DISASSEMBLY AND REASSEMBLY


caution
  • Only use CVT fluid of the specified brand. Use of CVT fluid other than specified will impair driveability and CVT endurance, and may lead to breakage of CVT.
  • Only use the specified vaseline. Use of vaseline other than specified will impair driveability and CVT endurance, and may lead to breakage of CVT.
  • Disassembly work should be done in a clean dust-proof room.
  • Prior to disassembly, clean any sand or dirt adhered to the outer parts of transmission using steam, washing oil or another solvent, outside the clean room, so as not to contaminate inner parts of transmission during disassembly or assembly. (Do not allow steam to get inside the transmission, and do not clean rubber parts with washing oil.)
  • After cleaning, remove the torque converter, and drain the CVT fluid.
  • Disassembly and assembly work should be done with bare hands or using plastic gloves.
  • Do not touch inner parts of the transmission after touching its outer parts. (Wash hands after touching the outer parts.)
  • Do not use cotton gloves and rags to prevent from lint; instead, use paper rags.
  • Prior to assembly or disassembly work, make sure conditions are appropriate.
  • Do not re-use the drained CVT fluid.

<F1CJA>
1.
 Roll rod adapter bracket
2.
 Harness bracket
3.
 Corrugate clamp bracket
4.
 Air breather bracket
5.
 Oil level gage
6.
 Oil filler tube
7.
 Control cable bracket
8.
 Breather hose

9.
 Washer
10.
 Manual control lever
11.
 Inhibitor switch
12.
 CVT fluid filter
13.
 O-ring
14.
 CVT fluid cooler
15.
 Secondary pulley speed sensor
16.
 Washer
17.
 O-ring
18.
 O-ring
19.
 Plug
20.
 Control valve
21.
 Bracket
22.
 O-ring
23.
 Oil strainer
24.
 Strainer pipe <Vehicles with AS&G system>
25.
 Spring washer
26.
 Manual valve lever
27.
 Bush
28.
 Lip seal
29.
 Snap ring
30.
 Valve body harness
31.
 Oil pan gasket
32.
 Magnet
33.
 Drain plug gasket
34.
 Drain plug
35.
 Oil pan
36.
 Torque converter
37.
 O-ring
38.
 Primary pulley speed sensor
39.
 O-ring
40.
 O-ring
41.
 Plug
42.
 Stud bolt
43.
 Valve assembly control <Vehicles with AS&G system>
44.
 O-ring <Vehicles with AS&G system>
45.
 Electric oil pump <Vehicles with AS&G system>
46.
 O-ring <Vehicles with AS&G system>

47.
 O-ring
48.
 Side oil seal
49.
 Adjusting shim
50.
 Outer race
51.
 Reduction gear assembly
52.
 Outer race
53.
 Adjusting shim
54.
 Outer race
55.
 Differential assembly
56.
 Outer race
57.
 Forward clutch assembly
58.
 Needle bearing
59.
 Seal ring
60.
 Oil pump cover
61.
 Turbine sensor <Vehicles with idle neutral control>
62.
 Baffle plate
63.
 Bracket
64.
 Clip
65.
 Pipe
66.
 Converter housing
67.
 Converter housing oil seal
68.
 Converter housing side oil seal
69.
 Oil pump chain
70.
 Drive sprocket
71.
 Thrust washer
72.
 Chain cover
73.
 Driven sprocket
74.
 Oil guide
75.
 Oil pump
76.
 Lip seal
77.
 Snap ring
78.
 Driven plate
79.
 Needle bearing
80.
 Sun gear
81.
 Needle bearing
82.
 Planet carrier
83.
 Needle bearing
84.
 Snap ring
85.
 Retaining plate
86.
 Drive plate
87.
 Dish plate
88.
 Snap ring
89.
 Retaining plate
90.
 Spring retainer assembly
91.
 Reverse brake piston
92.
 Detent spring

<W1CJA>
1.
 Transfer
2.
 Roll rod adapter bracket
3.
 Harness bracket
4.
 Corrugate clamp bracket
5.
 Air breather bracket
6.
 Oil filler tube
7.
 Oil level gage
8.
 Control cable bracket
9.
 Breather hose

