CVT Transmission Reassembly
CVT Transmission Reassembly
Special Tools Required
- Reverse Brake Spring Compressor 07TAE-P4V0110
- Start Clutch Installer 07TAE-P4VA131
1. Soak the reverse brake discs thoroughly in CVTF for at least 30 minutes.
2. '06 model: Install new O-rings (A) on the filter side of the 10.9 x 46 mm CVTF feed pipes (B), then install them with O-ring side into the housing.
3. Install the dowel pins (C) (two) and a new gasket (D) on the transmission housing (E).
4. Push the selector control shaft (F) toward the outside of the transmission housing, then install the intermediate housing (G).
5. Pull the selector control shaft back, then install the roller (H) in the intermediate housing by aligning the groove on the selector control shaft.
6. Install new O-rings (A) on the reverse brake piston (B), then install the piston in the intermediate housing (C).
7. Install the spring retainer/return spring assembly (D); install the return springs on the spring guides (E) on the reverse brake piston.
8. Install the reverse brake spring compressor through the drive pulley shaft to compress the return spring. Be sure the reverse brake spring compressor is set over the return springs, not over the reverse brake piston.
9. Compress the return springs and make sure that the reverse brake spring compressor is set over the return springs and the spring retainer tabs do not ride on the reverse brake piston.
10. Install the snap ring in the intermediate housing above the spring retainer, and remove the reverse brake spring compressor.
11. Check that the snap ring end gap (A) is 15 mm (0.59 in) or more.
12. Install the disc spring (A) on the reverse brake piston in the direction shown.
13. Starting with the reverse brake plates (B), alternately install the brake plates and the brake discs (C). Install the reverse brake end-plate (D), then install the snap ring (E).
14. Check that the snap ring inside diameter (A) is 143.5 mm (5.65 in) or more, and also the snap ring end gap (B) is 8.7 mm (0.34 in) or more.
15. Set up a dial indicator (A) on the reverse brake end-plate (B).
16. Zero the dial indicator by lifting the top disc (C) up against the reverse brake end-plate and the end-plate up against the snap ring (D).
17. Release the end-plate to lower the end-plate, and place a steel plate across width of the reverse brake end-plate.
18. Press the steel plate (A) down with 49 N (5 kgf, 11 lbf) using a force gauge or equivalent, and read the dial indicator (B). The dial indicator reads the clearance (C) between the reverse brake end-plate (D) and the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
19. If the clearance is out of the standard, select a new reverse brake end-plate from the following table.
REVERSE BRAKE END-PLATE
20. If replacing the reverse brake end-plate, make sure that the clearance is within the tolerance.
21. Install the snap ring retainer (A) over the drive pulley shaft (B).
22. Wrap the drive pulley shaft splines with tape to prevent O-ring damage. Install new O-rings (C) in the drive pulley shaft O-ring grooves, then remove the tape.
23. Install the forward clutch (D) on the drive pulley shaft, then install the snap ring (E) to secure the forward clutch.
24. Check that the snap ring outside diameter (A) is 41.4 mm (1.63 in) or less.
25. Install the ring gear (A) on the forward clutch (B).
26. Install the planetary carrier/input shaft assembly (C) through the drive pulley shaft (D) by aligning the sun gear (E) with the forward clutch discs and aligning the planetary carrier with the reverse brake discs.
27. Install the manual valve body separator plate (A) and the dowel pins (B) (two) on the intermediate housing, then install the manual valve body (C) and the detent spring (D).
28. Install new O-rings (A) on the 10.9 x 18.6 mm CVTF feed pipe (B), then install it on the manual valve body (C).
'06 model
'07-11 models
29. '06 model: Install new O-rings (D) on the 10.9 x 46 mm CVTF feed pipe (E), then install it with the filter end.
30. '07-11 models: Install new O-rings (F) on the 10.9 x 56 mm CVTF feed pipes (G), then install it with the filter end.
31. Install the 8 mm CVTF pipe (H) in the intermediate housing.
32. Install the two dowel pins (I) and a new gasket (J) on the intermediate housing.
33. '06 model: Install new O-rings (K) on the top of the 10.9 x 46 mm CVTF feed pipes (L).
34. Install new O-rings (M) on the CVTF feed pipes (N), then install them on the manual valve body and the intermediate housing.
35. Install the end cover (O) (16 bolts).
36. Turn the transmission end cover down.
37. Install the sealing ring (A) on a new secondary drive/park gear (B).
38. Insert the secondary drive/park gear (A) into the start clutch (B). Wiggle the secondary drive/park gear back and forth as it goes into the start clutch, and push in the secondary drive/park gear until it bottoms out.
39. Install the park pawl (A), the park pawl spring (B), and the park pawl shaft (C) on the transmission housing, then move the control lever to any position other than P.
40. Use CVT fluid to lubricate the new O-rings (D) for the driven pulley shaft, then install the O-rings on the shaft.
41. Place the start clutch (E) with the secondary drive/park gear onto the driven pulley shaft (F).
NOTE: Make sure to hold the secondary drive/park gear engaged into the start clutch when you install the start clutch with the secondary drive/park gear onto the driven pulley shaft.
