locknut in this step.
11. Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (C), transfer collar (D), 25 mm thrust shim (E), tapered roller bearing (F), conical spring washer (G), and locknut (H).
12. Put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.
13. Tighten the locknut 118 N.m (12.0 kgf.m, 86.8 lbf.ft). Do not stake the locknut in this step.
14. Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
15. Temporarily install the transfer holder (A) and dowel pin (B) without O-ring, and tighten the bolts. 2003-2004 models: 2005-2006 models
16. Rotate the companion flange in both directions until the transfer gears rotate one full turn in both directions.
17. Set a dial indicator (A) on the companion flange (B).
18. Measure the transfer gear backlash. Standard: 0.06-0.16 mm (0.02-0.06 in.)
19. Remove the transfer holder, and check the transfer drive gear tooth contact pattern.
20. If the backlash measurement is out of standard, adjust the backlash with the 35 mm thrust shim and recheck. Do not use more than two 35 mm thrust shims to adjust the backlash.
21. If the transfer gear tooth contact is incorrect, adjust the tooth contact with the 25 mm or 35 mm thrust shim. Do not use more than two of each thrust shim to adjust the tooth contact. Toe Contact Use a thicker 35 mm thrust shim to move the transfer output shaft toward the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear away from the transfer output shaft to adjust the transfer gear backlash as follows: Increase the thickness of the 25 mm thrust shim. Reduce the thickness of the 68 mm thrust shim by the amount you increased the 25 mm thrust shim. Heel Contact Use a thinner 35 mm thrust shim to move the transfer output shaft away from the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear toward the transfer output shaft to adjust the transfer gear backlash as follows: Reduce the thickness of the 25 mm thrust shim. Increase the thickness of the 68 mm thrust shim by amount you reduced the thickness of the 25 mm thrust shim. Flank Contact Use a thinner thrust shim to move the transfer drive gear toward the transfer output shaft. Flank contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Heel Contact. Face Contact Use a thicker thrust shim to move the transfer drive gear away from the transfer output shaft. Face contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Toe Contact. THRUST SHIM, 25 mm THRUST SHIM, 25 mm Shim No. Part Number Thickness 1.70 29411-P1C-000 1.70 mm (0.067 in.) 1.73 29412-P1C-000 1.73 mm (0.068 in.) 1.76 29413-P1C-000 1.76 mm (0.069 in.) 1.79 29414-P1C-000 1.79 mm (0.070 in.) 1.82 29415-P1C-000 1.82 mm (0.072 in.) 1.85 29416-P1C-000 1.85 mm (0.073 in.) 1.88 29417-P1C-000 1.88 mm (0.074 in.) 1.91 29418-P1C-000 1.91 mm (0.075 in.) 1.94 29419-P1C-000 1.94 mm (0.076 in.) 1.97 29420-P1C-000 1.97 mm (0.078 in.) 2.00 29421-P1C-000 2.00 mm (0.079 in.) 2.03 29422-P1C-000 2.03 mm (0.080 in.) 2.06 29423-P1C-000 2.06 mm (0.081 in.) 2.09 29424-P1C-000 2.09 mm (0.082 in.) 2.12 29425-P1C-000 2.12 mm (0.083 in.) 2.15 29426-P1C-000 2.15 mm (0.085 in.) 2.18 29427-P1C-000 2.18 mm (0.086 in.) 2.21 29428-P1C-000 2.21 mm (0.087 in.) 2.24 29429-P1C-000 2.24 mm (0.088 in.)
22. Remove the transfer holder (A) from the transfer housing (B) after adjusting the transfer gear backlash or transfer gear tooth contact. 2003-2004 models: 2005-2006 models
23. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
24. Install the special tool on the companion flange, then loosen the locknut.
25. Remove the locknut (A), conical spring washer (B), and companion flange (C) from the transfer output shaft (D).
26. Remove the transfer output shaft (A) from the transfer housing (B).
27. Install the new transfer spacer (C) on the transfer output shaft in the direction shown, and install them in the transfer housing.
28. Coat the threads of the locknut and transfer output shaft with ATF.
29. Install the companion flange (A), new O-ring (B), back-up ring (C), new conical spring washer (D), and new locknut (E) on the transfer output shaft (F). Install the conical spring washer in the direction shown.
30. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
31. Install the special tool on the companion flange.
32. Tighten the locknut while measuring the starting torque of the transfer output shaft. Starting Torque: 0.98-1.39 N.m (10.0-14.2 kgf.cm, 8.7-12.3 lbf.in.) Tightening Torque: 132-260 N.m (13.5-26.5 kgf.m, 97.6-192 lbf.ft) NOTE: Rotate the companion flange several turns to seat the tapered roller bearings, then measure the starting torque. If 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 starting torque with the locknut loose. If the tightening torque exceeds 260 N.m (26.5 kgf.m, 192 lbf.ft), replace the transfer spacer and reassemble the parts.
33. Remove the special tool.
34. Stake the locknut into the transfer output shaft in depth (A) of 0.7-1.2 mm (0.03-0.05 in.) using a 3.5 mm punch (B).
