Tuesday, June 7, 2011

Honda Odyssey front vibrates when brake applied?

Most of the cases its rotor.If rotors checked ok, then

WHEEL ALIGNMENT
2001OdysseyF1.00+2.071.0000+/-0.08
R 0.75-0.500+/-0.08

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Inspection



2001-04 Models
  1. Check the magnetic encoder after cleaning the encoder. If necessary, replace the front wheel bearing or rear wheel bearing unit, as outlined in the Suspension & Steering Section.
  2. Measure the air gap between the wheel sensor and the pulser all the way around while rotating the pulser. The specifications for the front are 0.02-0.04 in. (0.5-1.0mm) and for the rear are 0.01-0.04 in. (0.2-1.0mm). Remove the rear rotor to measure the gap on the rear wheel sensor. If the gap is more than 0.04 in. (1.0mm), check for a bent suspension arm.
    NOTE
    Install the wheel bearing with the magnetic encoder (brown color) toward the inside of the knuckle. Remove any oil, grease, dust, or other foreign material from the encoder surface. Keep magnetic tools away from the encoder surface. Be careful not to damage the encoder surface when you insert the wheel bearing.



    Click image to see an enlarged view

    Fig. Measuring the air gap between the front wheel speed sensor and pulser-2001-04 models



    Click image to see an enlarged view

    Fig. Measuring the air gap between the rear wheel speed sensor and pulser-2001-04 models


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Inspection



The wheel bearings are not adjustable.

  1. Raise the vehicle, and support it with safety stands in the proper locations.
  2. Remove the wheels, then reinstall the wheel nuts.
  3. Attach the dial gauge. Place the dial gauge against the hub flange.

    Click image to see an enlarged view

    Fig. Place the dial gauge against the hub flange

  4. Measure the bearing end play by moving the disc inward or outward. If the bearing end play measurement is more than 0-0.05 mm (0-0.002 in.), replace the wheel bearing.

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove the knuckle.
  3. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to distort the splash guard. Hold onto the hub to keep it from falling when pressed clear.

    Click image to see an enlarged view

    Fig. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press-2001-04 models



  1. Remove the snap ring (A) and the splash guard (B) from the knuckle (C).

    Click image to see an enlarged view

    Fig. Remove the snap ring (A) and the splash guard (B) from the knuckle (C)

  2. Press the wheel bearing (A) out of the knuckle (B) using the special tools and a press.

    Click image to see an enlarged view

    Fig. Press the wheel bearing (A) out of the knuckle (B) using the special tools and a press-2001-04 models



  3. Press the wheel bearing inner race (A) from the hub (B) using the special tool, commercially available bearing separator (C), and a press.

    Click image to see an enlarged view

    Fig. Press the wheel bearing inner race (A) from the hub (B) using the special tool, commercially available bearing separator (C), and a press-2001-04 models



To install:

  1. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly.
  2. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tools, and a press. Place the wheel bearing on the knuckle with the magnetic encoder side (black color) facing toward the inside. Be careful not to damage the magnetic encoder.

    Click image to see an enlarged view

    Fig. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tools, and a press. Place the wheel bearing on the knuckle with the magnetic encoder side (black color) facing toward the inside

  3. Install the snap ring (A) securely in the knuckle (B).
  4. Install the splash guard (C), and tighten the screws (D).

    Click image to see an enlarged view

    Fig. Install the snap ring (A) securely in the knuckle (B). Install the splash guard (C), and tighten the screws (D)

  5. Install the hub (A) onto the knuckle (B) using the special tools shown and a hydraulic press. Be careful not to distort the splash guard (C).

    Click image to see an enlarged view

    Fig. Install the hub (A) onto the knuckle (B) using the special tools shown and a hydraulic press. Be careful not to distort the splash guard (C)-2001-04 models


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The lower ball joints are replaced with the lower control arms as an assembly.