10.
 Washer
11.
 Manual control lever
12.
 Inhibitor switch
13.
 CVT fluid filter
14.
 O-ring
15.
 CVT fluid cooler
16.
 Secondary pulley speed sensor
17.
 Washer
18.
 O-ring
19.
 O-ring
20.
 Plug
21.
 Control valve
22.
 Bracket
23.
 O-ring
24.
 Oil strainer
25.
 Strainer pipe <Vehicles with AS&G system>
26.
 Spring washer
27.
 Manual valve lever
28.
 Bush
29.
 Lip seal
30.
 Snap ring
31.
 Valve body harness
32.
 Oil pan gasket
33.
 Magnet
34.
 Drain plug gasket
35.
 Drain plug
36.
 Oil pan
37.
 Torque converter
38.
 O-ring
39.
 Primary pulley speed sensor
40.
 O-ring
41.
 O-ring
42.
 Plug
43.
 Stud bolt
44.
 Valve assembly control <Vehicles with AS&G system>
45.
 O-ring <Vehicles with AS&G system>
46.
 Electric oil pump <Vehicles with AS&G system>
47.
 O-ring <Vehicles with AS&G system>

48.
 O-ring
49.
 Side oil seal
50.
 Adjusting shim
51.
 Outer race
52.
 Reduction gear assembly
53.
 Outer race
54.
 Adjusting shim
55.
 Outer race
56.
 Differential assembly
57.
 Outer race
58.
 Forward clutch assembly
59.
 Needle bearing
60.
 Seal ring
61.
 Oil pump cover
62.
 Turbine sensor <Vehicles with idle neutral control>
63.
 Baffle plate
64.
 Bracket
65.
 Clip
66.
 Pipe
67.
 Converter housing
68.
 Converter housing oil seal
69.
 Oil pump chain
70.
 Drive sprocket
71.
 Thrust washer
72.
 Chain cover
73.
 Driven sprocket
74.
 Oil guide
75.
 Oil pump
76.
 Lip seal
77.
 Snap ring
78.
 Driven plate
79.
 Needle bearing
80.
 Sun gear
81.
 Needle bearing
82.
 Planet carrier
83.
 Needle bearing
84.
 Snap ring
85.
 Retaining plate
86.
 Drive plate
87.
 Dish plate
88.
 Snap ring
89.
 Retaining plate
90.
 Spring retainer assembly
91.
 Reverse brake piston
92.
 Detent spring

DISASSEMBLY SERVICE POINT


caution Do not disassemble parts other than specified in this manual.
1.Remove the transfer from the transmission. <W1CJA>
2.Remove the roll rod adapter bracket from the transmission.
3.Remove the harness bracket, corrugate clamp bracket and air breather bracket from the transmission.
4.Remove the oil filler tube and oil level gage from the transmission.
5.Remove the control cable bracket and breather hose from the transmission.

6.Remove the torque converter from the transmission.

7.Remove the plug from the transmission case.

8.Remove the O-ring from the plug.

9.Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.

10.Remove the primary pulley speed sensor from the transmission case, and detach the O-ring from the sensor.

11.Remove the manual control lever from the manual shaft.

12.Remove the inhibitor switch from the transmission case.

13.
caution Be careful not to cause damage to the terminal body.
Remove the O-ring from the terminal body, and press the terminal body into the transmission case.

14.Remove the CVT fluid cooler from the transmission case, and detach the O-ring from the cooler.

15.Remove the CVT fluid filter from the transmission case.

16.Remove the mounting bolt of converter housing.
Bolt symbol
 A
 B
Shank length mm
 30
 35
Quantity
 18
 5

17.
caution Be careful because adjusting shim of the drive sprocket may depart.
Remove the converter housing by tapping with a plastic hammer etc.

18.Using the special tools, remove the outer race of reduction gear bearing from the converter housing.

  • Rear axle shaft oil seal remover (MB990590)
  • Slide hammer puller (MB992039)
19.Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.
Standard value: Φ61.949 - 61.979 mm

20.Using the special tools, remove the outer race of differential side bearing from the converter housing.

  • Rear axle shaft oil seal remover (MB990590)
  • Slide hammer puller (MB992039)
21.Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.
Standard value:
  • Φ67.949 - 67.979 mm <F1CJA>
  • Φ84.941 - 84.976 mm <W1CJA>

22.
caution When removing the oil seal, be careful not to cause damage to the converter housing.
Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.

23.Remove the clip.

24.
caution When removing the pipe, be careful not to strain it.
Remove the pipe from the converter housing.


25.Remove the plug from the converter housing.

26.Remove the O-ring from the plug.

27.Remove the O-ring from the input shaft.

28.Remove the chain cover.


29.Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

30.Remove the thrust washer from the oil pump cover.

31.Remove the snap ring from the oil pump.

32.Remove the reduction gear assembly from the transmission case.


33.Remove the differential assembly from the transmission case.

