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.
  • 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.

1.
 Drain plug
2.
 Drain plug gasket
3.
 Harness bracket
4.
 Harness bracket
5.
 Harness bracket
6.
 Harness bracket
7.
 Oil level gage
8.
 Oil filler tube
9.
 O-ring
10.
 Control cable bracket
11.
 Breather hose
12.
 Stud

13.
 Secondary pulley speed sensor
14.
 O-ring
15.
 Primary pulley speed sensor
16.
 O-ring
17.
 Output speed sensor
18.
 O-ring
19.
 Washer
20.
 Manual control lever
21.
 Inhibitor switch
22.
 CVT fluid cooler
23.
 O-ring
24.
 Side oil seal
25.
 Side oil seal
26.
 Oil pan
27.
 Oil pan gasket
28.
 Magnet
29.
 Transmission assembly

DISASSEMBLY SERVICE POINT


caution
  • Do not disassemble parts other than specified in this manual.

  • Be careful not to drop the torque converter during servicing work.

1.Remove the drain plug from the oil pan.
2.Remove the drain plug gasket from the drain plug.
3.Remove the harness bracket from the transmission assembly.
4.Remove the oil filler tube and oil level gage from the transmission case.
5.Remove the control cable bracket and breather hose from the transmission case.

6.Remove the secondary pulley speed sensor from the transmission case.

7.Remove the O-ring from the secondary pulley speed sensor.

8.Remove the primary pulley speed sensor from the transmission case.

9.Remove the O-ring from the primary pulley speed sensor.

10.Remove the output speed sensor from the transmission case.

11.Remove the O-ring from the output speed sensor.

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

13.Remove the inhibitor switch from the transmission case.

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

15.
caution When removing the 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 housing.

16.
caution When removing the oil seal, be careful not to cause damage to the converter housing.
Using a flat blade screwdriver etc., remove the side oil seal from the housing.

17.Remove the oil pan bolt from the transmission assembly.

18.Remove the oil pan and oil pan gasket from the transmission assembly.

19.Remove the magnet from the oil pan.

REASSEMBLY SERVICE POINT

1.Install the magnet on the oil pan.

2.
caution Do not re-use the oil pan gasket.
Install the oil pan and oil pan gasket on the transmission case.
3.Tighten each front oil pan mounting bolt to the temporarily torque.

4.
caution Wipe of CVT fluid after an CVT fluid application for the prevention from CVT fluid.
Tighten each oil pan mounting bolt to the specified torque of 5.9 ± 0.6 N·m in the order of number shown.

5.
caution
  • Do not re-use the oil seal.
  • Applied oil to the oil seal outside.
  • Be careful not to damage an oil seal lip at the time of drive shaft application attachment enough.
  • Wipe of CVT fluid after an CVT fluid application for the prevention from CVT fluid.
Using the special tool roll stopper bush r & i arbour (MB990982), install the side oil seal on the converter housing.
Depth from the case edge: within - 1.8 ± 0.5 mm (recessed).

6.
caution
  • Do not re-use the oil seal.
  • Applied oil to the oil seal outside.
  • Be careful not to damage an oil seal lip at the time of drive shaft application attachment enough.
  • Wipe of CVT fluid after an CVT fluid application for the prevention from CVT fluid.
Using the special tools roll stopper bush r & i arbour (MB990982), install the side oil seal on the transmission case.
Depth from the case edge: within - 1.8 ± 0.5 mm (recessed).

7.
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 cooler.
8.Install the CVT fluid cooler on the transmission case, and tighten the mounting bolts to the specified torque of 4.3 ± 0.5 N·m.
9.
caution Do not re-use the inhibitor switch.
Install the inhibitor switch on the transmission case in the following way.

10.Install the inhibitor switch on the transmission case.
11.Tighten each inhibitor switch mounting bolt to the temporarily torque.

12.Install the manual control lever on the manual shaft.
13.Install the washer on the manual shaft, and tighten the mounting nuts to the specified torque of 17 ± 2 N·m.
14.Set the manual shaft at N position.

15.Adjust the inhibitor switch so that a Φ5mm pin goes into the pin hole for N range position manual control lever and inhibitor switch.
16.
caution It checks that the pin is certainly inserted in the pin hole for N range position adjusted of manual control lever and inhibitor switch.
Inhibitor switch tighten the mounting bolts to the specified torque of 5.9 ± 1.0 Nm.
17.A pin is removed from a pinhole for N range position justification.

18.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
  • Wipe of CVT fluid after an CVT fluid application for the prevention from CVT fluid.
Install the O-ring on the output speed sensor.

19.Install the output speed sensor on the converter housing, and tighten the mounting bolts to the specified torque of 5.9 ± 1.0 N·m.

20.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
  • Wipe of CVT fluid after an CVT fluid application for the prevention from CVT fluid.
Install the O-ring on the primary pulley speed sensor.

21.Install the primary pulley speed sensor on the transmission assembly, and tighten the mounting bolts to the specified torque of 5.9 ± 1.0 N·m.

22.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
  • Wipe of CVT fluid after an CVT fluid application for the prevention from CVT fluid.
Install the O-ring on the secondary pulley speed sensor.

23.Install the secondary pulley speed sensor on the transmission assembly, and tighten the mounting bolts to the specified torque of 5.9 ± 1.0 N·m.

24.
caution When conducting measurements, measure two or more places, and find the average value.
Install the converter on the transmission assembly, and measure the size A to check if it meets the standard value.
Standard size A: 12.2 mm
25.Install the control cable bracket and breather hose on the transmission case.
26.Install the harness bracket on the transmission assembly.
27.
caution Do not re-use the O-ring.
Install the oil filler tube and oil level gage on the transmission case.

28.
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 35 ± 4 N·m.