Converter Case Cover: Installation

Select the front reduction drive gear shim.

Measure the height "H1" from the converter case cover upper face to the ball bearing catch surface.

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Using the ST, measure the height "H2" from the ST end face to the converter case cover mating surface.

Preparation tool:

ST: GAUGE (499575600)

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Using the ST, measure the height "H3" from the ST end face to the ball bearing end face.

Preparation tool:

ST: GAUGE (499575600)

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Using the following calculation and selection criteria table, select an appropriate thickness of the front reduction drive gear shim.
NOTE: Adjust using 1 piece.

C = (H3 - 15 mm (0.6 in)) - ((H2 - 15 mm (0.6 in)) - H1)

C	Clearance mm (in)
H1	Measured value (mm (in)) of step (1)
H2	Measured value (mm (in)) of step (2)
H3	Measured value (mm (in)) of step (3)
15 mm (0.6 in)	Thickness of ST

SELECTION CRITERIA FOR FRONT REDUCTION DRIVE GEAR SHIM ACCORDING TO CALCULATED VALUES

Clearance "C" mm (in)	Front reduction drive gear shim thickness mm (in)
1.070 - 1.174 (0.042 - 0.046)	1.0 (0.039)
1.175 - 1.274 (0.046 - 0.050)	1.1 (0.043)
1.275 - 1.374 (0.050 - 0.054)	1.2 (0.047)
1.375 - 1.474 (0.054 - 0.058)	1.3 (0.051)
1.475 - 1.580 (0.058 - 0.062)	1.4 (0.055)

Select the front reduction driven gear shim (front side).

Measure the height "H1" from the converter case cover upper face to the ball bearing catch surface.

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Using the ST, measure the height "H2" from the ST end face to the converter case cover mating surface.

Preparation tool:

ST: GAUGE (499575600)

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Set a new ball bearing to the reduction driven gear.

Using the ST, measure the height "H3" from the ST end face to the ball bearing end face.

Preparation tool:

ST: GAUGE (499575600)

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Using the following calculation and selection criteria table, select an appropriate thickness of the front reduction driven gear shim (front side).

NOTE: Adjust using 1 - 2 pieces.

C = (H3 - 15 mm (0.6 in)) - ((H2 - 15 mm (0.6 in)) - H1)

C	Clearance mm (in)
H1	Measured value (mm (in)) of step (1)
H2	Measured value (mm (in)) of step (2)
H3	Measured value (mm (in)) of step (4)
15 mm (0.6 in)	Thickness of ST

SELECTION CRITERIA FOR FRONT REDUCTION DRIVEN GEAR SHIM (FRONT SIDE) ACCORDING TO CALCULATED VALUES

Clearance "C" mm (in)	Front reduction driven gear shim (front side) thickness mm (in)
0.470 - 0.569 (0.019 - 0.022)	0.4 (0.016)
0.570 - 0.669 (0.022 - 0.026)	0.5 (0.020)
0.670 - 0.769 (0.026 - 0.030)	0.6 (0.024)
0.770 - 0.869 (0.030 - 0.034)	0.7 (0.028)
0.870 - 0.980 (0.034 - 0.039)	0.8 (0.031)

Remove the ball bearing from the reduction driven gear.

Install a new seal ring.
NOTE:
- Apply CVTF to the seal rings.
- Do not stretch the seal ring more than necessary.
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Install the front reduction driven gear shim (front side).

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Using the ST and a press, press-fit a new ball bearing.
NOTE: Apply CVTF to the press-fitting area.

Preparation tool:

ST: INSTALLER (20099AE020)

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Using vaseline, set the front reduction drive gear shim.

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Install a new O-ring.
NOTE: Apply CVTF to the O-rings.

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Apply liquid gasket to the mating surface of the converter case as shown in the figure, and temporarily install the converter case cover.
NOTE:
- Before applying liquid gasket, degrease the liquid gasket seal surface of the converter case and converter case cover.
- Install within 5 min. after applying liquid gasket.
Preparation items:

Liquid gasket: THREE BOND 1215B or equivalent

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Tighten the bolts securing the converter case cover.
Tightening torque:

24 N.m (2.4 kgf-m, 17.7 ft-lb)
Install the oil pump chain cover and the oil pump chain. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>OIL PUMP CHAIN>INSTALLATION .
Install the oil stopper plate (A) and lubrication pipe (B).
Tightening torque:

9 N.m (0.9 kgf-m, 6.6 ft-lb)

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Install the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>DRIVE PINION>INSTALLATION .