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CVT Transmission Disassembly and Reassembly
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Where icon is shown, click for further information. | |
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Mark or place all removed parts in order in a parts rack so they can be reassembled in their original places. | |
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Keep all foreign particles out of the transmission. | |
1. |
Transmission Hanger - Remove |
5. |
Left Differential Oil Seal - Remove |
7. |
Transmission Range Switch - Remove |
8. |
CVT Speed Sensor - Remove |
9. |
CVT Drive Pulley Speed Sensor - Remove |
10. |
Torque Converter Turbine Speed Sensor - Remove |
11. |
CVT Driven Pulley Pressure Sensor - Remove |
12. |
Sealing Bolt - Remove |
15. |
Transmission Fluid Pan - Remove |
17. |
Transmission Fluid Strainer - Remove |
18. |
Transmission Fluid Strainer - Check |
19. |
Valve Body Assembly - Remove |
20. |
10.9 x 26 mm Pipe - Remove |
21. |
8 x 133.5 mm Pipe - Remove |
22. |
12 x 56.7 mm Pipe - Remove |
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NOTE: Be careful not to drop the filter (A).
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24. |
10.9 x 18.5 mm Pipe - Remove |
25. |
14.3 x 36.2 mm Pipe - Remove |
26. |
18 x 18 mm Pipe - Remove |
27. |
Solenoid Wire Harness A - Remove |
28. |
Transmission Fluid Pump - Remove |
29. |
Shift Solenoid Valve O/P - Remove |
31. |
12 x 89 mm Pipe - Remove |
32. |
Lubrication Pipe D - Remove |
33. |
Lubrication Pipe E - Remove |
34. |
22 mm Sealing Ring - Remove |
36. |
Driven Pulley Shaft Bearing (End Cover Side) - Remove |
37. |
Parking Brake Pawl - Remove |
38. |
Parking Shaft - Remove |
39. |
Parking Pawl Spring - Remove |
40. |
Parking Brake Rod Holder - Remove |
41. |
Torque Converter Housing - Remove |
42. |
Input Shaft Oil Seal - Remove |
43. |
Right Differential Oil Seal - Remove |
44. |
Oil Guide Plate - Remove |
45. |
Lubrication Plate - Remove |
46. |
Transmission Fluid Pump Drive Sprocket and Transmission Fluid Pump Drive Chain - Remove |
47. |
Transmission Fluid Pump Driven Sprocket - Remove |
48. |
Differential Carrier Tapered Roller Bearing Outer Race (Torque Converter Housing Side) - Remove |
49. |
41 x 76.2 x 1 mm Spacer - Remove |
50. |
76 mm Thrust Shim - Remove |
51. |
Final Drive Shaft Tapered Roller Bearing Outer Race (Torque Converter Housing Side) - Remove |
52. |
80 mm Thrust Shim - Remove |
53. |
Oil Guide Plate - Remove |
54. |
Final Drive Shaft Assembly - Remove |
55. |
Differential Assembly - Remove |
56. |
Detent Spring - Remove |
57. |
Control Shaft and Detent Lever - Remove |
58. |
Control Shaft Oil Seal - Remove |
59. |
Manual Valve Body - Remove |
60. |
Manual Valve - Remove |
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Be careful not to drop the check balls. | |
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Do not use a magnet to remove the check balls, it may magnetize the check balls. | | |
62. |
Stator Shaft Flange - Remove |
63. |
Stator Shaft - Remove |
64. |
40 mm Sealing Ring - Remove |
65. |
47 mm Sealing Ring - Remove |
66. |
32 x 42 mm Thrust Shim - Remove |
67. |
29.55 x 45 x 3.62 mm Thrust Needle Bearing - Remove |
68. |
Input Shaft Assembly - Remove |
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NOTE: Note the depth (A) between the surface of the transmission housing (B) and the clutch guide (C). The recorded value of the depth will be the standard one when installing the input shaft assembly. |
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69. |
27 mm Sealing Ring - Remove |
70. |
24 mm Sealing Ring - Remove |
71. |
20 x 24 x 17 mm Needle Bearing - Remove |
72. |
24.5 x 39.1 x 3.2 mm Thrust Needle Bearing - Remove |
75. |
Cotter Retainer - Remove |
76. |
32.5 mm Cotter - Remove |
78. |
Planetary Carrier Assembly - Remove |
79. |
50 x 65 x 3 mm Thrust Washer - Remove |
80. |