42. Seat the start clutch by aligning the tip of the start clutch installer with the driven pulley shaft hole (A) and then pushing down the handle (B).
43. While holding the handle (A) down, push down the bottom part (B) of the start clutch installer until it contacts the seating surface of the start clutch.
44. Hold the upper hex section of the start clutch installer with a 19 mm wrench (A), then use an adjustable wrench to tighten the start clutch installer's lower nut (B) until the start clutch seats.
NOTE: When using the start clutch installer, hold the bolt (C) and then turn the nut (B). Turning the bolt could damage the start clutch installer.
45. Remove the start clutch installer.
46. Reach under the start clutch to confirm that the clutch end-plate can move up and down slightly (less than 1 mm).
47. Install the 25.5 mm cotters (A) to the cotter groove on the driven pulley shaft, then measure the clearance between the cotters and the start clutch guide (B) using a feeler gauge (C). Take measurements in at least three places, and use the average as the actual clearance.
48. If the clearance is out of the standard, remove the cotters, and measure its thickness.
49. Select and install new 25.5 mm cotters as a set, then recheck that the clearance is within the standard.
COTTERS, 25.5 mm
50. Install the cotter retainer and the snap ring.
51. Check that the snap ring outside diameter (A) is 33.9 mm (1.33 in) or less.
52. Install the thrust washer (A), the thrust needle bearing (B), the thrust washer (C), the CVTF pump drive sprocket hub (D), and the 22 x 28 mm thrust shim (E) on the input shaft (F), and install the snap ring (G) to secure them.
53. Check that the snap ring outside diameter (A) is 26.3 mm (1.04 in) or less.
54. Measure the clearance between the 22 x 28 mm thrust shim (A) and the snap ring (B) using a feeler gauge (C). Take measurements in at least three places, and use the average as the actual clearance.
55. If the clearance is out of the standard, remove the 22 x 28 mm thrust shim, and measure its thickness.
56. Select and install a new 22 x 28 thrust shim, then recheck that the clearance is within the standard.
THRUST SHIM, 22 x 28 mm
57. If the 22 x 28 mm thrust shim is replaced, install the snap ring, and check that the snap ring outside diameter is within the tolerance.
58. Place the secondary driven gear (A) on the transmission housing by aligning it with the secondary drive gear, then install the final drive shaft (B) through the secondary driven gear into the transmission housing.
59. Install the 25 x 35 mm thrust shim (C) on the final drive shaft.
60. Position the CVTF pump drive sprocket (D) on the sprocket hub (E), and put the CVTF pump drive chain (F) on the CVTF pump drive sprocket and the CVTF pump driven sprocket (G), then secure the CVTF pump drive sprocket with the three bolts.
61. Install the lubrication pipe (H).
62. Install the differential assembly (A).
63. Install new O-rings (B) on both ends of the CVTF passage pipe (C), then install the pipe in the pipe joint (D) of the transmission housing, and put the other end on the pipe guide (E).
64. Install the dowel pins (F) (three) and a new gasket (G) on the transmission housing.
65. Install the flywheel housing (H) on the transmission housing, and tighten the mounting bolts (19) with the harness clamp bracket (I).
66. Install a new O-ring (A) on the solenoid harness connector (B).
67. Install the CVTF pipes (C) on the lower valve body (D), then install the solenoid harness connector and the lower valve body in the transmission housing.
68. Install a new O-ring (E) on the CVTF strainer (F), then install the CVTF strainer on the lower valve body.
69. Install the CVTF pan (A) with the dowel pins (two) (B) and a new gasket (C).
70. Move the selector control lever (A) from the P position to the N position by turning the selector control lever.
NOTE: Do not squeeze the end (B) of the selector control shaft tips together when turning the shaft. If the tips are squeezed together it will cause a faulty shift position signal or position due to the play between the selector control shaft and the transmission range switch.
71. To set up a new transmission range switch (A) to the N position, align the cutouts (B) on the rotary-frame with the neutral positioning cutouts (C) on the transmission range switch. Then put a 2.0 mm (0.08 in) feeler gauge blade (D) in the cutouts to hold the switch in the N position.
NOTE: Be sure to use a 2.0 mm (0.08 in) feeler gauge blade or equivalent to hold the transmission range switch in the N position.
72. Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position with the 2.0 mm (0.08 in) blade (C).
73. Tighten the bolts (A) on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge (B).
74. Install the selector control shaft cover on the transmission range switch.
75. Install the breather cap (A) on the breather pipe (B) with its arrow (C) pointing to the flywheel housing.
76. '06 model: Install the CVT output shaft (driven pulley) speed sensor (A), the CVT speed sensor (B), and the CVT speed sensor (secondary) (C) with new O-rings (D).
77. '07-11 models: Install the CVT output shaft (driven pulley) speed sensor (A) and the vehicle speed sensor (B) with new O-rings (C).
78. Install the dipstick tube (A) with a new O-ring (B).
79. Install the CVT input shaft (drive pulley) speed sensor (C) with a new O-ring (D).
80. Install the CVTF cooler lines (E) with the line bolts (F) and new sealing washers (G).
81. Insert the CVTF dipstick into the tube.