DISASSEMBLY AND REASSEMBLY

1. Transfer assembly 2. Dynamic damper 3. RR roll stopper bracket 4. FR roll stopper bracket 5. Harness bracket 6. Oil filler tube 7. Oil level gage 8. Control cable bracket 9. Breather hose

10. Washer 11. Shift lever 12. Inhibitor switch 13. CVT fluid filter 14. O-ring 15. CVT fluid cooler 16. Secondary pulley speed sensor 17. O-ring 18. O-ring 19. Plug 20. Control valve 21. Bracket 22. O-ring 23. Oil strainer 24. Spring washer 25. Manual lever 26. Bush 27. Lip seal 28. Snap ring 29. Valve body harness 30. Oil pan gasket 31. Magnet 32. Drain plug gasket 33. Drain plug 34. Oil pan 35. Torque converter 36. O-ring 37. Primary pulley speed sensor 38. O-ring 39. O-ring 40. Plug 41. Stud bolt

42. O-ring 43. Side oil shim 44. Adjusting shim 45. Outer race 46. Reduction gear assembly 47. Outer race 48. Adjusting shim 49. Outer race 50. Differential assembly 51. Outer race 52. Forward clutch assembly 53. Needle bearing 54. Seal ring 55. Oil pump cover 56. Baffle plate 57. Bracket 58. Clip 59. Pipe 60. Converter housing 61. Converter housing oil seal 62. Oil pump chain 63. Adjusting shim 64. Drive sprocket 65. Thrust washer 66. Baffle plate 67. Driven sprocket 68. Baffle plate 69. Oil pump 70. Lip seal 71. Snap ring 72. Driven plate 73. Needle bearing 74. Sun gear 75. Needle bearing 76. Planet carrier 77. Needle bearing 78. Snap ring 79. Retaining plate 80. Drive plate 81. Dish plate 82. Snap ring 83. Retaining plate 84. Spring retainer assembly 85. Reverse brake piston 86. Detent spring

DISASSEMBLY SERVICE POINT

7.Remove the torque converter from the transmission.

8.Remove the plug from the transmission case.

9.Remove the O-ring from the plug.

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

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

12.Remove the shift lever from the manual shaft.

13.Remove the inhibitor switch from the transmission.

14. 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.

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

16.Remove the CVT fluid cooler filter from the transmission case.

17.Remove the fastening bolts of converter housing. Bolt symbol A B Bolt length mm 30 35 Quantity 18 5

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

19.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) 20.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: Φ 61.949 - 61.979 mm

21.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) 22.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: Φ 84.941 - 84.976 mm

23. 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.

24.Remove the clip.

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

26.Remove the plug from the converter housing.

27.Remove the O-ring from the plug.

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

29.Remove the adjusting shim from the drive sprocket.

30.Remove the baffle plate.

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

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

33.Remove the snap ring from the oil pump.

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

35.Remove the differential assembly from the transmission case.

36.Remove the bracket.

37.Remove the baffle plate.

38.Remove the baffle plate.

39.Remove the oil pump cover from the transmission case.

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

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

42.Remove the oil pan from the transmission case. 43.Remove the magnet from the oil pan.

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

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

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

47.Remove the bracket from the control valve assembly.

48.Remove the manual lever.

49.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 fastening bolts of the control valve assembly. Bolt symbol A B Bolt 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.

50.Remove the bush from the control valve.

51.Remove the lip seal from the transmission case.

52.Remove the valve body harness from the control valve.

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

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

55.Remove the lip seal from the transmission case.

56.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) 57.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: Φ 67.949 - 67.979 mm

58.Remove the adjusting shim from the transmission case.

59.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) 60.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: Φ 61.949 - 61.979 mm

61.Remove the adjusting shim from the transmission case.

62. 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.

63.Remove the detent spring from the transmission case.

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

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

66.Remove the sun gear from the planet carrier.

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

68.Remove the planet carrier from the transmission case.

