Part 2
ASSEMBLY
35. Install the detent spring (1) onto the transaxle case. Install the bolt to hold the detent spring to the transaxle case and tighten the mounting bolt to 7 Nm (61 in.lbs.).
36. Install the outer race of the differential bearing (1) into the converter housing using Installer 9668 and Installer C-4628 on 4WD, use Installer C-4628 on 2WD and Handle C-4171.
CAUTION: When adjusting the preload, apply CVT fluid on the bearing to make it roll smoothly. When conducting measurements, measure two or more places and calculate the average value.
37. Measure for the differential preload shim (1) in the following steps. Refer to the graphic as necessary when performing the steps.
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
38. The required differential preload is 0.17 to 0.29 mm (0.007 0.011 to in).
39. Measure the distance (1-3) from the edge of the transaxle case to the select shim installation surface. This is differential measurement one.
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
40. Install the differential assembly on the converter case and measure the distance (differential measurement two) (1-2) from the differential hub to the surface of the converter housing.
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
41. Install the outer race for the differential side bearing and measure the distance (differential measurement three) (1-2) from the differential case to the outer race of the differential side bearing.
42. The thickness of the required select shim is calculated as follows: differential measurement one, minus differential measurement two, plus differential measurement three, plus 0.23 mm (0.009 in).
CAUTION: Do not re-use the select shim.
43. Install the chosen select shim (1) into the transaxle case.
44. Install the outer race (1) of the differential bearing on the transaxle case using the Installer D-129 and Handle C-4171.
45. Install the outer race (1) of the reduction gear bearing into the converter housing using Installer C-4628 and Handle C-4171.
46. The required preload on the reduction gear assembly is 0.13-0.19 mm (0.005-0.0075 in). Measure for the required preload shim (3) as follows:
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
47. Measure the distance (reduction assembly measurement one) (1-2) from the edge of the transaxle case to the select shim installation surface.
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
48. Install the reduction gear assembly on the converter housing and measure the distance (reduction assembly measurement two) (1-2) from the top of the reduction gear assembly to the edge of the converter housing.
CAUTION: When adjusting the preload, apply CVT fluid on the bearing to make it roll smoothly. When conducting measurements, measure two or more places and calculate the average value.
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
49. Install the outer race of the reduction gear bearing and measure the distance (reduction assembly measurement three) (1-2) from the top of the reduction gear assembly to the outer race of the reduction gear bearing.
50. The thickness of the required select shim is calculated as follows: reduction assembly measurement one, minus reduction assembly measurement two, plus reduction assembly measurement three, plus 0.16 mm (0.006 in).
CAUTION: Do not re-use the select shim.
51. Install the chosen select shim (1) into the transaxle case.
52. Install the outer race (1) of the reduction gear bearing on the transaxle case using Installer C-4628 and Handle C-4171.
CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
53. Install the new lip seal (1) on the transaxle case.
CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the O-ring.
54. Install the new o-ring (1) onto the oil pump mounting bolts. (Only for bolts installed from the outside of the transaxle case).
NOTE: One of the oil pump retaining bolts is installed from the outside of the transaxle case in the rear part of the oil pump.
55. Install the oil pump on the transaxle case. Install and tighten the mounting bolts (1) to 19 Nm (14 ft. lbs.) Install and tighten the mounting bolt (2) to 28 Nm (20 ft. lbs.).
CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
56. Install the new lip seal (1) into the transaxle case.
57. Install the manual shaft (1) into the case.
58. Install the pin at the manual shaft using a punch (2).
59. To install the valve body assembly on to the transaxle case, 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 set the pulley ratio linkage in position.
60. Position the locating tab (1) of the terminal body and install the terminal body into the transaxle case.
61. Install the valve body assembly (1) up from the bottom side and install it into the transaxle case.
62. Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2).
CAUTION: Apply CVT fluid when installing the bushing.
63. Install the bushing (1) into the valve body assembly.
64. Tighten the mounting bolts of the valve body assembly to 8 Nm (70 in. lbs).
65. Install the manual lever (1) onto the manual shaft. Install and tighten the mounting nut to 22 Nm 194 in. lb.
66. Install the bracket (1) onto the valve body assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.).
CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.
67. Install the new o-ring (1) onto the new oil strainer.
68. Install the new oil strainer (1) onto the valve body assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.).
CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket.
69. Install the oil pan gasket (1) onto the transaxle case.