Part 1

ASSEMBLY

Special Tools:




























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





2. Install the primary sheave (2) with the sheave height sensor, (3) spring and pin (1) into the belt side case.





3. Install the secondary sheave positioning shim (3) into the belt side cover.





4. Install Puller (1) and Insert , (2) onto secondary sheave.





5. Move the secondary sheave (3) close enough to the primary (2) sheave to allow the drive belt (1) to be put around both secondary and primary sheaves.

NOTE: The drive belt is directional and will need to be installed in the same direction as noted in disassembly. if installed incorrectly failure will occur.

6. Install the drive belt (1).

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

7. Compress the secondary (3) sheave to the stop.
8. Install the drive belt (1) around both secondary (3) and primary (2) sheaves.
9. Install the primary sheave into place.
10. Remove Puller and Insert from the primary sheave.





11. Install the bolts (2) that hold both sheaves to the case (1).






CAUTION: Remove moisture, oil, and used sealant from the sealant application surface. Make sure that the starting point and the ending point are between two bolt holes.

12. Apply Loctite 509 sealer onto the belt side of the transaxle case.
13. Install the belt side assembly to the transaxle case.
14. Install the case bolts (1) to hold the drive belt assembly (2) to the transaxle. tighten to 45 Nm (33 ft. lbs.).






CAUTION: Inspect the reverse brake piston and, if damaged, replace it before installation. Apply CVT fluid to the seal when installing the reverse brake piston.

NOTE: Rotate reverse brake piston into place.

15. Rotate and install the reverse brake piston (1)(Figure 9) into the transaxle case.





16. Align the return springs (3)(Figure 10) of the spring retainer assembly (1) to the locating posts (2) of the reverse clutch piston.






NOTE: There is a notch in the retaining plate that points to the top of the case.

17. Install the retaining plate (1)(Figure 11) into the transaxle case with the notch on the plate to the top (2).






CAUTION: Set the spring compressor on top of the spring retainer assembly.

18. Compress the reverse brake return spring using Compressor (1)(Figure 12) and Compressor and install the snap ring into the transaxle case using a screwdriver.





19. Install the dish plate (1) with the convex side down onto the reverse brake piston.
20. Install driven plate (2) and then a drive plate (6) until all the driven and drive plates are installed.
21. Install the retaining plate (3) into the reverse brake assembly.
22. Install the reverse brake snap ring (4) into the transaxle case.






CAUTION: When conducting measurements, measure two or more places and calculate the average value.

23. Measure the clearance between the snap ring and the retaining plate (1)(Figure 14). The correct clutch clearance is 1.2-1.5 mm (0.047-0.059 in.). If the clutch clearance is not within specifications, measure the existing retaining plate and select the correct retaining plate.






CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.

NOTE: The inner race will need to face down.

24. Install the needle bearing (1) (Figure 15) onto the reverse brake piston. Check for the direction of the needle bearing while installing.






NOTE: The inner race will need to face down

25. Install the planetary carrier assembly (1)(Figure 16) onto the reverse brake.






CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.

26. Install the needle bearing (1)(Figure 17) onto the primary pulley side of the sun gear.





27. Install the sun gear (1)(Figure 18) onto the planetary carrier.






CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.

NOTE: The inner race will need to face up.

28. Install the needle bearing (1)(Figure 19) on the forward clutch drum side of the sun gear.





29. Install the forward clutch assembly (1)(Figure 20) into the transaxle case.





30. Measure the total end play (2) in the following steps. Total end play should be 0.25 - 0.55 mm (0.010 - 0.022 in).






NOTE: Gauge Bar can be used for doing the following measurement.

31. Measure the distance (1) from the oil pump cover installation surface of the transaxle case to the needle bearing installation surface of the forward clutch drum. Call this measurement one.






NOTE: Gauge Bar can be used for doing the following measurement.

32. Measure the distance (1 to 2) as shown. Call this measurement two.
33. Calculate the bearing thickness required to achieve the necessary end play with the following formula. The bearing thickness is equal to measurement one, minus measurement two minus, the nominal end play (0.40 mm or 0.016 "in).






CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.

34. Install the selected needle bearing (1)(Figure 24) on the forward clutch assembly.





35. Install the detent spring (1) (Figure 25) 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)(Figure 26) into the converter housing using Installer and Installer on 4WD, use Installer on 2WD and Handle.










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)(Figure 27) in the following steps. Refer to the graphic as necessary when performing the steps.






NOTE: Gauge Bar 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 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)(Figure 29) from the differential hub to the surface of the converter housing.






NOTE: Gauge Bar 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)(Figure 30) 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)(Figure 31) into the transaxle case.





44. Install the outer race (1) of the differential bearing on the transaxle case using the Installer and Handle.





45. Install the outer race (1)(Figure 33) of the reduction gear bearing into the converter housing using Installer and Handle.










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)(Figure 34) as follows:






NOTE: Gauge Bar 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 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)(Figure 36) 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 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)(Figure 37) 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)(Figure 38) into the transaxle case.





52. Install the outer race (1)(Figure 39) of the reduction gear bearing on the transaxle case using Installer and Handle.






CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.

53. Install the new lip seal (1)(Figure 40) 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)(Figure 41) 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)(Figure 42) 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)(Figure 43) 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)(Figure 45) of the terminal body and install the terminal body into the transaxle case.





61. Install the valve body assembly (1)(Figure 46) up from the bottom side and install it into the transaxle case.





62. Align the notch (1)(Figure 47) of the pulley ratio linkage with the sheave position sensor (2).