Transmission Disassembly

Transmission Disassembly

Special Tools Required
^ Reverse brake spring compressor 07TAE-P4V0110
^ Start clutch remover 07TAE-P4V0120

1. Remove the ATF pan (A) (18 bolts), the dowel pins (B) (2), and the ATF pan gasket (C).





2. Remove the ATF strainer (D) (two bolts).
3. Remove the eight bolts securing the lower valve body (E), lower the lower valve body, and hold it.
4. Remove the bolt securing the solenoid harness connector (F), and remove the lower valve body, dowel pins (G) and the solenoid harness connector from the transmission housing.
5. Remove the ATF magnets (H) (I), clean and reinstall them in the ATF pan.
6. Remove the 0-ring (J) from the ATF strainer, and remove the 0-ring (K) from the solenoid harness connector. Install new ones when reinstalling the lower valve body.
7. Clean the inlet opening (A) of the ATF strainer (B) thoroughly with compressed air, then check that it is in good condition and that the inlet opening is not clogged.





8. Test the ATF strainer by pouring clean ATF through the inlet opening, and replace it if it is clogged or damaged.
9. Shift the transmission with its end cover down.
10. Remove the flywheel housing (A) (19 bolts) and the harness clamp bracket (B).





11. Remove the differential assembly (C).
12. Remove the ATF passage pipe (D) and the lubrication pipe (E).
13. Remove the three bolts securing the ATF pump drive sprocket (F), then remove the ATF pump drive chain (G) and the ATF pump drive sprocket.
14. Remove the snap ring (H) from the input shaft (I), and remove the thrust shim (J), the ATF pump drive sprocket hub (K), the thrust washer (L), the thrust needle bearing (M), and the thrust washer (N) from the input shaft.
15. Remove the park pawl shaft (O), and remove the park pawl spring (P) and the park pawl (Q).
16. Remove the final drive shaft (R), then remove the secondary driven gear (S).
17. Remove the snap ring (T) securing the start clutch (U), and remove the cotter retainer (V) and the cotters (W).
18. Set the start clutch remover On the start clutch (A), and attach the pawl (B) of the start clutch remover to the park gear (C) securely. Do not place the pawl of the start clutch remover on the start clutch guide. If the pawl contacts the start clutch guide, the clutch guide may be damaged. Be sure not to allow dust and other foreign particles to enter the driven pulley shaft.





19. Remove the start clutch (A) from the driven pulley shaft.





20. Remove the secondary drive gear from the start clutch.
21. Remove the sealing ring (A) from the secondary drive gear (B), and clean it; it is reinstalled on new secondary drive gear when assembling the transmission.





22. Remove the line bolts, then remove the ATF cooler lines.
23. Remove the ATF dipstick guide pipe.
24. Remove the transmission range switch.
25. '06 model: Remove the CVT input shaft (drive pulley) speed sensor, the CVT output shaft (driven pulley) speed sensor, the CVT speed sensor, and the CVT speed sensor (secondary).
26. '07-08 models: Remove the CVT input shaft (drive pulley) speed sensor, the CVT output shaft (driven pulley) speed sensor, and the CVT speed sensor.
27. Turn the transmission upside down, and set it on a workbench to prevent damaging to the input shaft and the driven pulley shaft.
28. Remove the end cover (A) (16 bolts).





29. Remove the ATF feed pipes (B).
30. Remove the ATF feed pipe (10.9 x 18.6 mm) (C) from the manual valve body (D).
31. Remove the manual valve body, the detent spring (E), the dowel pins (F) (two), and the separator plate (G).
32. Remove the 8 mm ATF pipe (H) and the ATF feed pipe (10.9 x 46 mm) (I).
33. Remove the planetary carrier/input shaft assembly (A), then remove the ring gear (B).





34. Remove the reverse brake snap ring (C), then remove the reverse brake end-plate (D), the brake discs (E), the brake plates (F), and the disc spring (G).
35. Remove the snap ring (H) securing the forward clutch end-plate (I), then remove the forward clutch end-plate, the clutch discs (J), and the clutch plates (K).
36. Remove the snap ring (L) securing the forward clutch (M) to the drive pulley shaft, then remove the forward clutch and the snap ring retainer (N).
37. Install the reverse brake spring compressor to remove the snap ring securing the reverse brake return spring retainer.





38. Compress the return spring using the reverse brake spring compressor. Be sure the reverse brake spring compressor is set over the reverse brake return springs.





39. Remove the snap ring (A) while compressing the return spring.





40. Remove the reverse brake spring compressor, then remove the spring retainer/return spring assembly (B).
41. Apply air pressure to reverse brake pressure circuit hole (C) to remove the reverse brake piston (D).
42. Remove the roller (A).





43. Remove the intermediate housing (B).
44. Remove the ATF feed pipes (10.9 x 46 mm) (C).