CVT Automatic Transaxle - Disassembly

DISASSEMBLY


















1. Refer to the exploded views as necessary when performing the following steps.




2. Drain the CVT fluid from the transaxle assembly.
3. Remove the power transfer unit assembly and O-ring (4WD only).
4. Remove the torque converter (1) from the transaxle.




5. Install Transmission Service Stand 9878 (1) to the belt side of the transmission case (3) using the upper transmission mount bolts (2).




6. Remove the output speed sensor (1) from the converter housing. Remove and discard the O-ring from the output speed sensor.

CAUTION: Set aside and reuse any adjusting shim found between the output speed sensor and the converter housing.




7. Remove the input speed sensor (1) from the transaxle case. Remove and discard the O-ring from the input speed sensor.




8. Remove the nut (1) holding the shift lever (2) to the manual shaft.
9. Remove the shift lever from the manual shaft.




10. Remove the bolts (2) holding the transmission range sensor (TRS) (1) to the transaxle case.
11. Remove the (TRS) transmission range sensor (1) from the transaxle case and the manual shaft.




12. Remove the snap ring (1) from the terminal body (2) and press the terminal body into the transaxle case.

CAUTION: Be careful not to cause damage to the terminal body.




13. Remove CVT fluid cooler (1) from transaxle case. Remove and discard the CVT fluid cooler O-ring.




14. Remove the bolts holding the CVT fluid filter to the transaxle case.
15. Remove the CVT fluid filter (1) from the transaxle case.




16. Remove the converter housing mounting bolts.




17. Remove the converter housing (1) by tapping with plastic hammer.

CAUTION: There is a possibility that the drive sprocket adjusting shim may be dislodged and fall out.




18. Remove outer race of reduction gear bearing (1) from the converter housing using Puller 7794-A and Puller C-637.




19. Remove differential side oil seal (1) from converter housing using a screwdriver. (2WD)




20. Remove converter housing oil seal (1) from converter housing using a screwdriver.




21. Remove outer race (1) of differential side bearing from converter housing using a suitable punch.

CAUTION: When removing the outer race, tap the outer race on both sides evenly. When removing the outer race, do not damage the converter housing.




22. Remove and discard the O-ring (1) from the input shaft.




23. Remove the adjusting shim (1) from the drive sprocket, if necessary.




24. Remove the nuts holding the baffle plate (1) to the transaxle.
25. Remove the baffle plate.




26. Expand the snap ring (1) and remove the driven sprocket (3), the oil pump chain (2), and the drive sprocket.




27. Remove the thrust washer (1) from the oil pump cover.




28. Remove the snap ring (1) from the oil pump.




29. Remove the reduction gear assembly (1) from the transaxle case.




30. Remove the differential assembly (1) from the transaxle case.




31. Remove the bolts holding the bracket (1) to the oil pump cover and the transaxle.
32. Remove the bracket (1).




33. Remove the bolts holding the baffle plate (1) to the transaxle.
34. Remove the baffle plate.




35. Remove the bolts holding the reaction shaft support (1) to the transaxle.
36. Remove the reaction shaft support from the transaxle case.




37. Remove and discard the seal rings (1) from the reaction shaft support.




38. Remove the bolts holding the oil pan (1) to the transaxle case.
39. Remove the oil pan from the transaxle case.




40. Remove the oil pan gasket (1) from the transaxle case.




41. Remove the bolts holding the oil strainer (1) to the valve body.
42. Remove the oil strainer.
43. Remove and discard the oil strainer O-ring.




44. Remove the bolt (2) holding the oil pump to the transaxle case from the rear of the transaxle.
45. Remove the bolts (1) holding the oil pump to the transaxle case from inside the transaxle.
46. Remove the oil pump from the transaxle case.





NOTE: One of the oil pump retaining bolts is installed from the outside of the transaxle case into the rear part of the oil pump.

47. Remove and discard the O-ring (1) from the oil pump mounting bolt. (Only on bolt installed from the outside of the transaxle case).




48. Remove and discard the lip seal (1) from the transaxle case.




49. Remove the bolt holding the detent spring (1) to the transaxle case.
50. Remove the detente spring from the transaxle case.




