Part 2

OIL SEAL INSTALLATION / SIDE CLEARANCE





1. Install a 2.50 mm (0.098 inch) thick 80 mm wide set ring in the transmission housing.

NOTE: Do not install the oil seal yet.





2. Install the differential assembly into the transmission housing using the special tool as shown.





3. Install the flywheel housing, and tighten the bolts.





4. Measure the clearance between the 80 mm set ring and outer race of the ball bearing in the transmission housing.





5. If the clearance is more than the standard, select a new set ring from the table, and install it.

NOTE: If the clearance measured in step 4 is standard, it is not necessary to perform steps 7 and 8.

6. Remove the flywheel housing.
7. Replace the 2.50 mm (0.098 inch) set ring, 80 mm with the one of the correct thickness selected in step 5.





8. Install the oil seal in the transmission housing using the special tools as shown.





9. Install the oil seal in the flywheel housing using the special tools as shown.

FLYWHEEL HOUSING INPUT SHAFT OIL SEAL REPLACEMENT



REPLACEMENT





1. Remove the input shaft oil seal from the flywheel housing.





2. Install the oil seal in the flywheel housing using the special tools as shown.

TRANSMISSION HOUSING BEARINGS



DRIVEN PULLEY SHAFT BEARING REPLACEMENT





1. To remove the driven pulley shaft bearing from the transmission housing, expand the snap ring with snap ring pliers, then push the bearing out using the special tools and a press as shown.

NOTE: Do not remove the snap ring unless it's necessary to clean the groove in the housing.

2. Expand the snap ring with snap ring pliers, insert the new bearing part-way into the housing using the special tools and a press as shown. Install the bearing with the groove facing outside the housing.

NOTE: Coat all parts with Continuously Variable Transmission (CVT)Fluid.





3. Release the pliers, then using the special tools, push the bearing down into the housing until the snap ring snaps in place.





4. After installing the bearing verify the following:
- The snap ring is seated in the bearing and housing grooves.
- The ring end gap is correct.

SECONDARY GEAR SHAFT BEARING REPLACEMENT





1. Remove the secondary gear shaft bearing using the special tools as shown.





2. Install the new secondary gear shaft bearing until it bottoms in the transmission housing, using the special tools as shown.

FLYWHEEL HOUSING BEARING



SECONDARY GEAR SHAFT BEARING REPLACEMENT





1. Remove the secondary gear shaft bearing using the special tool as shown.





2. Install the new secondary gear shaft bearing until it bottoms in the flywheel housing, using the special tools as shown.

RING GEAR BEARING REPLACEMENT



REPLACEMENT





1. Remove the ring gear bearing.





2. Install the new ring gear bearing until it bottoms in the ring gear, using the special tools as shown.

CONTROL SHAFT ASSEMBLY



REMOVAL / INSTALLATION





1. Remove the bolt and lock washer.
2. Remove the control lever from the control shaft.
3. Remove the control shaft assembly.
4. Install the control shaft assembly in the transmission housing.
5. Install the control lever to the control shaft.
6. Install and tighten the bolt with a new lock washer.

TRANSMISSION REASSEMBLY



REASSEMBLY

CAUTION: While reassembling, be sure not to allow dust and other foreign particles to enter into the transmission.





NOTE:
- Coat all parts with Continuously Variable Transmission (CVT) Fluid.
- Replace the following parts:
- O-rings
- Sealing rings
- Sealing washers
- Gaskets
- Start clutch assembly and secondary drive gear assembly

1. Install the Automatic Transmission Fluid (ATF) feed pipe in the transmission housing, and install the three ATF feed pipes with new O-rings in the transmission housing.
2. Install the two dowel pins and new transmission housing gasket on the transmission housing.
3. Push the control shaft assembly toward the outside of the transmission housing, then install the intermediate housing assembly (four bolts).
4. Install the manual valve body separator plate and the two dowel pins on the intermediate housing, then install the manual valve body with the detent spring (five bolts).
5. Put the control shaft assembly back, then install the roller in the intermediate housing.
6. Install the reverse brake piston in the intermediate housing.
7. Install the spring retainer/return spring assembly on the reverse brake piston.

NOTE: Install the return springs on the spring guides of the reverse brake piston securely.





8. Install the special tool to compress the return spring as shown.
9. Compress the return springs, then install the snap ring in the intermediate housing above the spring retainer.





10. Verify that the snap ring end gap is correct.
11. Soak the reverse brake discs thoroughly in CVT Fluid for minimum 30 minutes.
12. Install the disc spring on the reverse brake piston.
13. Starting with a reverse brake plate, alternately install the reverse brake plates and discs. Install the reverse brake end plate, and the snap ring.





14. Measure the clearance between the reverse brake end plate and the top disc with a dial indicator. Zero the dial indicator with a reverse brake end plate lowered, and lift it up to the snap ring. The distance that the reverse brake and plate moves is the clearance between the reverse end plate, and the top disc.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

15. If the clearance is not within the standard, remove the reverse brake end plate and measure its thickness.





16. Select and install a new reverse brake end plate, then recheck.

NOTE: If the thickest reverse brake end plate is installed, but the clearance is still over the standard, replace the reverse brake discs and plates.

