Converter Case Cover

Converter Case Cover

REMOVAL
1) Remove the transmission assembly from the vehicle.
2) Remove the air breather hose.
3) Remove the oil pan and control valve body.
4) Remove the transmission harness.
5) Remove the extension case.
6) Remove the rear drive shaft.
7) Remove the transfer clutch assembly.
8) Remove the transfer reduction driven gear assembly.
9) Remove the intermediate case.
10) Remove the forward clutch assembly.
11) Remove the reduction driven gear.
12) Remove the transmission case.
13) Remove the primary pulley, secondary pulley and variator chain.
14) Remove the drive pinion shaft assembly.
15) Remove the oil stopper plate and lubrication pipe.





16) Flip over the converter case.
17) Remove the converter case cover.





18) Remove the O-ring.





19) Remove the seal ring from converter case cover.





INSTALLATION
1) Clean the mating surface of converter case cover and converter case.
2) Adjust the shims of front reduction drive gear and front reduction driven gear.
3) Install the O-ring.

NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.





4) Apply CVTF to the selected shims and install each to the catch surface of bearing.
5) Install the seal ring to converter case cover.

NOTE:
^ Use a new seal ring.
^ When installing the seal ring, do not expand the seal ring too much.





6) Apply liquid gasket seamlessly to the mating surface of converter case cover.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent





7) Install the converter case cover.





8) Flip over the converter case cover.
9) Install the oil stopper plate and lubrication pipe.





10) Install the drive pinion shaft assembly.
11) Install the primary pulley, secondary pulley and variator chain.
12) Install the transmission case.
13) Install the forward clutch assembly.
14) Install the intermediate case.
15) Install the transfer reduction driven gear assembly.
16) Install the transfer clutch assembly.
17) Install the rear drive shaft.
18) Install the extension case.
19) Install the transmission harness.
20) Install the control valve body and oil pan.
21) Install the air breather hose.
22) Install the transmission assembly to the vehicle.

DISASSEMBLY
1) Remove the oil pump chain cover.
2) Using TORX(R) E16, remove the center support COMPL.





3) Remove the plug and O-ring.





ASSEMBLY
1) Install the plugs.

NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.





2) Using TORX(R) E16, install the center support COMPL.





3) Install the oil pump chain cover.

INSPECTION
^ Replace if its tooth surfaces are broken, damaged or excessively worn.
^ Check the bearing for seizure or wear.
^ Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

ADJUSTMENT
When replacing the converter case cover, select the following shims.
^ Select the shim for front reduction drive gear.
^ Select the shim for front reduction driven gear.