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.
  • *: When the connection of the CVT fluid cooler and the oil cooler hose is disconnected, replace the CVT fluid cooler and the oil cooler hose with new ones. When connecting the new CVT fluid cooler and the oil cooler hose, be careful not to let the CVT fluid or the like adhere.
  • When the transmission assembly or the valve body assembly are replaced, carry out the following operations.

    • Initialisation procedure for CVT learned value (Refer to GROUP 23A - Initialisation Procedure for CVT Learned Value .)
    • Learning procedure (Refer to GROUP 23A - Learning Procedure .)

1.
 Roll rod adapter bracket
2.
 Transfer <W1CJC>
3.
 Radiator hose bracket
4.
 Harness bracket
5.
 Corrugate clamp bracket
6.
 Air breather bracket
7.
 Control cable bracket
8.
 Oil level gage
9.
 Oil filler tube
10.
 O-ring
11.
 Breather hose
12.
 Oil cooler feed hose
13.
 Eye bolt
14.
 Gasket
15.
 Oil cooler pipe assembly
16.
 Oil cooler return hose
17.
 Eye bolt
18.
 Gasket
19.
 Oil cooler tube assembly

20.
 Drain plug
21.
 Drain plug gasket
22.
 Torque converter
23.
 O-ring
24.
 Plug
25.
 O-ring
26.
 Turbine speed sensor
27.
 O-ring
28.
 Primary pulley speed sensor
29.
 O-ring
30.
 Secondary pulley speed sensor
31.
 O-ring
32.
 Washer
33.
 Manual control lever
34.
 Inhibitor switch
35.
 CVT fluid cooler
36.
 Filter cover
37.
 O-ring
38.
 CVT fluid filter
39.
 Side oil seal
40.
 Side oil seal <F1CJC>
41.
 Converter housing oil seal
42.
 Snap ring
43.
 Oil pan
44.
 Magnet
45.
 Oil pan gasket
46.
 Oil strainer
47.
 O-ring
48.
 Bracket
49.
 Manual valve lever
50.
 Spring washer
51.
 Valve body assembly
52.
 Valve body harness
53.
 Lip seal
54.
 Transmission assembly

DISASSEMBLY SERVICE POINT


caution Do not disassemble parts other than specified in this manual.
1.Remove the transfer from the transmission. <W1CJC>
2.Remove the radiator hose bracket, harness bracket, corrugate clamp bracket and air breather bracket from the transmission.
3.Remove the oil filler tube and oil level gage from the transmission.
4.Remove the control cable bracket and breather hose from the transmission.
5.Remove the oil cooler feed hose, oil cooler return hose, oil cooler pipe assembly, oil cooler tube assembly <Vehicles with air-cooled oil cooler assembly>, eye bolt and gasket from the transmission.
6.Remove the drain plug and drain plug gasket from the oil pan.

7.Remove the torque converter from the transmission.

8.
caution When removing the O-ring, be careful not to cause damage to the input shaft.
Remove the O-ring from the input shaft.

9.Remove the plug from the transmission case, and detach the O-ring from the plug.

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

11.Remove the primary pulley speed sensor from the side cover, and detach the O-ring from the sensor.

12.Remove the secondary pulley speed sensor from the transmission case, and detach the O-ring from the sensor.

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

14.Remove the inhibitor switch from the transmission case.

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

16.Remove the filter cover from the transmission case.

17.Remove the O-ring and CVT fluid filter from the transmission case.

18.
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.

19.
caution When removing the side 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 converter housing. <F1CJC>

20.
caution When removing the converter housing oil seal, be careful not to cause damage to the converter housing and input shaft.
Remove the converter housing oil seal from the converter housing.

21.
caution Be careful not to cause damage to the terminal body.
Remove the snap ring from the terminal body, and press the terminal body into the transmission case.

22.Remove the oil pan from the transmission case.
23.Remove the magnet from the oil pan.

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

25.Remove the oil strainer.
Bolt symbol
 A
 B
Shank length mm
 44
 12
Quantity
 1
 2
26.Remove the O-ring from the oil strainer.

27.Remove the bracket from the valve body assembly.

