Honda HR-V Owners & Service Manuals

Honda HR-V: AWD Control Unit Connector For Inputs And Outputs (AWD)

AWD Control Unit Inputs and Outputs for 24P Connector (Connector Disconnected)

Differential - Testing & Troubleshooting

Differential - Testing & Troubleshooting

AWD SYSTEM BLEEDING (AWD)

Procedure

NOTE: Whenever the rear differential assembly is disassembled, the AWD with intelligent control system must be bled.

1. HDS - Connect

2. AWD System - Air Bleed

  1. Select the ADJUSTMENT in the AWD WITH INTELLIGENT CONTROL with the HDS
  2. Select the AIR BLEEDING in the ADJUSTMENT with the HDS.NOTE : See the HDS Help menu for specific instructions.

3. Rear Differential Fluid - Check

REAL TIME AWD ELECTRONIC WIRING DIAGRAM

Refer to appropriate wiring diagram.System Wiring Diagrams

REAR DIFFERENTIAL DISASSEMBLY AND REASSEMBLY (AWD)

Special Tools Required

Oil Seal Driver, 41.8 mm 07947-6890100

Differential - Testing & Troubleshooting

Companion Flange Holder 07RAB-TB4010B

Differential - Testing & Troubleshooting

Holder Handle 07JAB-001020B

Differential - Testing & Troubleshooting

Exploded View

1. Rear Differential - Exploded View

Differential - Testing & Troubleshooting
Fig. 2: Differential Exploded View With Torque Specifications

Disassembly

1. Rear Differential Pump Motor - Remove

2. Rear Differential Fluid Temperature Sensor - Remove

3. Rear Differential Fluid Pressure Sensor - Remove

4. Rear Differential Solenoid Valve Connector Assembly - Remove

Differential - Testing & Troubleshooting

  1. Disconnect the connector (A)
  2. Remove the rear differential solenoid valve connector assembly (B).

5. Oil Filler Plug and Drain Plug - Remove

Differential - Testing & Troubleshooting

  1. Remove the drain plug (A) with the sealing washer (B)
  2. Remove the oil filler plug (C) with the sealing washer (D).

6. Rear Differential Subharness - Remove

Differential - Testing & Troubleshooting

  1. Disconnect the ground terminal (A)
  2. Remove the harness clip (B)
  3. Remove the harness bracket (C).

7. Companion Flange - Remove

Differential - Testing & Troubleshooting

  1. Pry up the stake on the locknut (A) from the groove of the clutch guide, making sure the tab completely clears the groove to prevent damaging the clutch guide.

Differential - Testing & Troubleshooting

  1. Install the companion flange holder and the holder handle on the companion flange.

Differential - Testing & Troubleshooting

  1. Loosen the locknut (A) counterclockwise so its tab (B) comes out from the groove (C) in the clutch guide.

Differential - Testing & Troubleshooting

  1. Tighten the locknut (A) until its tab (B) aligns with the groove (C)
  2. Clean any dirt from inside the groove in the clutch guide, then loosen the locknut.

Differential - Testing & Troubleshooting

  1. Remove the locknut (A), the spring washer (B), the back-up ring (C), and the O-ring (D).

Differential - Testing & Troubleshooting

  1. Remove the companion flange (A) with a commercially available puller.

8. Oil Pump Cover - Remove

Differential - Testing & Troubleshooting

  1. Remove the oil pump cover (A) and oil pump cover seal (B)
  2. Remove the inner rotor (C) and the outer rotor (D)
  3. Remove the fluid strainer (E) and the dowel pins (F).

9. Oil Pump Case - Remove

Differential - Testing & Troubleshooting

  1. Remove the oil pump case (A)
  2. Remove the dowel pins (B).

10. Differential Clutch Assembly - Remove

Differential - Testing & Troubleshooting

  1. Remove the baffle cover (A)
  2. Remove the differential clutch assembly (B).

11. Oil Pump Body Assembly - Remove

Differential - Testing & Troubleshooting

  1. Remove the 32.3 mm shim (A)
  2. Remove the 94.6 mm shim (B)
  3. Remove the oil pump body assembly (C)
  4. Remove the dowel pins (D) and the O-ring (E).