34.Remove the oil pan from the transmission case.
35.Remove the magnet from the oil pan.

36.Remove the oil pan gasket from the transmission case.

37.Remove the strainer pipe fastened at two locations with clips B and C.

38.Remove the oil strainer.
Bolt symbol
 A
 B
 C
Shank length mm
 12
 44
 12
Quantity
 1
 1
 1

39.Remove the O-ring from the oil strainer.

40.Remove the bracket from the control valve assembly.

41.Remove the manual valve lever.

42.Remove the two valve body harness connectors.



43.Remove the control valve assembly from the transmission case in the following way.
(1) Insert pins etc. (Φ3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.
(2) Remove mounting bolt of the control valve assembly.
Bolt symbol
 A
 B
Shank length mm
 54
 44
Quantity
 10
 1
(3) Remove the control valve assembly from the transmission case.
note Tilt the control valve assembly, and after removing from the manual shaft side, remove the terminal body from the transmission case.

44.Remove the bush from the control valve.

45.Remove the lip seal from the transmission case.

46.
caution When removing the turbine sensor, do not deform the turbine sensor bracket.
Remove the turbine sensor harness connector and bracket mounting bolts.
47.Remove the valve body harness from the control valve.

48.Remove the bracket.

49.Remove the oil guide.

50.Remove the baffle plate.

51.Remove the two turbine sensor mounting bolts and the two bracket mounting bolts, and then remove the turbine sensor.
52.Remove the oil pump cover mounting bolt, and then remove the oil pump cover from the transmission case.

53.Remove the seal ring from the oil pump cover.

54.Remove the needle bearing from the forward clutch assembly.

55.Remove the oil pump from the transmission case. (One fastening bolt is installed at the backside from the transmission case side.)

56.Remove the O-ring from the oil pump fastening bolt.

57.Remove the lip seal from the transmission case.

58.Using the special tools, remove outer race of the differential side bearing from the transmission case.

  • Rear axle shaft oil seal remover (MB990590)
  • Slide hammer puller (MB992039)
59.Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the transmission case side; if the standard value is not satisfied, then replace the CVT assembly.
Standard value: Φ67.949 - 67.979 mm

60.Remove the adjusting shim from the transmission case.

61.Using the special tools, remove outer race of the reduction gear bearing from the transmission case.

  • Rear axle shaft oil seal remover (MB990590)
  • Slide hammer puller (MB992039)
62.Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the transmission case side; if the standard value is not satisfied, then replace the CVT assembly.
Standard value: Φ61.949 - 61.979 mm

63.Remove the adjusting shim from the transmission case.

64.
caution When removing the side oil seal, be careful not to cause damage to the transmission case.
Using a flat blade screwdriver etc., remove the side oil seal from the transmission case.

65.Remove the detent spring from the transmission case.

66.Remove the forward clutch assembly from the transmission case.

67.Remove the needle bearing on forward clutch drum side from the sun gear.

68.Remove the sun gear from the planet carrier.

69.Remove the needle bearing on primary pulley side from the sun gear.

70.Remove the planet carrier from the transmission case.

71.Remove the needle bearing from the planet carrier.

72.
caution Check if there is a damage, deformation, a burn mark or permanent set on the dish plate, driven plate, snap ring, and drive plate. Replace any defective part.
Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transmission case.

73.
caution
  • Set the spring compressor right on top of the spring of spring retainer assembly.
  • Do not remove the return spring from the spring retainer assembly.
Using the special tool, Spring compressor (MB992139), compress the return spring, and remove the snap ring from the transmission case.
74.Remove the retaining plate and return spring assembly.


75.
caution Be careful because that the reverse brake piston may be stuck if compressed air is fed excessively.
Feed the air in the oil hole shown in the diagram, and remove the reverse brake piston from the transmission case.

IDENTIFICATRION OF NEEDLE BEARINGS




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 transmission 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."

1.
caution
  • Do not re-use the reverse brake piston.
  • Apply CVT fluid when installing the reverse brake piston.
Install the reverse brake piston, while turning it, on the transmission case.

2.Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.


3.
caution When installing the retaining plate, align the tangs at positions A, B, C in the diagram.
Install the retaining plate on the transmission case.


4.
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 transmission case by means of a flat blade screwdriver etc.

5.Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transmission case.


6.
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 transmission 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
(For reverse brake clearance)

7.
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.

8.Install the planet carrier on the reverse brake.

9.
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.

10.Install the sun gear on the planet carrier.

11.
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.

12.Install the forward clutch assembly on the transmission case.