35. Temporarily install the transfer holder (A) and dowel pin (B) without the O-ring, and tighten the bolts. 2003-2004 models: 2005-2006 models
36. Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
37. Rotate the companion flange several times to seat the tapered roller bearings.
38. Measure the starting torque at the companion flange (C) using a torque wrench (D). Standard 2003-2004 models: 2.16-3.57 N.m (22.0-36.4 kgf.cm, 19.1-31.6 lbf.in.) 2005-2006 models: 2.75-4.22 N.m (28.1-43.1 kgf.cm, 24.5-37.4 lbf.in.)
39. Remove the transfer holder from the transfer housing.
40. If the measurement is within the standard, go to step 53.
41. If the measurement is out of standard, put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.
42. Loosen the locknut.
43. Remove the locknut (A) and conical spring washer (B).
44. Remove the tapered roller bearing (C), 25 mm thrust shim (D), transfer collar (E), transfer drive gear (F), and transfer shaft (G) from the transfer holder (H).
45. Remove the tapered roller bearing outer race (A) and the 68 mm thrust shim (B) from the transfer holder (C).
46. Measure the thickness of the 68 mm thrust shim, and select the new 68 mm thrust shim. THRUST SHIM, 68 mm THRUST SHIM, 68 mm Shim No. Part Number Thickness ZV 23974-P1C-020 1.41 mm (0.056 in.) ZW 23975-P1C-020 1.44 mm (0.057 in.) ZX 23976-P1C-020 1.47 mm (0.058 in.) ZY 23977-P1C-020 1.50 mm (0.060 in.) ZZ 23978-P1C-020 1.53 mm (0.060 in.) A 23941-PW5-000 1.56 mm (0.061 in.) B 23942-PW5-000 1.59 mm (0.063 in.) C 23943-PW5-000 1.62 mm (0.064 in.) D 23944-PW5-000 1.65 mm (0.065 in.) E 23945-PW5-000 1.68 mm (0.066 in.) F 23946-PW5-000 1.71 mm (0.067 in.) G 23947-PW5-000 1.74 mm (0.069 in.) H 23948-PW5-000 1.77 mm (0.070 in.) 1 23949-PW5-000 1.80 mm (0.071 in.) J 23950-PW5-000 1.83 mm (0.072 in.) K 23951-PW5-000 1.86 mm (0.073 in.) L 23952-PW5-000 1.89 mm (0.074 in.) M 23953-PW5-000 1.92 mm (0.076 in.) N 23954-PW5-000 1.95 mm (0.077 in.) O 23955-PW5-000 1.98 mm (0.078 in.) P 23956-PW5-000 2.01 mm (0.079 in.) Q 23957-PW5-000 2.04 mm (0.080 in.) R 23958-PW5-000 2.07 mm (0.081 in.) S 23959-PW5-000 2.10 mm (0.083 in.) T 23960-PW5-000 2.13 mm (0.084 in.) U 23961-PW5-000 2.16 mm (0.085 in.) V 23962-PW5-000 2.19 mm (0.086 in.) W 23963-PW5-000 2.22 mm (0.087 in.) X 23964-PW5-000 2.25 mm (0.089 in.) Y 23965-PW5-000 2.28 mm (0.090 in.) Z 23966-PW5-000 2.31 mm (0.091 in.) AA 23967-PW5-000 2.34 mm (0.092 in.) AB 23968-PW5-000 2.37 mm (0.093 in.) AC 23969-PW5-000 2.40 mm (0.094 in.) AD 23970-PW5-000 2.43 mm (0.096 in.) AZ 23941-PW8-000 2.46 mm (0.097 in.) BZ 23942-PW8-000 2.49 mm (0.098 in.) CZ 23943-PW8-000 2.52 mm (0.099 in.) DZ 23944-PW8-000 2.55 mm (0.100 in.) EZ 23945-PW8-000 2.58 mm (0.102 in.)
47. Install the new 68 mm thrust shim (A) in the transfer holder, then install the tapered roller bearing outer race (B) with the special tools.
48. Install the transfer shaft (A) in the transfer holder (B), and install the transfer drive gear (C), transfer collar (D), 25 mm thrust shim (E), tapered roller bearing (F), conical spring washer (G), and locknut (H). Install the conical spring washer in the direction shown.
49. Put a 14 mm hex wrench (A) in the transfer shaft (B), then secure the hex wrench in a bench vise.
50. Tighten the locknut 118 N.m (12.0 kgf.m, 86.8 lbf.ft). Do not stake the locknut in this step.
51. Temporarily install the transfer holder (A) and dowel pin (B) without the O-ring, and tighten the bolts. 2003-2004 models: 2005-2006 models
52. Rotate the companion flange several turns to seat the tapered roller bearings, and recheck the starting torque. Remove the transfer holder after adjusting the starting torque.
53. Stake the locknut into the transfer shaft in depth (A) of 0.7-1.2 mm (0.03-0.05 in.) using a 3.5 mm punch (B).
54. Install the new O-ring (A) on the transfer holder (B), then install the transfer holder with the dowel pin (C) on the transfer housing (D). 2003-2004 models: 2005-2006 models