17. After replacing the reverse brake end plate, make sure that the clearance is within the standard.
18. Remove the snap ring, reverse brake end plate, discs, plates, and disc spring.
19. Install the snap ring retainer on the drive pulley shaft.
20. Wrap the drive pulley shaft splines with tape to prevent damage to the O-rings, then install new 0rings.





21. Install the forward clutch assembly on the drive pulley shaft, then install the snap ring.





22. Verify that the outside diameter of the snap ring is correct.
23. Install the input shaft and the sun gear as a sub assembly.





24. Install the thrust needle bearing and the thrust washer on the sun gear.
25. Install the carrier assembly on the forward clutch.





26. Install the thrust washer, the thrust needle bearing, and the thrust washer on the carrier assembly.
27. Install the ring gear and the 25 x 31 mm thrust shim, then install the snap ring.





28. Verify that the outside diameter of the snap ring is correct.





29. Measure the clearance between the 25 x 31 mm thrust shim and the snap ring.

STANDARD: 0.05 - 0.11 mm (0.0020 - 0.0043 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

30. If the clearance is out of tolerance, remove the 25 x 31 mm thrust shim and measure its thickness.





31. Select and install a new 25 x 31 mm thrust shim, then recheck.
32. After replacing the 25 x 31 mm thrust shim, make sure that the clearance is within tolerance and the snap ring outside diameter is correct.
33. Install the disc spring in the direction shown.





34. Starting with a reverse brake plate, alternately install the reverse brake plates and discs. Install selected reverse brake end plate, then install the snap ring.





35. Verify that the snap ring end gap is correct.





36. Install the manual valve body lines A and B with new O-rings on the manual valve body and the intermediate housing.
37. Install the two dowel pins and new end cover gasket on the intermediate housing, then install new 0rings on the ATF feed pipes.
38. Install the end cover (three 6 mm bolts, eleven 8 mm bolts).

NOTE: Install the nine 8 mm bolts in the end cover (two 8 mm bolts remain in the end cover) then tighten the eleven 8 mm bolts.





39. Install the park pawl, spring, and shaft on the transmission housing, then move the control lever to any gear other than [P] position.
40. Install the secondary gear shaft with selected 25 x 35 mm thrust shim.
41. Wrap the driven pulley shaft splines with tape to prevent damage to the O-rings, then install new 0rings.
42. Assemble the secondary drive gear assembly in the start clutch assembly, then install them on the driven pulley shaft.





43. Pull the handle of the special tool up, then install the tip of it into the driven pulley shaft hole, and set the special tool on the start clutch.





44. Push the handle of the special tool, then tighten the nut to seat the secondary drive gear assembly on the driven pulley shaft securely.
45. Pull the handle of the special tool up, and remove the special tool.





46. Install the cotters, then measure the clearance between the cotters and the start clutch guide.

STANDARD: 0 - 0.13 mm (0 - 0.005 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

47. If the clearance is not within the standard, remove the cotters and measure their thickness.





48. Select and install new cotters, then recheck.
49. After replacing the 25.5 mm cotters, make sure that the clearance is the standard.
50. Install the cotter retainer and the snap ring.





51. Verify that the outside diameter of the snap ring is correct.





52. Install the thrust washers, the Automatic Transmission Fluid (ATF)pump drive sprocket hub and the 22 x 28 mm thrust shim on the input shaft, then install the snap ring.





53. Verify that the outside diameter of the snap ring is correct.





54. Measure the clearance between the 22 x 28 mm thrust shim and the snap ring.

STANDARD: 0.37 - 0.65 mm (0.015 - 0.026 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

55. If the clearance is out of tolerance, remove the 22 x 28 mm thrust shim and measure its thickness.





56. Select and install a new 22 x 28 mm thrust shim, then recheck.
57. After replacing the 22 x 28 mm thrust shim, make sure that the clearance is within tolerance and the snap ring outside diameter is correct.





58. Install the Pitot flange using its cutout as shown to clear the Pitot pipes.





59. Install the ATF pump drive sprocket, and put the ATF pump drive chain on the ATF pump drive and driven sprockets, then install and tighten the bolts (three bolts).





60. Install the differential assembly.
61. Install the ATF passage line assembly with new O-rings (one bolt).
62. Install the three dowel pins and new flywheel housing gasket on the transmission housing.
63. Install the flywheel housing and connector bracket (twenty bolts).
64. Install the ATF passage line holder assembly (two bolts).





65. Install the solenoid harness connector with a new O-ring (one bolt), then install the lower valve body assembly with three dowel pins (eight bolts).
66. Install the ATF strainer with a new O-ring (two bolts).
67. If necessary, assemble the ATF pan, ATF filter, and the ATF cooler inlet line.
68. Install the ATF pan with the two dowel pins and a new ATF pan gasket (fourteen bolts).
69. Install the ATF cooler inlet line bracket bolt.
70. Install the ATF cooler outlet line with the line bolt and new sealing washers.