Disassembly
TransaxleSpecial Tool(s):
1. Remove and discard the 4 retainers and remove the transaxle insulator.
2. Remove the bolts and remove the rear transaxle mount.
3. Remove the bolt and remove the transmission fluid level indicator and tube.
4. Remove the transmission fluid level indicator tube grommet.
5. Using the special tool, remove the torque converter.
6. Make an identifying mark on the torque converter where the pump pilot is located for correct installation.
7. CAUTION: Be careful not to cross-thread the bolts while installing the special tool.
Install the special tool onto the transaxle case.
^ Tighten to 55 Nm (41 ft. lbs.).
8. Position the transaxle into the bench fixture.
9. Remove the side shaft gear assembly bolts.
10. Remove the side shaft gear assembly from the case.
11. Remove the transmission fluid pan.
12. Remove and discard the transmission fluid pan gasket.
13. NOTE: Check the transaxle case to see if the filter pickup tube seal is stuck in the case. If the pickup tube seal is in the case it will need to be removed.
Remove and discard the transmission fluid filter.
^ Use a suitable seal pick to remove the seal if it is stuck in the case.
14. Remove the main electrical outer shell bolt.
15. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Rotate the outer shell connector in order to release it from the mechatronic electrical connector.
^ Rotate the connector counterclockwise to remove.
16. Remove the electrical connector by lifting it out of the case.
17. CAUTION: Do not pull up on the wire harness. Damage to the wiring harness could result.
Depress the tabs on the electrical connectors and pull up on the connectors to disconnect.
18. CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt. This is used for keeping the sensor a specific distance from the differential gears.
Remove the OSS sensor bolt, sensor and spacer.
19. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Remove the 8 bolts from the mechatronic unit.
20. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Remove the mechatronic unit from the transaxle.
21. CAUTION: Vehicles having transmissions with transmission build dates prior to December 6, 2005 have longer feed tubes for the primary and secondary feed tubes. The shorter feed tube goes in the main pressure case hole.
Vehicles having transmissions with transmission build dates after December 6, 2005 use the same size, shorter feed tube in the primary, secondary and main pressure feed tube locations.
Be sure to note what size the feed tubes are when removed and install them in the same case hole location they were removed from.
Short and long feed tubes cannot be interchanged because CVT cases built after December 6, 2005 that use the shorter feed tube in all 3 locations have shallower case holes in the primary and secondary feed tube locations. Putting the longer feed tubes in these cases will result in cross leakage when the mechatronic assembly is installed. Putting shorter feed tubes in a location that used the longer hole may also result in a cross leak when the mechatronic assembly is installed from the tube being pushed farther down and not sealing.
NOTE: The 5 feed tubes may stick in the case or the mechatronic assembly, make sure that all 5 feed tubes are removed.
NOTE: Note the location of the 5 feed tubes for reassembly.
Remove all of the 5 feed tubes.
1 Remove the clutch (manual valve) supply feed tube.
2 Remove the primary pressure feed tube.
3 Remove the secondary pressure feed tube.
4 Remove the main (pump) pressure feed tube.
5 Remove and discard the torque converter clutch pressure feed tube.
22. Remove and discard all of the seals on the feed tubes.
1 Remove and discard the inside and outside O-ring seals from the clutch (manual valve) supply feed tube.
2 Remove and discard the O-ring seals from the primary pressure feed tube, secondary pressure feed tube and the main (pump) pressure feed tube.
3 Discard the torque converter clutch pressure feed tube.
23. Remove and discard the 26 retaining bolts for the transaxle converter housing.
24. Remove the converter housing. It will be necessary to pry the case halves apart.
25. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
Remove and discard the converter housing gasket.
26. Remove the differential assembly.
27. Remove the input shaft. Remove and discard the planet carrier thrust washer.
28. Remove and discard the O-ring seals and the split ring seal.
29. NOTE: There is a selective fit washer under this bearing.
Remove the upper input shaft roller bearing.
30. NOTE: This is a selective fit washer.
Remove the upper input shaft roller bearing washer.