40 x 63 x 5.5 mm Washer - Remove |
81. |
Reverse Brake - Remove |
83. |
Spring Retainer/Return Spring Assembly - Remove |
84. |
Reverse Brake Piston - Remove |
85. |
Final Drive Shaft Tapered Roller Bearing Outer Race (Transmission Housing Side) - Remove |
86. |
Differential Carrier Tapered Roller Bearing Outer Race (Transmission Housing Side) - Remove |
87. |
41 x 92 x 1 mm Spacer - Remove |
89. |
Cotter Retainer - Remove |
90. |
25.5 mm Cotter - Remove |
91. |
Driven Pulley Shaft Bearing (Transmission Housing Side) - Remove |
92. |
Secondary Drive Gear - Remove |
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Where icon is shown, click for further information. | |
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Keep all foreign particles out of the transmission. | |
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When you reassemble the transmission, apply a light coat of clean transmission fluid on all oil seals, O-rings, bearings, and shaft splines. Also soak the forward clutch assembly and the reverse brake discs, in clean transmission fluid for at least 30 minutes prior to installation. | |
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Be careful not to damage the O-rings. | |
1. |
Secondary Drive Gear - Install |
2. |
Driven Pulley Shaft Bearing (Transmission Housing Side) - Install |
3. |
25.5 mm Cotter - Install |
4. |
Cotter Retainer - Install |
6. |
41 x 92 x 1 mm Spacer - Install |
7. |
Differential Carrier Tapered Roller Bearing Outer Race (Transmission Housing Side) - Install |
8. |
Final Drive Shaft Tapered Roller Bearing Outer Race (Transmission Housing Side) - Install |
9. |
Reverse Brake Piston - Install |
10. |
Spring Retainer/Return Spring Assembly - Install |
12. |
Reverse Brake - Install |
13. |
Reverse Brake Clearance - Adjust |
14. |
40 x 63 x 5.5 mm Washer - Install |
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NOTE: Make sure the 40 x 63 x 5.5 mm washer is installed in the correct direction. | |
15. |
50 x 65 x 3 mm Thrust Washer - Install |
16. |
Planetary Carrier Assembly - Install |
18. |
32.5 mm Cotter - Install |
19. |
Cotter Retainer - Install |
22. |
24.5 x 39.1 x 3.2 mm Thrust Needle Bearing - Install |
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NOTE: Make sure the 24.5 x 39.1 x 3.2 mm thrust needle bearing is installed in the correct direction. | |
23. |
20 x 24 x 17 mm Needle Bearing - Install |
24. |
24 mm Sealing Ring - Install |
25. |
27 mm Sealing Ring - Install |
26. |
Input Shaft Assembly - Install |
27. |
29.55 x 45 x 3.62 mm Thrust Needle Bearing - Install |
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NOTE: Make sure the 29.55 x 45 x 3.62 mm thrust needle bearing is installed in the correct direction. | |
28. |
32 x 42 mm Thrust Shim - Install |
29. |
47 mm Sealing Ring - Install |
30. |
40 mm Sealing Ring - Install |
31. |
Stator Shaft - Install |
32. |
Stator Shaft Flange - Install |
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NOTE: Align the hole (A) of the stator shaft flange with the dowel pin (B) of the stator shaft when installing the stator shaft flange. |
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Be careful not to drop the check balls. | |
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Do not use a magnet to install the check balls, it may magnetize the check balls. | |
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34. |
Manual Valve - Install |
35. |
Manual Valve Body - Install |
36. |
Control Shaft Oil Seal - Install |
37. |
Control Shaft and Detent Lever - Install |
38. |
Detent Spring - Install |
39. |
Differential Assembly and Final Drive Shaft Assembly - Install |
NOTE: Make sure to assemble the final drive shaft and the final driven gear correctly (Combination A or B) as shown in the chart if either one of them or both are to be replaced. Correct combinations of the shaft and gear can be identified by the presence or the absence of the groove as shown in the chart.
