Reassembly Service Point
CAUTION:
When the outer races of reduction gear bearing and differential side bearing are removed, measure the mounting bore diameters of outer race in the converter housing and transaxle case, and replace the housing case or the CVT assembly if the standard value is not satisfied. The standard values are listed in "SERVICE SPECIFICATIONS."
CAUTION:
- Do not re-use the reverse brake piston.
- Apply transmission fluid when installing the reverse brake piston.
- Install the reverse brake piston, while turning it, on the transaxle case.
- Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.
CAUTION: When installing the retaining plate, align the tangs at positions A, B, C in the diagram.
- Install the retaining plate on the transaxle case.
CAUTION:
- Set the spring compressor right on top of the spring of spring retainer assembly.
- Do not re-use the snap ring.
- When installing the snap ring, make sure that the joint falls in the area A in the diagram.
- Using the special tool, Spring compressor (MB992139), compress the return spring, and install the snap ring on the transaxle case by means of a flat blade screwdriver etc.
- Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case.
CAUTION:
- When conducting measurements, measure two or more places, and find the average value.
- Do not re-use the snap ring.
- When installing the snap ring, make sure that the joint falls in the area A in the diagram.
- Using a flat blade screwdriver etc., install the snap-ring on the transaxle case, and measure clearance between the snap ring and retaining plate. Select the snap ring so as to obtain standard value of the clearance. For selection of the snap ring, refer to "SERVICE SPECIFICATIONS ."
Standard value: 1.2 - 1.5 mm (0.05 - 0.06 in) (For reverse brake clearance)
CAUTION:- Apply vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
- Install the needle bearing on the reverse brake piston. Refer to A in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
- Install the planet carrier on the reverse brake.
CAUTION:
- Apply vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
- Install the needle bearing on the primary pulley side of the sun gear. Refer to B in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
- Install the sun gear on the planet carrier.
CAUTION:
- Apply vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
- Install the needle bearing on the forward clutch drum side of the sun gear. Refer to C in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
- Install the forward clutch assembly on the transaxle case.
CAUTION: When conducting measurements, measure two or more places, and find the average value.
- Measure the total end play A in the following way.
- Measure the distance M1 from the oil pump cover mounting surface of the transaxle case to the needle bearing mounting surface of the forward clutch drum.
- Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transaxle case.
- Calculate the total end play by the following expression. Select the needle bearing so that the total end play meets its standard value.
Total end play = M1 - M2 - bearing thickness
Standard value: 0.25 - 0.55 mm (0.010 - 0.021 in)
(For total end play)
CAUTION:- Apply vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
- Install the selected needle bearing on the forward clutch assembly. Refer to D in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
CAUTION:
- Do not re-use the seal rings.
- Apply vaseline when installing the seal rings.
- Install the seal rings on the oil pump cover.
CAUTION: Do not re-use the bolt.
- Install the detent spring on the transaxle case, and tighten the fastening bolt at the specified torque of 6.9 N.m (61 in-lb).
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- Install the O-ring on the plug.
- Install the plug on the converter housing to the specified torque of 7.5 N.m (66 in-lb).
CAUTION: Do not strain the pipe when attaching it.
- Install the pipe on the converter housing.
- Install the clip, and tighten the bolt at the specified torque of 5.9 N.m (52 in-lb).
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
- Using the special tools, Install the differential bearing outer race.
- Bar (MB990779) < F1CJA >
- Real axle shaft bushing installer (MB990780) < F1CJA >
- Differential oil seal installer (MB991168) < W1CJA >
- Adapter (MB991702) < W1CJA >
CAUTION:- When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
- When conducting measurements, measure two or more places, and find the average value.
- Measure the preload A of the differential assembly in the following way.
- Measure the distance M3 from the edge of transaxle case to the mounting surface of adjusting shim.
- Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing.
- Install the outer race on differential side bearing, and measure the distance M5 from the differential case to the outer race of differential side bearing.
- Using the following expression, calculate the distance M6 from the edge of converter housing to the outer race of differential side bearing.
M6 = M4 - M5
- Using the following expression, calculate thickness of the adjusting shim.
Thickness of adjusting shim = M3 - M6 + preload
Standard value: 0.17 - 0.23 mm (0.007 - 0.009 in)
(For differential preload)
CAUTION: Do not re-use the adjusting shim.
- Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ."
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
- Using the special tool, Real axle shaft bushing installer (MB990780), install the outer race of differential side bearing on the transaxle case.
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
- Using the special tools, install the outer race of reduction gear bearing on the converter housing.
- Installer adapter (MB990932)
- Installer bar (MB990938)
CAUTION:- When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
- When conducting measurements, measure two or more places, and find the average value.
