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Part 4 Honda CRV Differential Rebuild

Installing the Racing Diffs CRV Clutch Upgrade!

So next its time to get into some exciting performance parts installation for our customers RT-AWD Honda CRV Rear Differential! Time to Install some Racing Diffs clutches into our performance rebuild. To begin I want to say to “EVERYONE” to prevent pre-mature wear of the Molybdenum Clutch surface you should pre-soak these clutches for atleast 10 minutes prior to installation. Our install today is for educational purposes so I will not be soaking mine as the clutch cage will be sent out to the hot tank tomorrow with the remaining components of the differential.

Racing Diffs RT-AWD CRV/ Element/ Cross-tour Performance Clutch Upgrade Kit

So to start I recommend the following tools to aid you in your quest for faster TQ transfer and immediate response from these Differentials:

  • Rags! Lots of Rags.
  • #2 Strait Blade Screw Driver or 45 Degree Scribe.
  • Needle Nose Pliers.
  • Small Bucket to Pre-Soak the Clutches and Friction Discs.
  • Small Baggies to place smaller parts to keep everything organized.
  • 5 Ton Hydraulic Center Press.
  • Mechanics Gloves or an Equivalent Protective Glove.
  • Eye Protection.
  • 1 Ltr of Liqui-Moly DSG Dual Clutch Gear Oil.

Alright open the contents of the Racing Diffs clutch box and remove the stickers. Open the packaging that the clutches come in and set the clutches to the side! You should have 11 friction discs and 10 clutches in your box set to the side ready to be pre-soaked. These clutches require a light weight ATF Automatic Transmission Fluid designed for transmissions with LSD’s. So naturally I consulted Racing Diffs and several other companies to find a viable source of ATF that will work with the dual pump fluid viscosity allowing the hydraulic pumps to operate correctly and not cause issues with clutch engagement or dual pump functionality. We recommend using Liqui-Moly VW DSG ATF Oil. It is the correct viscosity for the Honda dual pump to function at its optimal performance and it has viscous properties also to promote a better friction coefficient for the Racing Diffs Molybdenum Ceramic Coated Clutches.

To start this process first you will need to remove the pressure plate from the Torque Control Unit (Clutch Bell). With the clutch bell facing down lift the pressure plate from the clutch cage and place it to the side.  Pay particular attention not to drop any of the 7.8 mm ball bearings when removing the pressure plate from the clutch bell.

Remove the RAMP clutch assembly from the clutch cage and place all of the ball bearings in a safe place. Using your 5 ton hydraulic press apply pressure to the clutch cage RAMP assembly and remove the first of 2 snap rings from the clutch cage.

WARNING! The TCU is under spring pressure! When removing the snap rings from the RAMP assembly and from the clutch assembly they are under significant spring pressure. We recommend using a 5 ton hydraulic press to apply downward pressure to perform this task. Use eye protection at all times to protect you from possible harm from inadvertent assembly separation.

Next we remove all of the contents of the RAMP assembly and store in a safe location and inspect for damage!

Following the removal of the first snap ring and RAMP assembly removal the second snap ring is clearly visible. This is the clutch stack that transfers power from the driveshaft to the rear wheels. Repeat the steps of removal for the first snap ring above. Use your eye protection and apply downward pressure to the clutch assembly and remove the second snap ring from the clutch cage!

Once this process is finished the clutch assembly should be free to remove. Lift the assembly from the clutch cage with the pressure spring and start removing clutches from the assembly. Pay particular attention to the arrangement of the clutches and inspect for damage and debris during removal. Especially nicks, scratches, and or foreign objects and other damage to the clutch cage assembly. Anything more than a fingernail worth of damage to the mating surfaces will cause issues with the clutches releasing and engagement. File Smooth or replace the cage as needed.

Once all of the clutches are removed place the first Racing Diffs Friction Disc into the clutch cage with a Racing Diffs clutch. Note: If you followed the instructions listed above your Racing Diffs clutches and friction discs will be coated in Liqui-Moly so they will be slippery . Please use caution when handling them to avoid dropping them causing damage to the friction disc or clutches.

Once the first friction disc and clutch is present inside of the clutch cage insert the clutch pinion adapter into the clutch cage and align with the splines of the clutch until the clutch pinion adapter sits flush. Ensure that the clutch splines fully engage into the clutch pinion adapter and that the clutch pinion adapter spins free with the clutch aligned easily. Then continue installation of the clutch assembly until the clutches and friction discs align with the top of the Clutch Pinion Adapter.

Install the pressure plate spring into the center of the clutch pinion adapter and move the assembly back to the 5 ton hydraulic center press. Note: The clutch pressure plate has 4 – alignment tabs that align the clutch pinion adapter to the clutch pressure plate and will need to be aligned to ensure proper fitment before applying force with the 5 ton hydraulic press.

Clutch Pinion Adapter and Clutch Pressure Plate Alignment Tabs

Using the 5 ton hydraulic press and your strait blade screw driver. Align the clutch pressure plate tabs with the clutch pinion adapter and apply pressure to depress the pressure plate spring until the clutch pressure plate sits flush and install the snap ring into the clutch cage assembly until it fits into the second set of snap ring grooves in the clutch cage assembly. Once the snap ring is firmly in place release pressure from your 5 ton hydraulic press and begin installation of the RAMP assembly.

Install the concave RAMP assembly spring with the concave side down and the wide side facing up! During compression of the RAMP assembly under the 5 ton hydraulic center press this spring will depress making it flat and level allowing the installation of the last and final snap ring to retain the RAMP assembly. It will maintain spring pressure on the RAMP assembly forcing the system to remain under pressure allowing the required clearances for operation of the RAMP assembly.

Install the ramp assembly spring, remaining Racing Diffs friction disc, ramp clutch then the last friction disc. Then head back to the 5 ton hydraulic press and depress the RAMP assembly into the clutch cage assembly and install the remaining snap ring into the assembly to complete the installation. Install the 7.8 mm RAMP assembly ball bearings and onto the RAMP assembly in the clutch cage and install the RAMP assembly roller bearing ensuring it seats properly into the RAMP Clutch assembly then install the RAMP pressure plate into the clutch cage making sure that it fits firmly into the grooves in the clutch cage and reinstall the TCU back onto the differential pinion.

Thats it! Your done! For more information about our products and services please reach out to us by emailing us at Admin@Automotiveknd.com or messaging us on Facebook, Instagram, Twitter or Tumblr. Additionally we can be reached during the hours of 9 am to 6:30 pm est (240) 317-9679.

If you like what you see and have an area of these builds you would like us to focus on or you just need technical information for your build please reach out to us at one of the methods provided above and our knowledgeable staff and technicians will support you in your quest for performance. Thanks for following our builds and for your support!

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