Lower Control Arm

Control Arm Bushing Replacement




The lower control arm bushings are serviced with the lower control arm as an assembly.

Removal & Installation



2001-04 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    Front wheel
    Lower ball joint
    Front inner flange bolt
    Rear inner flange bolt
    Lower control arm


To install:


NOTE
Use a new split pin for assembly.

  1. Install or connect the following:

    Lower control arm. Tighten the inner flange bolt (A) to 69 ft. lbs. (93 Nm) and bolt (B) to 90 ft. lbs. (122 Nm) (69 ft. lbs. for 2004 models). Refer to the accompanying illustration for the locations of bolts A and B.
    Lower ball joint. Tighten the nut to 43-51 ft. lbs. (59-69 Nm).
    Front wheel

  2. Check the wheel alignment and adjust as necessary.

    Click image to see an enlarged view

    Fig. Tighten the lower control arm bolts to the specifications-2001-04 models shown



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  1. Steering Knuckle

    Print

    Removal & Installation



    2001-04 Models
    1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
    2. Remove the wheel nuts (A) and front wheel (B).
    3. Raise the locking tab on the spindle nut (C), then remove the nut.

      Click image to see an enlarged view

      Fig. Remove the wheel nuts (A) and front wheel (B). Raise the locking tab on the spindle nut (C), then remove the nut-2001-04 models

    4. Remove the brake hose mounting bolt (A).
    5. Remove the caliper mounting bolts (B), and hang the caliper assembly (C) to one side. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper from the undercarriage.

      Click image to see an enlarged view

      Fig. Remove the brake hose mounting bolt (A). Remove the caliper mounting bolts (B), and hang the caliper assembly (C) to one side-2001-04 models

    6. Remove the wheel sensor (A) from the knuckle (B). Do not disconnect the wheel sensor connector.

      Click image to see an enlarged view

      Fig. Remove the wheel sensor (A) from the knuckle (B). Do not disconnect the wheel sensor connector-2001-04 models

    7. Remove the 6 mm brake disc retaining screws (A).
    8. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively.

      Click image to see an enlarged view

      Fig. Remove the 6 mm brake disc retaining screws (A). Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub-2001-04 models

    9. Remove the brake disc from the knuckle.
    10. Check the front hub for damage and cracks.
    11. Remove the cotter pin (A) from the tie-rod end ball joint, then loosen the nut (B).

      Click image to see an enlarged view

      Fig. Remove the cotter pin (A) from the tie-rod end ball joint, then loosen the nut (B)-2001-04 models

    12. Remove the tie-rod ball joint from the knuckle using the special tool.
    13. Remove the lock pin (A) from the lower arm ball joint castle nut (B), and remove the nut.

      Click image to see an enlarged view

      Fig. Remove the lock pin (A) from the lower arm ball joint castle nut (B), and remove the nut-2001-04 models

    14. Remove the lower ball joint from the knuckle using the special tool.
    15. Remove the damper pinch bolts (A) and flange nuts (B) from the damper.
    16. Pull the knuckle outward, and remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer, then remove the knuckle.

      Click image to see an enlarged view

      Fig. Remove the damper pinch bolts (A) and flange nuts (B) from the damper. Pull the knuckle outward, and remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer-2001-04 models


    To install:

    1. Install the knuckle in the reverse order of removal, and pay particular attention to the following items:

      Be careful not to damage the ball joint boots when installing the knuckle.
      Torque all mounting hardware to the specified torque values.
      Torque the castle nuts to the lower torque specifications, then tighten them only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it.
      Install new lock pins on the castle nuts after torquing.
      Raise the locking tab on the spindle nut, then remove the nut.
      Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc.
      Before installing the new spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft.
      Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel.
      Check the front wheel alignment, and adjust it if necessary.

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Transaxle Removal & Installation

2001-04 Models



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the transaxle.
  3. Remove the engine appearance covers and install a support fixture to the engine lifting eyes.