13.
caution When conducting measurements, measure two or more places, and find the average value.
Measure the total axial play A in the following way.
(1) Measure the distance M1 from the oil pump cover mounting surface of the transmission case to the needle bearing mounting surface of the forward clutch drum.
(2) Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transmission case.
(3) Calculate the total axial play by the following expression. Select the needle bearing so that the total axial play meets its standard value.
Total axial play = M1 - M2 - bearing thickness
Standard value: 0.25 - 0.55 mm
(For total axial play)

14.
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.

15.
caution
  • Do not re-use the seal rings.
  • Apply vaseline when installing the seal rings.
Install the seal rings on the oil pump cover.

16.
caution Do not re-use the bolt.
Install the detent spring on the transmission case, and tighten the fastening bolt at the specified torque of 6.9 N·m.

17.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the plug.


18.Install the plug on the converter housing to the specified torque of 7.5 N·m.

19.
caution Do not strain the pipe when attaching it.
Install the pipe on the converter housing.

20.Install the clip, and tighten the bolt at the specified torque of 5.9 N·m.


21.
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>




22.
caution
  • When adjusting the preload, apply CVT 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.
(1) Measure the distance M3 from the edge of transmission case to the mounting surface of adjusting shim.
(2) Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing.
(3) 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.
(4) 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
(5) Using the following expression, calculate thickness of the adjusting shim.
Thickness of adjusting shim = M3 - M6 + preload
Standard value: 0.17 - 0.23 mm
(For differential preload)

23.
caution Do not re-use the adjusting shim.
Install the selected shim on the transmission case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS."

24.
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 transmission case.

25.
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)




26.
caution
  • When adjusting the preload, apply CVT 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.
(1) Measure the distance M7 from the edge of transmission case to the mounting surface of adjusting shim.
(2) 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.
(3) 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.
(4) 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
(5) Using the following expression, calculate the thickness of adjusting shim.
Thickness of adjusting shim = M7 - M10 + preload
Standard value: 0.11 - 0.17 mm
(For reduction gear preload)

27.
caution Do not re-use the adjusting shim.
Install the selected adjusting shim on the transmission case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS."

28.
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 transmission case.

  • Installer adapter (MB990932)
  • Installer bar (MB990938)

29.
caution
  • Do not re-use the lip seal.
  • Apply CVT fluid when installing the lip seal.
Install the lip seal on the transmission case.

30.
caution
  • Do not re-use the O-rings.
  • Apply CVT fluid when installing the O-rings.
Install the O-rings on the oil pump mounting bolt.

31.Install the oil pump on the transmission case to the specified tightening torque of 19 N·m. (One fastening bolt is installed at the backside from the transmission case side. Only this bolt should be tightened to the specified torque of 28 N·m.)

32.
caution
  • When re-using the turbine sensor, do not replace the oil pump cover.
  • When installing the turbine sensor, do not deform the turbine sensor bracket.
  • With the turbine sensor bracket installed, make sure that the turbine sensor is not pulled by the harness.
Install the oil pump cover and turbine sensor on the transmission case, and then temporarily tighten the mounting bolts.
33.Tighten the two turbine sensor mounting bolts to the specified torque of 6.9 N·m.

34.Install the baffle plate, and fix the mounting bolt temporarily.

35.Install the oil guide, and tighten the mounting bolt to the specified torque of 5.9 N·m.

36.Install the bracket, and tighten the fastening bolts of the bracket to the bolts to the specified torque of 26 N·m.
37.Tighten the mounting bolts for the oil pump cover, turbine sensor, and baffle plate to the specified torque of 19 N·m.

38.
caution Do not re-use the snap ring.
Install the snap ring on the oil pump.

39.
caution
  • Do not re-use the lip seal.
  • Apply CVT fluid or vaseline when installing the lip seal.
Install the lip seal on the transmission case.

40.Install the valve body harness to the transmission case.
Install the terminal body on the transmission case, while aligning the detent of terminal body with the transmission case as shown in the diagram.

41.Tighten the mounting bolts for turbine sensor bracket to the specified torque of 7.9 N·m and connect the harness connector.





42.Install the control valve assembly on the transmission case as follows.
(1) Insert pins etc. (Φ3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.
(2)
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 transmission case.
(3)
caution Apply CVT fluid when attaching the bush.
Install the bush on the control valve assembly.
(4) Install the fastening bolts of control valve assembly, and tighten to the specified torque of 7.9 N·m.
Bolt symbol
 A
 B
Shank length mm
 54
 44
Quantity
 10
 1

43.Install the manual valve lever, and tighten the fastening nuts to the specified torque of 22.1 N·m.