51. Remove the forward clutch assembly (1) from the transaxle case.




52. Remove needle bearing (1) from forward clutch drum side of the sun gear.




53. Remove the sun gear (1) from the planetary carrier.




54. Remove the needle bearing (1) from the sun gear.




55. Remove the planetary carrier assembly (1) from the transaxle case.




56. Remove the needle bearing (1) from the planetary carrier.




57. Remove the bolts holding the bracket (1) to the valve body assembly.
58. Remove the bracket from the valve body assembly.




59. Remove the nut holding the manual lever (1) to the manual shaft.
60. Remove the manual lever.




61. Use this picture when removing valve body attaching bolts.





CAUTION: Tilt the valve body assembly away from the transaxle case on the manual shaft side to ease removal. Pay attention to completely remove the terminal body from the transaxle case.

62. Remove the valve body assembly from the transaxle case as follows:
a. Insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of the valve body assembly to fix the pulley ratio linkage (1).
b. Remove the bolts holding the valve body assembly to the transaxle case.
c. Remove the valve body assembly from the transaxle case.




63. Remove and set aside the bushing (1) from the valve body.




64. Remove the pin at the manual shaft using a punch (2).
65. Remove the manual shaft from case.




66. Remove and discard the lip seal (1) from the transaxle case.




67. Remove outer race (1) of differential side bearing from converter main housing using Puller 9664 and Puller C-637.




68. Remove the selective shim (1) from the transaxle case.




69. Remove outer race of reduction gear bearing (1) from transaxle case using Puller C-637 and Puller 7794-A.




70. Remove the selective shim (1) from the transaxle case.





CAUTION: When removing the side oil seal, do not damage the transaxle case.

71. Remove side oil seal (1) from transaxle case using a screwdriver.





CAUTION: Check if there is damage, deformation, or burning on the surface of any of the drive or driven plates. Check for permanent fatigue of the dish plate, driven plates, retaining plate, snap ring, and the drive plates. Replace all reverse brake components if any of these conditions exist.

72. Remove the reverse brake snap ring using a screwdriver. Then remove the reverse brake retaining plate, the drive plates, the driven plates, and the dish plate from the transaxle case.





CAUTION: Set the spring compressor right on top of the return spring of the spring retainer assembly. Do not remove the return springs from the spring retainer assembly.

73. Compress the reverse brake return spring using Compressor 5058A (1) and Compressor 9875. Remove the snap ring (2) from the transaxle case.
74. Remove the retaining plate and the spring retainer assembly.





CAUTION: There is a possibility that the reverse brake piston might be stuck if excessive pressure is required to remove.

75. Try removing the reverse brake piston from the transaxle case by hand if unable to remove by hand, apply compressed air to the fluid passage (1). and remove the reverse brake piston from the transaxle case.




76. Remove the case bolts (1) at the drive belt assembly (2).

NOTE: Pin at pulley sensor stays with drive belt assembly case.

77. Separate drive belt assembly case from main housing.




78. Remove the bolts (2) that hold both sheaves to the case (1).





CAUTION: Do not allow the Puller 9874 to come in contact with the belt at any time

79. Install the Puller 9874 (1) and Insert 8513A (2) onto the secondary sheave (3).





CAUTION: Do not over tighten the compressor tool. Tighten to no more than 7 Nm (50 in. lbs.)

NOTE: The belt is directional, look for an arrow indicating the direction of the belt for installation

80. Compress sheave (2) to the stop.





CAUTION: Do not allow the primary sheave to contact the drive surface of the secondary sheave.

NOTE: You may need to lightly tap case while holding secondary sheave.

81. Lift and move the secondary sheave (1) closer to the primary sheave.




82. Remove the pin (1) from the sheave height sensor (3).




83. Lift the primary sheave (3) enough to remove the sheave height sensor (1).




84. Remove the drive belt (1) from both secondary (3) and primary sheaves (2).
85. Remove the secondary sheave.




86. Remove the shim (3) under the secondary sheave (1).




87. Remove the primary sheave.
88. Remove bolts at the park pawl.
89. Remove the park pawl.