Chain and Disc Set I

Chain and Disc Set I - 01J, Continuously Variable Transmission (CVT)

Special tools, testers and auxiliary items required

^ Seal installer 3241
^ Puller T10055
^ Pre-tensioning tool T40130
^ Thrust piece T40131
^ Puller T40132
^ Pressure air hose for tire valves

Removing

Proceed as follows:

- Remove transmission.
- Attach transmission to assembly stand.
- Remove transmission.
- Remove Transmission control unit (TCU) J217.
- Remove hydraulic control unit.





- Remove axial sealing elements - A - (4 pieces) and - B -.

Note:
^ The axial sealing elements must be replaced.





- Remove cover - arrow - from sensor wheel "II".





- Remove sensor wheel "II" using 2 screwdrivers - arrows -.

Note:
^ The sensor wheel must be replaced.





- Remove sensor wheel using "I" with puller T40132 and puller T10055.

Note:
^ The sensor wheel must be replaced.





- Remove oil pipe - arrow - by hand upward.

Note:
^ Do not use any tools otherwise the sealing surfaces will be damaged.





- Remove circlip - 3 - from disc set shaft "I" - 1 -.
- Mark and remove shim - 2 -.

CAUTION!
Danger of interchanging.
^ To prevent interchanging them, secure the shim - 2 - to circlip - 3 - with a tie wrap.





- Remove intermediate housing - arrow - ; pay attention to the different length; if necessary, mark the installation position of the bolts.
- Remove intermediate housing.





- Mark thrush washer - 1 - and remove it from the disc set "I" - 3 -.
- Remove spacer ring - 2 - (if equipped depending on version!) from disc set "I".

CAUTION!
Danger of interchanging.
^ Mark the thrust washer - 1 - with color.





- Remove intermediate housing seal - 1 -.
- Remove alignment bushing - 3 -.

Note:
^ The alignment bushing - 3 - must be removed, so that the retaining device T40130/1 can be mounted to the transmission.
^ The alignment bushing - 2 - can remain attached to the transmission.





- Remove oil guide piece "I" - 1 - ; to do so, carefully remove the retaining pins - arrows -.





- Pull oil guide piece "II" - arrow - upward.

Measure chain height:

Note:
^ For the chain height, the height of the chain bolt is used.





- Measure height - a - of the chain bolt - 1 -.

Note:
^ The chain and the chain bolt - 1 - are illustrated in section.
^ In the following work procedure, there will be a difference between two chain heights.

Transmission with chain height - a - = 34 mm:





- Mount retaining device T40130/2 onto disc set "II".

^ The O-ring in retaining device T40130/2 and sealing surfaces on the disc set must be clean and coated with ATF.

- Center aligning device T40130/1 to the adapter T40130/2 and bolt is to the transmission housing - lower arrows -, as illustrated.
- Insert bolt - 1 - far enough until the adapter T40130/2 presses against the disc set "II".
- Connect pressure air hose - 2 - for the tire valves to the adapter T40130/2 and give approximately 3 bar pressure.

^ The disc set opens, the chain relaxes.

- To secure the upper sides, push both hooks in direction of - arrow -.
- Lock hooks in this position with the knurled screws, at the same time, do not clamp the chain.





Transmission with chain height - a - = 38 mm:





- Mount retaining device T40130/2 onto the disc set "II".

^ The O-ring in the retaining device T40130/2 and sealing surfaces on the disc set must be clean and coated with ATF.

- Center frame T40130/1 with spacers T40130/5 and T40130/6 on the retaining device T40130/2 and mount it to the transmission housing - lower arrows -, as illustrated.
- Insert bolt - 1 - far enough until adapter T40130/2 presses against the disc set "II".
- Connect pressure air hose - 2 - for the tire valves to adapter T40130/2 and give approximately 3 bar pressure.

^ The disc set opens, the chain relaxes.

- To secure the upper sides, push both hooks in direction of - arrow -.
- Lock hooks in this position with the knurled screws, at the same time, do not clamp the chain.