44.Connect the two valve body harness connectors.

45.Install the bracket on the control valve assembly, and tighten the fastening bolts to the specified torque of 7.9 N·m.

46.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the oil strainer.

47.Install the oil strainer, and tighten the fastening bolts to the specified torque of 7.9 N·m.
Bolt symbol
 A
 B
 C
Shank length mm
 12
 44
 12
Quantity
 1
 1
 1

48.Push the strainer pipe into the hole and at the same time, push into clips B and C.

49.
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 transmission case with dowel pin holes A of the oil pan gasket.
Install the oil pan gasket on the transmission case.
50.Install the magnet on the oil pan.

51.
caution When installing the oil pan, align the dowel pins of transmission case with dowel pin holes A of the oil pan.
Install the oil pan on the transmission case, and tighten the bolts to the specified torque of 7.9 N·m.
52.
caution Do not re-use the drain plug gasket.
Install the drain plug and drain plug gasket on the transmission case, and tighten to the specified torque of 34.3 N·m.

53.
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.


54.
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.

55.Install the chain cover, and tighten the fastening nuts to the specified torque of 5.9 N·m.

56.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the input shaft.


57.Install the differential assembly on the transmission case.

58.Install the reduction gear assembly on the transmission case.


59.
caution
  • Do not re-use the converter housing oil seal.
  • Apply CVT 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 (recessed).

60.
caution
  • Do not re-use the converter housing side oil seal.
  • Apply CVT 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)


61.
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 transmission case in the following way.
Specified sealant: Loctite 509
L1
 9 mm
L2
 5 mm
L3
 Φ1.5 mm
L4
 R8.5 mm
L5
 R5 - 8 mm
L6
 3 - 5 mm
L7
 Φ17 mm
L8
 3.5 mm

62.Install the converter housing on the transmission case, and tighten the fastening bolts to the specified torque of 45 N·m.
Bolt symbol
 A
 B
Shank length mm
 30
 35
Quantity
 18
 5

63.
caution Do not re-use the snap ring.
Install the snap ring on the terminal body.

64.
caution
  • Do not re-use the side oil seal.
  • Apply CVT fluid when installing the side oil seal.
Using the special tool, Oil seal installer (MB992140), install the side oil seal on the transmission case.
Depth from the case edge:
Within - 1.8 ± 0.5 mm (recessed)



65.
caution Do not re-use the inhibitor switch.
Install the inhibitor switch on the transmission case as follows:
(1) Install the inhibitor switch on the transmission case.
(2) Install the shift lever on the manual shaft, and tighten the fastening nuts to the specified torque of 17.2 N·m.
(3) Set the manual shaft at N position.
(4) Insert pins etc. (Φ5 mm) in adjusting holes in both inhibitor switch and shift lever, and after alignment, tighten the fastening bolts to the specified torque of 5.5 N·m.

66.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the oil ring on the primary pulley speed sensor.

67.Install the primary pulley speed sensor on the transmission case, and tighten the fastening bolts to the specified torque of 5.9 N·m.

68.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the secondary pulley speed sensor.

69.Install the secondary pulley speed sensor on the transmission case, and tighten the fastening bolts to the specified torque of 5.9 N·m.

70.
caution
  • Apply CVT fluid or vaseline when installing the CVT fluid filter.
  • Do-not re-use the CVT fluid filter.
Install the CVT fluid filter on the transmission case.

71.
caution
  • Do not re-use the O-ring.
  • Apply CVT 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 CVT fluid filter.

72.Install the CVT fluid cooler on the transmission case, and tighten the fastening bolts to the specified torque of 4.2 N·m.

73.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the plug.

74.Fasten the plug on the transmission case to the specified torque of 7.5 N·m.

75.
caution When conducting measurements, measure two or more places, and find the average value.
Install the converter on the transmission, and measure the size A to check if it meets the standard value.
Standard size A: 15.9 mm
76.Install the control cable bracket and breather hose on the transmission case, and tighten the fastening bolts to the specified torque of 25 ± 4 N·m.
77.Install the oil filler tube and oil level gage on the transmission case, and tighten the fastening bolts to the specified torque of 8.5 ± 3.5 N·m.
78.Install the harness bracket on the transmission case, and tighten the fastening bolts to the specified torque of 25 ± 4 N·m.
79.Install the roll rod adapter bracket on the transmission case, and tighten the fastening bolts to the specified torque of 90 ± 10 N·m.
80.Install the transfer on the transmission to the specified torque of 68 ± 9 N·m. <W1CJA>