- Measure the preload A of the reduction gear assembly in the following way.
- Measure the distance M7 from the edge of transaxle case to the mounting surface of adjusting shim.
- Install the reduction gear assembly on the converter housing, and measure the distance M8 from the edge of reduction gear assembly to the edge of converter housing.
- Install the outer race of reduction gear side bearing on the bearing, and measure the distance M9 from the edge of reduction gear assembly to the outer race of reduction gear bearing.
- Using the following expression, calculate the difference M10 from the outer race of reduction gear bearing to the edge of converter housing.
M10 = M8 - M9
- Using the following expression, calculate the thickness of adjusting shim.
Thickness of adjusting shim = M7 - M10 + preload
Standard value: 0.11 - 0.17 mm (0.005 - 0.006 in)
(For reduction gear preload)
CAUTION: Do not re-use the adjusting shim.
- Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ."
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
- Using the special tools, install the outer race of reduction gear bearing on the transaxle case.
- Installer adapter (MB990932)
- Installer bar (MB990938)
CAUTION:- Do not re-use the lip seal.
- Apply transmission fluid when installing the lip seal.
- Install the lip seal on the transaxle case.
CAUTION:
- Do not re-use the O-rings.
- Apply transmission fluid when installing the O-rings.
- Install the O-rings on the oil pump mounting bolt.
- Install the oil pump on the transaxle case to the specified tightening torque of 19 N.m (14 ft-lb). (One fastening bolt is installed at the backside from the transaxle case side. Only this bolt should be tightened to the specified torque of 28 N.m [21 ft-lb].)
CAUTION: Do not re-use the snap ring.
- Install the snap ring on the oil pump.
CAUTION:
- Do not re-use the lip seal.
- Apply transmission fluid or vaseline when installing the lip seal.
- Install the lip seal on the transaxle case.
- Install the valve body harness on the control valve.
- Install the control valve assembly on the transaxle case in the following way.
- Insert pins etc. (ø3 mm [ø0.1 in]) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.
- Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the diagram.
CAUTION: Align the notch of pulley ratio linkage with the prong of pulley sensor.
- Slide the control valve assembly from the bottom, and install it on the transaxle case.CAUTION: Apply transmission fluid when attaching the bush.
- Install the bush on the control valve assembly.
- Install the mounting bolt of control valve assembly, and tighten to the specified torque of 7.9 N.m (70 in-lb).
Bolt symbol A B Shank length mm (in) 54 (2.1) 44 (1.7) Quantity 10 1
- Install the manual valve lever, and tighten the fastening nuts to the specified torque of 22.1 N.m (16 ft-lb).
- Install the bracket on the manual valve assembly, and tighten the mounting bolt to the specified torque of 7.9 N.m (70 in-lb).
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- Install the O-ring on the oil strainer.
- Install the oil strainer, and tighten the mounting bolt to the specified torque of 7.9 N.m (70 in-lb).
Bolt symbol A B C Shank length mm (in) 12 (0.5) 44 (1.7) 12 (0.5) Quantity 1 1 1 CAUTION:- Do not re-use the oil pan gasket.
- Remove any moisture, oil, and used gasket from the mounting surface of oil pan gasket.
- When installing the oil pan gasket, align the dowel pins of transaxle case with dowel pin holes A of the oil pan gasket.
- Install the oil pan gasket on the transaxle case.
- Install the magnet on the oil pan.
CAUTION: When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
- Install the oil pan on the transaxle case, and tighten the mounting bolt to the specified torque of 7.9 N.m (70 in-lb).
CAUTION: Do not re-use the drain plug gasket.
- Install the drain plug and drain plug gasket on the transaxle case, and tighten to the specified torque of 34.3 N.m (25 ft-lb).
- Install the oil pump cover on the transaxle case, and fix the mounting bolt temporarily.
- Install the baffle plate, and fix the mounting bolt temporarily.
- Install the oil guide, and tighten the mounting bolt to the specified torque of 5.9 N.m (52 in-lb).
- Install the bracket, and tighten the fastening bolts of the bracket to the bolts to the specified torque of 26 N.m (19 ft-lb).
- Tighten the fastening bolts of the oil pump cover and baffle plate to the bolts to the specified torque of 19 N.m (14 ft-lb).
CAUTION:
- Make sure the tang of thrust washer is aligned with the mounting hole of oil pump cover.
- Apply vaseline when installing the thrust washer.
- Install the thrust washer on the oil pump cover.
CAUTION: Pull the driven sprocket up softly to make sure it is securely attached.
