Primary Pulley and Secondary Pulley: Installation

NOTE: When replacing the primary pulley and secondary pulley, always replace them as a set.

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 a new seal ring.
NOTE:
- Apply CVTF to the seal rings.
- Do not stretch the seal ring more than necessary.
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When replacing the primary pulley and secondary pulley, select the primary pulley shim.

Using the ST, measure the height "H1" from the ST end face to the primary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

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(A)	Measurement surface

Using the ST, measure the height "H2" from the ST end face to the secondary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

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(A)	Measurement surface

Using the following calculation and selection criteria table, select an appropriate thickness of the primary pulley shim.

NOTE: Adjust using 1 to 2 pieces.

A = (H1 - H2) + C + 32.1195 mm (1.2645 in) - B

A	Pulley alignment mm (in)
H1	Measured value (mm (in)) of step (1)
H2	Measured value (mm (in)) of step (2)
B	Specified primary pulley dimension*
C	Specified secondary pulley dimension*
32.1195 mm (1.2645 in)	Constant

*: The specified dimensions of the primary pulley and secondary pulley are stamped only on repair parts.

Primary pulley shim selection criteria table for calculated values

Pulley alignment mm (in)	Thickness of primary pulley shim mm (in)
0.026 - 0.150 (0.001 - 0.006)	0.1 (0.004)
0.151 - 0.250 (0.006 - 0.010)	0.2 (0.008)
0.251 - 0.350 (0.010 - 0.014)	0.3 (0.012)
0.351 - 0.450 (0.014 - 0.018)	0.4 (0.016)
0.451 - 0.550 (0.018 - 0.022)	0.5 (0.020)
0.551 - 0.650 (0.022 - 0.026)	0.6 (0.024)
0.651 - 0.750 (0.026 - 0.030)	0.7 (0.028)
0.751 - 0.850 (0.030 - 0.033)	0.8 (0.031)
0.851 - 0.950 (0.034 - 0.037)	0.9 (0.035)
0.951 - 1.056 (0.037 - 0.042)	1.0 (0.039)

Set the primary pulley shim.

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Align the bolt hole of primary bearing retainer with the bolt hole of the converter case, and install the primary pulley with a new seal washer.
Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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Using the ST, expand the chain groove of the secondary pulley.
Preparation tool:

ST: EXPANDER PULLEY (18769AA020)

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(A) Chain groove
Install the secondary pulley.
1. Set the variator chain to the primary pulley.
2. Intersect the chain groove of primary pulley and the chain groove of secondary pulley, and set the secondary pulley while placing the variator chain on the secondary pulley.
  CAUTION: Be careful not to scratch the primary pulley, secondary pulley and variator chain.
3. Align the bolt hole of secondary bearing retainer with the bolt hole of drive pinion retainer, and install the secondary pulley mounting bolt.
NOTE: Apply CVTF to the threaded portion of the bolts and seat surface.

Tightening torque:

33 N.m (3.4 kgf-m, 24.3 ft-lb)

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Engage the cutout portions of support rod and drive pinion retainer and install the support rod.

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Align the cutout portions of lubrication pipe with the cutout portions of drive pinion retainer, and install the lubrication pipe.

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Install the chain guide to the variator chain.
Install the chain guide so that the support rod and lubrication pipe pass through, and then remove the ST (EXPANDER PULLEY).

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Install the transmission case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>TRANSMISSION CASE>INSTALLATION .