28.Remove the manual valve lever.


29.Remove the valve body assembly from the transmission case in the following way.
(1) Remove mounting bolts of the valve body assembly.
Bolt symbol
 A
 B
 C
Shank length mm
 54
 44
 54
Quantity
 8
 1
 2
(2) Remove the valve body assembly from the transmission case.
note Tilt the valve body assembly, and after removing from the manual shaft side, remove the terminal body from the transmission case.

30.Remove the valve body harness from the valve body assembly.

31.Remove the lip seal from the transmission case.

REASSEMBLY SERVICE POINT

1.
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.





2.Install the valve body assembly on the transmission case as follows.
(1) Install the valve body harness on the valve body assembly.
(2)
caution
  • Push in the valve body harness until the detent contacts the transmission case.
  • Be careful not to cause damage to the terminal body.
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) Slide the valve body assembly from the bottom, and install it on the transmission case.
(4) Install the fastening bolts of valve body assembly, and tighten to the specified torque of 7.9 N·m.
Bolt symbol
 A
 B
 C
Shank length mm
 54
 44
 54
Quantity
 8
 1
 2

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

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

5.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the oil strainer.

6.Install the oil strainer, and tighten the fastening bolts to the specified torque of 7.9 N·m.
Bolt symbol
 A
 B
Shank length mm
 44
 12
Quantity
 1
 2

7.
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.

8.Install the magnet on the oil pan.

9.
caution When installing the oil pan, align the dowel pins of transmission case with dowel pin holes A of the oil pan.
Tighten each oil pan mounting bolt to the specified torque of 5.9 N·m in the order of number shown.

10.
caution Do not re-use the snap ring.
Install the snap ring on the terminal body.


11.
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 A:
Within -1.0 ± 0.5 mm (recessed).


12.
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 A:
Within -1.8 ± 0.5 mm (recessed)


13.
caution
  • Do not re-use the side oil seal.
  • Apply CVT fluid when installing the side oil seal.
Using the special tools, install the side oil seal on the converter housing. <F1CJC>

  • Oil seal installer (MB992206)
  • Handle (MB992075)
Depth from the case edge A:
Within -6.3 ± 0.5 mm (recessed)

14.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring and CVT fluid filter on the transmission case.

15.Install the filter cover on the transmission case, and tighten the fastening bolts to the specified torque of 5.1 N·m.

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



17.
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 5.9 N·m.

18.
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.

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

20.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the primary pulley speed sensor.

21.Install the primary pulley speed sensor on the side cover, and tighten the fastening bolts to the specified torque of 5.9 N·m.

22.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the turbine speed sensor.

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

24.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the plug.

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

26.
caution
  • Do not re-use the O-ring.
  • Apply CVT fluid when installing the O-ring.
Install the O-ring on the input shaft.

27.
caution When conducting measurements, measure two or more places, and find the average value.
Install the torque converter on the transmission, and measure the size (A) to check if it meets the standard value.
Standard size (A): 13 mm
28.
caution Do not re-use the drain plug gasket.
Install the drain plug and drain plug gasket on the oil pan, and tighten to the specified torque of 34.3 N·m.
29.
caution Do not re-use the gasket.
Install the oil cooler feed hose, oil cooler return hose, oil cooler pipe assembly, oil cooler tube assembly <Vehicles with air-cooled oil cooler assembly>, eye bolt and gasket on the transmission, and tighten to the specified torque.

  • Eye bolt: 44 ± 5 N·m
  • Oil cooler tube assembly mounting bolt: 9.5 ± 3.5 N·m
30.Install the control cable bracket and breather hose on the transmission, and tighten the fastening bolts to the specified torque of 25 ± 4 N·m.
31.Install the oil filler tube and oil level gage on the transmission, and tighten the fastening bolts to the specified torque of 8.5 ± 3.5 N·m.
32.Install the radiator hose bracket, harness bracket, corrugate clamp bracket and air breather bracket on the transmission, and tighten the fastening bolts to the specified torque of 25 ± 4 N·m.
33.Install the transfer on the transmission, and tighten the fastening bolts to the specified torque of 69 ± 9 N·m. <W1CJC>