Part 1
ILLUSTRATED INDEXPart 1 Of 2:
Part 2 Of 2:
Transmission / Lower Valve Body Assembly
Part 1 Of 2:
Part 2 Of 2:
Transmission Housing / Flywheel Housing
Part 1 Of 2:
Part 2 Of 2:
End Cover/Intermediate Housing
TRANSMISSION HOUSING / LOWER VALVE BODY REMOVAL
REMOVAL
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the lower valve body, replace the following:
- O-rings
- Automatic Transmission Fluid (ATF) pan gasket
- Sealing washers
1. Remove the ATF cooler inlet line bracket bolt.
2. Remove the ATF cooler outlet line.
3. Remove the ATF pan (fourteen bolts).
4. Remove the ATF strainer (two bolts).
5. Remove the one bolt securing the solenoid harness connector, then push the connector.
6. Remove the lower valve body (eight bolts).
7. Clean the inlet opening of the ATF strainer thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged.
8. Replace the ATF strainer if it is clogged or damaged.
NOTE: The ATF strainer can be reused if it is not clogged.
TRANSMISSION HOUSING / FLYWHEEL HOUSING REMOVAL
REMOVAL
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the transmission housing/flywheel housing, replace the following:
- O-rings
- Secondary drive gear assembly
- Start clutch assembly
- Flywheel housing gasket
1. Remove the ATF passage line holder assembly.
2. Remove the flywheel housing (twenty bolts).
3. Remove the ATF passage line assembly (one bolt).
4. Remove the ATF pump drive sprocket (three bolts), then remove the ATF pump drive chain.
5. Move the Pitot flange toward its cutout, then remove the Pitot flange.
6. Remove the snap ring securing the ATF pump drive sprocket hub, then remove the 22 x 28 mm thrust shim, the ATF pump drive sprocket hub and the thrust washers.
7. Remove the differential assembly.
8. Remove the park pawl shaft, the park pawl spring and the park pawl.
9. Remove the snap ring securing the start clutch, then remove the cotter retainer and the cotters.
10. Set the special tool on the start clutch, and attach the pawl of the special tool to the park gear securely as shown.
CAUTION:
- Do not place the pawl of the special tool on the start clutch guide. If the pawl of the special tool contacts the start clutch guide, the start clutch guide may be damaged.
- Be sure not to allow dust and other foreign particles to enter into the driven pulley shaft.
11. Remove the start clutch and the secondary drive gear assembly using the special tool, then remove the secondary gear shaft.
END COVER / INTERMEDIATE HOUSING REMOVAL
REMOVAL
NOTE:
- Clean all parts in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the end cover/intermediate housing, replace the following parts:
- O-rings
- End cover gasket
- Transmission housing gasket
- Sealing rings
- Sealing washers
1. Remove the end cover (three 6 mm bolts, eleven 8 mm bolts).
2. Remove the manual valve body lines A and B.
3. Remove the snap ring securing the ring gear, then remove the thrust shim and the ring gear.
4. Remove the snap ring securing the reverse brake discs and plates, then remove the reverse brake end plate, brake discs, brake plates, and disc spring.
5. Remove the carrier with the thrust washers and the thrust needle bearing from the forward clutch.
6. Remove the sun gear and the input shaft as a sub assembly by pulling it. The sun gear is press fitted tightly into input shaft.
7. Remove the snap ring securing the forward clutch, and remove the snap ring securing the forward clutch end plate, then remove the forward clutch end plate.
8. Reinstall the carrier on the forward clutch, then secure the carrier with the snap ring on the forward clutch end plate.
9. Remove the forward clutch and carrier assembly together.
10. Install the special tool to remove the snap ring securing the reverse brake return spring retainer as shown.
11. Compress the return springs, then remove the snap ring.
CAUTION: If the spring retainer tab is on the reverse brake piston, the spring retainer may be damaged. Be sure the spring retainer tab is not on the piston.
12. Remove the special tool, then remove the spring retainer/return spring assembly.
13. Remove the sealing bolt securing the reverse brake pressure inspection hole.
14. Apply air pressure to the inspection hole to remove the reverse brake piston.
15. Remove the snap ring retainer from the drive pulley shaft.
16. Remove the manual valve body (five bolts).
17. Remove the roller and push the control shaft assembly toward the outside of the transmission housing, then remove the intermediate housing (four bolts).