    Click image to see an enlarged view

    Fig. Support the engine while removing the transaxle-2001-04 models

  4. Remove or disconnect the following:

    Air intake assembly
    Battery
    Battery tray
    Transaxle oil cooler lines
    Starter motor
    Transaxle ground cable
    Shift control solenoid valve connectors
    Clutch pressure switch connectors
    Mainshaft speed sensor connector
    Pressure control solenoid valve connectors
    Connector bracket
    Wiring harness cover
    Countershaft speed sensor connector
    Gear position switch connector
    Front motor mount
    Vacuum tube
    Splash shield
    Heated Oxygen Sensor (HO 2 S) connectors
    Exhaust front pipe
    Stabilizer bar links
    Lower ball joints
    Shift cable bracket
    Shift cable cover
    Shift control lever
    Torque converter
    Power steering hose bracket
    Power steering gear and brace
    Rear engine mount
    Transaxle lower mounts

  5. Matchmark the front subframe to the vehicle body.
  6. Support the subframe with a jack.
  7. Support the steering gear with safety wire and remove the subframe.
  8. Separate the inner CV-joints from the transaxle and intermediate shaft and support the axle halfshafts out of the work area with safety wire.
  9. Remove or disconnect the following:

    Intermediate shaft
    Transaxle flange bolts
    Transaxle

    Click image to see an enlarged view

    Fig. Remove the subframe bolts-2001-04 models



To install:


NOTE
Use new circlips, split pins and self-locking nuts for assembly.

  1. Install or connect the following:

    Transaxle. Tighten the flange bolts to 47 ft. lbs. (64 Nm).
    Intermediate shaft. Tighten the bolts to 29 ft. lbs. (39 Nm).
    Axle halfshafts

  2. Raise the subframe into position and align the matchmarks. Tighten the subframe bolts to 76 ft. lbs. (103 Nm). Tighten the front subframe bracket bolts to 54 ft. lbs. (74 Nm) and the rear bracket bolts to 86 ft. lbs. (117 Nm).
  3. Install or connect the following:

    Transaxle lower mounts. Tighten the nuts to 28 ft. lbs. (38 Nm).
    Rear engine mount. Tighten the bolts to 28 ft. lbs. (38 Nm).
    Power steering gear. Tighten the bolts to 29 ft. lbs. (39 Nm).
    Power steering gear brace. Tighten the bolts to 43 ft. lbs. (58 Nm).
    Power steering hose bracket
    Torque converter. Tighten the bolts to 105 inch lbs. (12 Nm).
    Shift control lever
    Shift cable cover
    Shift cable bracket
    Lower ball joints. Tighten the nuts to 43-51 ft. lbs. (59-69 Nm).
    Stabilizer bar links. Tighten the nuts to 58 ft. lbs. (78 Nm).
    Exhaust front pipe
    HO 2 S connectors
    Splash shield
    Vacuum tube
    Front motor mount. Tighten the nut to 40 ft. lbs. (54 Nm).
    Gear position switch connector
    Countershaft speed sensor connector
    Wiring harness cover
    Connector bracket
    Pressure control solenoid valve connectors
    Mainshaft speed sensor connector
    Clutch pressure switch connectors
    Shift control solenoid valve connectors
    Transaxle ground cable
    Starter motor
    Transaxle oil cooler lines
    Battery tray
    Battery
    Air intake assembly

  4. Fill the transaxle to the correct level.
  5. Start the engine and check for leaks.
  6. Check the wheel alignment and adjust as necessary.
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Overhaul

Outboard Joint



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    Axle halfshaft from the vehicle and place it in a vise
    Outboard joint boot clamps and push the boot back
    Outboard joint by driving it off the axle shaft with a brass drift and hammer or tool 07XAC-001020A, if available
    Outboard joint boot

    Click image to see an enlarged view

    Fig. Removing the outboard joint using tool 07XAC-001020A



To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Install the outboard joint boot and clamps to the axle shaft.
  2. Fill the outboard joint with grease. Install the outboard joint to the axle shaft. Tap the stub shaft with a brass hammer to seat the circlip.
  3. Fill the outboard joint boot with grease and install the boot clamps.
  4. Install the axle halfshaft to the vehicle.