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40. |
Oil Guide Plate - Install |
41. |
80 mm Thrust Shim - Install |
42. |
Final Drive Shaft Tapered Roller Bearing Outer Race (Torque Converter Housing Side) - Install |
43. |
76 mm Thrust Shim - Install |
44. |
41 x 76.2 x 1 mm Spacer - Install |
45. |
Differential Carrier Tapered Roller Bearing Outer Race (Torque Converter Housing Side) - Install |
46. |
Transmission Fluid Pump Driven Sprocket - Install |
47. |
Transmission Fluid Pump Drive Sprocket and Transmission Fluid Pump Drive Chain - Install |
48. |
Lubrication Plate - Install |
49. |
Oil Guide Plate - Install |
50. |
Right Differential Oil Seal - Install |
51. |
Input Shaft Oil Seal - Install |
52. |
Torque Converter Housing - Install |
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Tighten the torque converter housing mounting bolts in a crisscross pattern in at least two steps. | |
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Be careful not to drop the oil guide plate. | | |
53. |
Parking Brake Rod Holder - Install |
54. |
Parking Brake Pawl, Parking Shaft, and Parking Pawl Spring - Install |
55. |
Driven Pulley Shaft Bearing (End Cover Side) - Install |
57. |
22 mm Sealing Ring - Install |
58. |
Lubrication Pipe D and E - Install |
59. |
12 x 89 mm Pipe - Install |
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NOTE: Tighten the end cover mounting bolts in a crisscross pattern in at least two steps. | |
61. |
Shift Solenoid Valve O/P - Install |
62. |
Transmission Fluid Pump - Install |
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NOTE: Align the guide pin (A) of the transmission fluid pump with the guide hole (B) of the stator shaft flange. |
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63. |
Solenoid Wire Harness A - Install |
64. |
18 x 18 mm Pipe - Install |
65. |
14.3 x 36.2 mm Pipe - Install |
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NOTE: You can install the pipe regardless of its direction. | |
66. |
10.9 x 18.5 mm Pipe - Install |
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The joint pipe has the filter (A). The filter end should face the valve body assembly side. | |
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Be careful not to drop the filter. | |
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68. |
12 x 56.7 mm Pipe - Install |
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NOTE: You can install the pipe regardless of its direction. | |
69. |
8 x 133.5 mm Pipe - Install |
70. |
10.9 x 26 mm Pipe - Install |
71. |
Valve Body Assembly - Install |
72. |
Transmission Fluid Strainer - Install |
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NOTE: Do not pinch solenoid wire harnesses A and B. | |
74. |
Transmission Fluid Pan - Install |
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Tighten the transmission fluid pan mounting bolts in a crisscross pattern in at least two steps. | |
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Do not pinch solenoid wire harnesses A and B. | | |
77. |
Sealing Bolt - Install |
78. |
CVT Driven Pulley Pressure Sensor - Install |
79. |
Torque Converter Turbine Speed Sensor - Install |
80. |
CVT Drive Pulley Speed Sensor - Install |
81. |
CVT Speed Sensor - Install |
82. |
Transmission Range Switch - Install |
84. |
Left Differential Oil Seal - Install |
85. |
Breather Cap - Install |
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NOTE: Be sure to install the suction hole of the breather cap to the torque converter side. | |
86. |
Filler Cap B - Install |
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NOTE: Turn the lever toward the front of the vehicle, and install it. | |
87. |
Filler Cap A - Install |
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NOTE: Turn the lever toward the front of the vehicle, and install it. | |
88. |
Transmission Hanger - Install |
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