69.Remove the needle bearing from the planet carrier.

70. 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.

71. 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. 72.Remove the retaining plate and return spring assembly.

73. 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

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

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 end 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 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

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 6.9 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. Differential Oil Seal Installer (MB991168) Adapter (MB991702)

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 case, 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 Preload standard value: 0.17 - 0.29 mm

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 Preload standard value: = 0.13 - 0.19 mm

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 fastening bolts.

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

33. 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.

34.Install the valve body harness on the control valve.

35.Install the control valve assembly on the transmission case in the following way. (1) Insert pins etc. (Φ 3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage. (2) Install the terminal body on the transmission case, while aligning the detent of terminal body with the transmission case as shown in the diagram. (3) 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. (4) caution Apply CVT fluid when attaching the bush. Install the bush on the control valve assembly. (5) Install the fastening bolts of control valve assembly, and tighten to the specified torque of 7.9 N·m. Bolt symbol A B Bolt length mm 54 44 Quantity 10 1

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

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

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

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

40. 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. 41.Install the magnet on the oil pan.

42. 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 fastening bolts to the specified torque of 7.9 N·m. 43. 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.

44.Install the oil pump cover on the transmission case, and fix the fastening bolts temporarily.

45.Install the baffle plate, and fix the fastening bolts temporarily.

46.Install the baffle plate, and tighten the fastening bolts to the specified torque of 5.9 N·m.

47.Install the bracket, and tighten the fastening bolts of the oil pump cover, baffle plate, and bracket to the specified torque of 26 N·m.

48. 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.

49. 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.

50.Measure the clearance A between the oil pump drive sprocket and the converter housing in the following way. (1) Measure the distance M11 between the edge of transmission case and the adjusting shim mounting surface of drive sprocket. (2) Measure the distance M12 between the edge of converter housing and the surface contacting the adjusting shim. (3) Using the following expression, calculate the thickness of adjusting shim. Standard value of clearance = M11 + M12 -adjusting shim thickness Standard value: 0.10 - 0.23 mm (4) caution Apply vaseline when installing the adjusting shim. Install the selected adjusting shim on the drive sprocket. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS."

51.Install the baffle plate, and tighten the fastening nuts to the specified torque of 5.9 N·m.

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

53.Install the differential assembly on the transmission case.

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

55. caution Do not re-use the converter housing oil seal. Apply CVT fluid when installing the converter housing oil seal. Using the Special Tool, 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).

56. caution Remove any moisture, oil and oil sealant from the application surface. 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 Φ 1.5 mm L4 R 8.5 mm L5 R 5 - 8 mm L6 3 - 5 mm L7 Φ 17 mm L8 3.5 mm

57.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 Bolt length mm 30 35 Quantity 18 5

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

59. caution Do not re-use the side oil seal. Apply CVT fluid when installing the side oil seal. Using the Special Tool, install the side oil seal on the transmission case. Oil Seal Installer (MB992140) Handle (MB992075) Depth from the case edge: within - 1.8 ± 0.5 mm (recessed).

60.Install the inhibitor switch on the transmission case in the following way. (1) caution Do not re-use the inhibitor switch. 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. (Φ 5 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.

61. 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.

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

63. 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.

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

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

66. 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.

67.Install the CVT fluid cooler on the transmission case, and tighten the fastening bolts to the specified torque of 4.2 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 plug.

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

70. 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 71.Install the control cable bracket and breather hose on the transmission to the specified torque of 23 ± 3 N·m. 72.Install the oil filler tube and oil level gage on the transmission to the specified torque of 11 ± 1 N·m. 73.Install the harness bracket on the transmission to the specified torque of 23 ± 3 N·m. 74.Install the RR roll stopper bracket and FR roll stopper bracket on the transmission to the specified torque of 90 ± 10 N·m. 75.Install the dynamic damper on the transfer to the specified torque of 44 ± 6 N·m. 76.Install the transfer on the transmission to the specified torque of 68 ± 9 N·m.