    Click image to see an enlarged view

    Fig. Front axle exploded view


Inner Joint



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    Axle halfshaft from the vehicle.
    Inboard joint boot clamps and push the boot back
    Inboard joint housing from the axle
    Rollers from the spider
    Snapring and the spider from the axle shaft
    Inboard joint boot

    Click image to see an enlarged view

    Fig. View of the locking tab type boot band



    Click image to see an enlarged view

    Fig. View of the double loop tab type boot band



To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Install or connect the following:

    Inboard joint boot and clamps to the axle shaft
    Spider with a new snapring
    Rollers to the spider

  2. Fill the joint housing with grease and install it.
  3. Fill the inboard joint boot with grease and install the boot clamps. Make sure to adjust the length of the driveshafts as shown in the accompanying illustration.
  4. Install the axle halfshaft to the vehicle.

    Click image to see an enlarged view

    Fig. Make sure to adjust the length of the driveshafts as shown-2001-04 models


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Front drive axle

Intermediate Shaft

Print

Removal & Installation



  1. Drain the automatic transmission fluid Reinstall the drain plug, using a new washer.
  2. Remove the right driveshaft.

    Click image to see an enlarged view

    Fig. Remove the rear warm-up three-way catalytic converter (WU-TWC) bracket (B) and heat shield (A)

  3. Remove the rear warm-up three-way catalytic converter (WU-TWC) bracket (B) and heat shield (A).

    Click image to see an enlarged view

    Fig. Remove the flange bolt (A) and two dowel bolts (B)

  4. Remove the flange bolt (A) and two dowel bolts (B).

    Click image to see an enlarged view

    Fig. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontally until it is clear of the differential to prevent damage to the differential oil seal (B)

  5. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontally until it is clear of the differential to prevent damage to the differential oil seal (B).

To install:

  1. Use brake cleaner to thoroughly clean the areas where the intermediate shaft (A) contacts the transmission (differential), and dry them with compressed air. Do not wash the rubber parts with solvent. Insert the intermediate shaft assembly into the differential. Hold the intermediate shaft horizontally to prevent damage to the differential oil seal (B).
  2. Install the flange bolt (A) and two dowel bolts (B).
  3. Install the heat shield and rear warm-up three-way catalytic converter (WU-TWC) bracket.
  4. Install the right driveshaft.
  5. Refill the automatic transmission with the recommended transmission fluid.

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Half shaft:--

Removal & Installation

2001-04 Models



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the transaxle.
  3. Remove or disconnect the following:
    NOTE
    If removing the left halfshaft, drain the transmission fluid, it is not necessary to drain the fluid if removing the right halfshaft.



    Negative battery cable
    Front wheels



    Stabilizer bar link
    Lower ball joint
    Spindle nut

  4. Pry the inboard joint from the transaxle or intermediate shaft.
  5. Remove the outer CV-joint stub shaft from the hub by tapping the stub shaft with a plastic hammer.

To install:


NOTE
Use new circlips, split pins and self-locking nuts for assembly.

  1. Install the outer CV-joint stub shaft into the hub.
  2. Install the inner CV-joint to the transaxle or intermediate shaft until the circlip locks in the retaining groove.
  3. Install or connect the following:

    Lower ball joint. Tighten the nut to 43-51 ft. lbs. (59-69 Nm).
    Stabilizer bar link. Tighten the nut to 58 ft. lbs. (78 Nm).
    Spindle nut. Tighten the nut to 181 ft. lbs. (245 Nm).
    Front wheels
    Negative battery cable

  4. Fill the transaxle to the correct level and check for leaks.
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