Continuation for transmission with all chain heights:





- Turn chain so that the link with the production date stamped on it - A - is visible.
- Open chain on the 4th chain bolt next to the marked chain link.
- Place a rag under chain to prevent any welding points from falling into the transmission.
- Break off any lower welding points on both halves of the 4th chain bolt - arrow -.
- Remove two piece chain bolt upward.

CAUTION!
Do not bend the chain, this could damage it.





- Mark installation position of the glide track - 2 -.
- Unclip glide track on the oil pipe - 1 -, remove the chain and glide track.





- Remove disc set "I" - arrow - upward.

Installing

^ Tightening specifications.

CAUTION!
^ Check bearing "D" and bearing "E" for wear.
^ Check chain, disc set "I" and "II", bearing "C" and suction jet pump for wear.

Note:
^ If the disc set "I" is being replaced, then the shim and the circlip must be measured again Go To Determining shim and circlip.

- Carefully install the disc set "I" - arrow - into the roller bearing.

^ The splines must engage into the splines on the input shaft.





- Attach glide track - 2 - to the chain, which was marked during removal, to the oil pipe - 1 -.
- Pull chain so that both open ends align.





- Reconnect chain - arrows -, so that the chain links are straight and parallel to each other.





^ Due to design, the distance of the chain links to each other is different - arrow -.





- Install both halves of the chain bolt - 1 - and - 2 - from the top, as illustrated.

^ The welding points - arrows - face upward.
^ The broken off welding points on the chain bolt face downward.
^ Both halves of the chain bolt are formed asymmetrical.





- Loosen knurled-head screw and push the hook opposite direction of - arrow - toward the outside.
- Remove pressure air hose - 2 - for tire valve from the retaining device T40130/2.
- Bleed retaining device T40130/2 via pressure air valve.

^ The valve need on the pressure air valve must pushed down using a small screwdriver.
^ The disc set closes, the chain tensions itself.





- Install oil guide piece "II" - arrow -.





- Install oil guide piece "I" - 1 -.

^ The retaining bolts - arrows - must engage into the holes in the transmission housing.





- Install thrust washer - 1 - on disc set "I" - 3 - according to the marking made during removal.
- If equipped, install the spacer - 2 -. Note the installation position, as illustrated.

Note:
^ If, in the disc set "I" a spacer - 2 - was installed, then it can be installed again if the former bearing "D" with inner race was not replaced. For bearing "D" without an inner race, a spacer cannot be installed.

CAUTION!
Danger of interchanging.





- Remove intermediate housing seal - 1 -.
- Make sure alignment sleeves - 2 and 3 - are installed, if necessary install them.





- Install intermediate housing.
- Install bolts - arrow - for the intermediate housing and tighten in diagonal sequence and in stages.

^ Depending on the version, the bolts can have different lengths.

Note:
^ If the same disc set "I" was installed again, then the original shim and a new circlip - with the same strength and the old circlip - are installed.

- Rotate the transmission housing on the engine/transmission support, so that the disc set "I" contacts the intermediate housing by its own weight.





Note:
^ The circlip - 3 - fits into the groove on the shaft and the bearing does not get damaged when the sensor wheel "I" is not installed.

- Install marked shim - 2 - onto the shaft for the disc set "I" - 1 -.
- Install new circlip - 3 - into the groove on the shaft for the disc set and press it in.

^ Observe installed location: The bores in the circlips eyes are conical. The narrow side points up
^ The circlip must contact the base of the groove.

Note:
^ The following illustrates the intermediate housing facing upward opposite the transmission bearing.
^ Always replace the sensor wheels "I" and "II".





- Carefully tap the new sensor wheel "I" and sleeve T40131 with a rubber hammer all the way in - arrow -.





- Carefully tap new sensor wheel "II" and sleeve 3241 with a rubber hammer all the way in.
- Turn the transmission on the engine/transmission support so that the intermediate housing faces upward once again.





- Install oil pipe - arrow - by hand.

Note:
^ Do not use any tools otherwise the sealing surfaces will be damaged.





- Install cover - arrow - for sensor wheel "II".

^ Locating tab on rear side of cover must be inserted into small hole on transmission surface.

- Install hydraulic control unit.
- Install Transmission Control Module (TCM) J217.
- Install cover.
- Install transmission.