12. Rear Differential Solenoid Valve - Remove

Differential - Testing & Troubleshooting

  1. Remove the rear differential solenoid valve (A), the O-ring (B), and the square washer (C).

Reassembly

1. Rear Differential Solenoid Valve - Install

Differential - Testing & Troubleshooting

  1. Apply rear differential fluid to a new O-ring (A)
  2. Install the rear differential solenoid valve (B) with the O-ring, and the square washer (C).

2. Oil Pump Body Assembly - Install

Differential - Testing & Troubleshooting

  1. Apply rear differential fluid to a new O-ring (A)
  2. Install the dowel pins (B) with the O-ring
  3. Install the oil pump body assembly (C)
  4. Install the 32.3 mm shim (D)
  5. Install the 94.6 mm shim (E).

3. Differential Clutch Assembly - Install

Differential - Testing & Troubleshooting

  1. Install the differential clutch assembly (A)
  2. Install the baffle cover (B).

4. Oil Pump Case - Install

Differential - Testing & Troubleshooting

  1. Remove the dirt and oil from the sealing surfaces
  2. Apply liquid gasket (P/N 08C70-K0334M) evenly to the sealing surface
  3. Install the component within 5 minutes of applying the liquid gasket. Make sure you seal the entire circumference of the bolt holes to prevent fluid leakage.

    NOTE :

    • If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
    • Allow it to cure at least 30 minutes after assembly before filling the differential with recommended fluid.

Differential - Testing & Troubleshooting

  1. Install the dowel pins (A)
  2. Install the oil pump case (B)
  3. Torque the mounting bolts in a crisscross pattern in several steps.

5. Oil Pump Cover - Install

Differential - Testing & Troubleshooting

  1. Install the fluid strainer (A) and the dowel pins (B)
  2. Install the inner rotor (C) and the outer rotor (D) with the "." marks (E) facing the oil pump case side
  3. Install the oil pump cover (F) with a new oil pump cover seal (G)
  4. Torque the mounting bolts in a crisscross pattern in several steps.

6. Companion Flange - Install

Differential - Testing & Troubleshooting

  1. Set the companion flange (A) to the clutch guide shaft
  2. Drive on the companion flange using the 41.8 mm oil seal driver.

Differential - Testing & Troubleshooting

  1. Check the length of clutch guide shaft as shown.

    NOTE: Make sure to drive on the companion flange until 2 to 3 thread pitches of the clutch guide shaft appears.

Differential - Testing & Troubleshooting

  1. Apply rear differential fluid to the used locknut
  2. Set the used locknut to the clutch guide shaft
  3. Install the companion flange holder and the holder handle on the companion flange
  4. Tighten the used locknut
  5. Remove the used locknut, then remove the companion flange holder and the holder handle
  6. Check the companion flange has been set to the bottom.

Differential - Testing & Troubleshooting

  1. Apply rear differential fluid to a new O-ring (A)
  2. Install the O-ring, a new back-up ring (B), the spring washer (C), and a new locknut (D).

    NOTE : Be sure to install the spring washer in the direction shown.

Differential - Testing & Troubleshooting

  1. Install the companion flange holder and the holder handle on the companion flange.
  2. Tighten the locknut to the specified torque.

    Specified Torque: 108 N.m (11.0 kgf.m, 80 lbf.ft)

Differential - Testing & Troubleshooting

  1. Stake the locknut tab (A) into the groove in the clutch guide.

7. Oil Filler Plug and Drain Plug - Install

Differential - Testing & Troubleshooting
Fig. 3: Oil Filler And Drain Plug With Torque Specifications

  1. Install the drain plug (A) with a new sealing washer (B)
  2. Install the oil filler plug (C) with a new sealing washer (D) finger-tight.

8. Rear Differential Solenoid Valve Connector Assembly - Install

Differential - Testing & Troubleshooting

  1. Apply rear differential fluid to the O-ring (A)
  2. Install the rear differential solenoid valve connector assembly (B)
  3. Connect the connector (C).

9. Rear Differential Fluid Pressure Sensor - Install

10. Rear Differential Fluid Temperature Sensor - Install

11. Rear Differential Pump Motor - Install

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