- Expand the snap ring, and install the driven sprocket, oil pump chain, and drive sprocket.
- Install the chain cover, and tighten the mounting nut to the specified torque of 5.9 N.m (52 in-lb).
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- Install the O-ring on the input shaft.
- Install the differential assembly on the transaxle case.
- Install the reduction gear assembly on the transaxle case.
CAUTION:
- Do not re-use the converter housing oil seal.
- Apply transmission fluid when installing the converter housing oil seal.
- Using the special tools, install the converter housing oil seal on the converter housing.
- Oil seal installer (MB992141)
- Handle (MB992075)
Depth from the case edge: within - 1.0 ± 0.5 mm (-0.04 ± 0.05 mm)
(Recessed).
CAUTION:- Do not re-use the converter housing side oil seal.
- Apply transmission fluid when installing the converter housing side oil seal.
- Using the special tools, install the converter housing side oil seal on the converter housing. < F1CJA >
- Oil seal installer (MB992206)
- Handle (MB992075)
CAUTION:- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.
- Apply the sealant on the converter housing mounting surface of the transaxle case in the following way.SEALANT SPECIFICATION
L1 9 mm (0.4 in) L2 5 mm (0.2 in) L3 ø1.5 mm (ø0.06 in) L4 R8.5 mm (R0.33 in) L5 R5 - 8 mm (R0.2 - 0.3 in) L6 3 - 5 mm (0.1 - 0.2 in) L7 ø17 mm (ø0.7 in) L8 3.5 mm (0.14 in) - Install the converter housing on the transaxle case, and tighten the mounting bolt to the specified torque of 45 N.m (33 ft-lb).
Bolt symbol A B Shank length mm (in) 30 (1.2) 35 (1.4) Quantity 18 5 CAUTION: Do not re-use the snap ring. - Install the snap ring on the terminal body.
CAUTION:
- Do not re-use the side oil seal.
- Apply transmission fluid when installing the side oil seal.
- Using the special tools, install the side oil seal on the transaxle case.
- Oil seal installer (MB992140)
- Handle (MB992075)
Depth from the case edge: within - 1.8 ± 0.5 mm (-0.07 ± 0.02 mm)
(Recessed).
- Install the transmission range switch on the transaxle case in the following way.
CAUTION: Do not re-use the transmission range switch.
- Install the transmission range switch on the transaxle case.
- Install the manual control lever on the manual shaft, and tighten the fastening nuts to the specified torque of 17.2 N.m (13 ft-lb).
- Set the manual shaft at N position.
- Insert pins etc. (ø5 mm[ø0.2 in]) in adjusting holes in both transmission range switch and manual control lever, and after alignment, tighten the mounting bolt to the specified torque of 5.5 N.m (49 in-lb).
CAUTION:- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- Install the O-ring on the primary pulley speed sensor.
- Install the primary pulley speed sensor on the transaxle case, and tighten the mounting bolt to the specified torque of 5.9 N.m (52 in-lb).
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- Install the O-ring on the secondary pulley speed sensor.
- Install the secondary pulley speed sensor on the transaxle case, and tighten the mounting bolt to the specified torque of 5.9 N.m (52 in-lb).
CAUTION:
- Apply transmission fluid or vaseline when installing the transmission fluid filter.
- Do-not re-use the transmission fluid filter.
- Install the transmission fluid filter on the transaxle case.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- When installing O-ring, make sure that projection of the O-ring is put into the groove on the filter.
- Install the O-ring on the transmission fluid filter.
- Install the transmission fluid cooler on the transaxle case, and tighten the mounting bolt to the specified torque of 4.2 N.m (37 in-lb).
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- Install the O-ring on the plug.
- Fasten the plug on the transaxle case to the specified torque of 7.5 N.m (66 in-lb).
CAUTION: When conducting measurements, measure two or more places, and find the average value.
- Install the converter on the transaxle, and measure the size A to check if it meets the standard value.
Standard size A: 15.9 mm (0.63 in)
- Install the control cable bracket and breather hose on the transaxle to the specified torque of 25 ± 4 N.m (18 ± 2 ft-lb).
- Install the oil filler tube and oil level gage on the transaxle to the specified torque of 8.5 ± 3.5 N.m (75 ± 30 in-lb).
- Install the harness bracket, corrugate clamp bracket and air breather bracket on the transaxle to the specified torque of 25 ± 4 N.m (18 ± 2 ft-lb).
- Install the roll rod adapter bracket on the transaxle to the specified torque of 90 ± 10 N.m (66 ± 7 ft-lb).
- Install the transfer on the transaxle to the specified torque of 69 ± 9 N.m (51 ± 6 ft-lb).