31. Remove the input shaft roller bearing.
32. Remove the fluid baffle screws and the baffle.
33. Remove the chain lube feed tube retainer screws and the retainer.
34. Remove the chain lube feed tube.
35. Remove and discard the feed tube O-ring seal.
36. NOTE: Note the location of the transaxle range sensor wiring.
Remove the 2 bolts and the manual lever detent spring.
37. NOTE: The manual valve will need to be in the PARK position in order to remove the valve assembly.
NOTE: It may require some rocking movement back and forth in order to get the valve off the O-ring seals on the clutch feed tube.
Remove the 2 bolts for the range selector valve assembly and remove the valve assembly.
38. Remove and discard the sun gear retaining ring.
39. Remove the sun gear and bearing spacer.
40. Inspect the sun gear and spacer for damage.
^ If damage is indicated, install a new sun gear and spacer.
41. Remove the forward clutch assembly.
42. CAUTION: Be careful when removing the retaining ring that it does not fall into the case, damage to the case will result.
Using a magnet and a small screwdriver, remove and discard the guide pin retaining ring.
43. Using a magnet, remove the guide pin retaining ring washer.
44. Install the special tool onto the variators.
45. Secure the special tool with a strap.
46. Remove the special tool.
47. Remove the end portion of the transmission holding fixture tool that fits into the bench fixture. Install the end portion onto the variator holding fixture so it can be mounted into the bench fixture.
48. Install the transaxle case half and the variator assembly into the bench fixture.
^ Remove the strap.
49. NOTE: The feed tube under the primary cover may stick in the cover or in the case.
Remove and discard the bolts for the primary cover and remove the cover.
50. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
Remove and discard the primary cover gasket.
51. Remove and discard the O-ring seal from the feed tube and the square cut seal.
52. NOTE: If the feed tube is not in the case, it may be stuck in the cover.
Remove the feed tube.
^ If equipped with a primary feed tube that has removable O-ring seals, remove the feed tube and remove and discard the O-ring seals.
^ If equipped with a primary feed tube that has a bonded seal, remove and discard the feed tube.
53. Remove and discard the bolts for the secondary cover and remove the cover.
54. CAUTION: Use care when cleaning the gasket surface not to scratch or gouge it, a transmission leak could result.
NOTE: Using a plastic scraper, make sure that all gasket material is removed from the case.
Remove and discard the seal on the secondary feed tube and the gasket from the case.
55. Remove and discard the secondary feed tube snap ring.
56. NOTE: The feed tube under the pressure filter cover may stick in the cover or in the case.
Remove the pressure filter cover.
57. NOTE: If the feed tube is not in the case it may be stuck in the cover.
Remove the high pressure filter feed tube.
^ If equipped with a high pressure filter feed tube that has removable O-ring seals, remove the feed tube and discard the O-ring seals.
^ If equipped with a high pressure filter feed tube that has a bonded seal, remove and discard the feed tube.
58. Remove and discard the pressure filter.
59. NOTE: The case half will only need to be removed from the variators if installing a new chain and variator assembly or a new case.
NOTE: Make sure that the manual control lever is in the PARK position when removing the primary variator nut.
NOTE: The primary variator nut has been tightened to 500 Nm (369 ft. lbs.).
Using the special tool, remove and discard the primary variator nut.
60. NOTE: Make sure that the manual control lever is in the PARK position when removing the secondary variator nut.
NOTE: The secondary nut had been tightened to 150 Nm (111 ft. lbs.).
Using the special tool, remove and discard the secondary variator nut.
61. CAUTION: The chain and variators are a matched set of components. All 3 components (chain, primary variator and secondary variator) are installed as an assembly. Do not attempt to install an individual component. Transmission failure will result.
NOTE: The short variator insert goes on top of the primary variator.
Install the special tools.
62. CAUTION: In order for the cover to be removed evenly from the variators, both of the bolts must be turned 1/4 turn at a time. Failure to follow this instruction will cause damage to the variators and case.
Using the special tools, lift the transaxle case up off the variator assembly.
63. For the cleaning and inspection of the variators, refer to Variator/Chain and Spur Gear Assembly.