MANUAL VALVE BODY
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Clean all parts thoroughly insolvent or carburetor cleaner, and dry with compressed air. Blowout all passages.
- Coat all parts with Continuously Variable Transmission (CVT) Fluid during assembly.
FORWARD CLUTCH
Illustrated Index
DISASSEMBLY
1. Remove the snap ring, then remove the clutch end plate, clutch discs, and plates.
2. Remove the disc spring.
3. Install the special tools as shown,
4. Compress the return spring.
5. Remove the snap ring. Then remove the special tools, spring retainer, and return spring.
6. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other end while applying air pressure.
REASSEMBLY
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Lubricate all parts with Continuously Variable Transmission (CVT) Fluid before reassembly.
1. Inspect the check valve; if it's loose, replace the piston.
2. Install new O-rings on the clutch piston.
3. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.
NOTE: Lubricate the piston O-ring with CVT Fluid before installing.
CAUTION: Do not pinch the O-ring by installing the piston with too much force.
4. Install the return spring and spring retainer, and position the snap ring on the retainer.
5. Install the special tools as shown.
6. Compress the return spring.
7. Install the snap ring.
8. Remove the special tools.
9. Install the disc spring.
NOTE: Install the disc spring in the direction shown.
10. Soak the clutch discs thoroughly in Continuously Variable Transmission (CVT) Fluid for a minimum of 30 minutes.
11. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with flat side toward the disc.
NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter.
12. Install the snap ring.
13. Verify that the snap ring end gap is correct.
14. Measure the clearance between the clutch end plate and top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.
NOTE: Take measurements in at least three places, and use the average as the actual clearance.
15. If the clearance is out of tolerance, select a new clutch end plate from the following table, then recheck.
NOTE: If the thickest clutch end plate is installed but the clearance is still over the standard, replace the clutch discs and clutch plates.
16. After replacing the clutch end plate, make sure that the clearance is within tolerance.
SECONDARY GEAR SHAFT
25 X 35 mm THRUST SHIM SELECTION
1. Measure the distance between the flywheel housing surface and the ball bearing as shown, then note the measurement (Measurement A).
2. Install the secondary gear shaft in the transmission housing.
3. Measure the distance between the transmission housing surface and the thrust washer mounting surface of the secondary gear shaft as shown, then note the measurement (Measurement B).
4. Calculate 25 x 35 mm thrust shim thickness by following formula.
FORMULA:
25 x 35 mm Thrust Shim Thickness
= Measurement A - Measurement B + Flywheel
Housing Gasket Thickness: 0.5 mm (0.020 inch)
Example:
Measurement A: 32.7 mm (1.287 inch)
Measurement B: 30.1 mm (1.185 inch)
25 x 35 mm Thrust Shim Thickness
= 32.7 mm (1.287 inch) - 30.1 mm (1.185 inch)
+ 0.5 mm (0.020 inch)
= 3.1 mm (0.122 inch)
Select 25 x 35 mm Thrust Shim D.
5. Select the 25 x 35 mm thrust shim from the following the table.
DIFFERENTIAL
Illustrated Index
BACKLASH INSPECTION
1. Place the differential assembly on V-blocks, and install both axles.
2. Check the backlash of both pinion gears.
3. If the backlash is out of tolerance, replace the differential carrier.
BEARING REPLACEMENT
NOTE: Check the bearings for wear and rough rotation. If the bearings are OK, removal is not necessary.
1. Remove the ball bearings using a bearing puller.
2. Install the new ball bearings using the special tool with a press as shown.
DIFFERENTIAL CARRIER REPLACEMENT
1. Remove the final driven gear from the differential carrier.
NOTE: The final driven gear bolts have left-hand threads.
2. Install the final driven gear with its chamfered side on the inner bore facing the differential carrier.
3. Tighten the bolts to the specified torque in a crisscross pattern.
TORQUE: 98 Nm (72 ft. lbs.)
OIL SEAL REMOVAL
1. Remove the differential assembly.
2. Remove the oil seal from the transmission housing.
3. Remove the oil seal from the flywheel housing.