Disassembly Service Point

DISASSEMBLY SERVICE POINT

CAUTION:
Do not disassemble parts other than specified in this manual.

1. Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.
2. Remove the harness bracket from the transaxle.
3. Remove the oil filler tube and oil level gage from the transaxle.
4. Remove the control cable bracket and breather hose from the transaxle.





5. Remove the torque converter from the transaxle.





6. Remove the plug from the transaxle case.





7. Remove the O-ring from the plug.





8. Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.





9. Remove the primary pulley speed sensor from the transaxle case, and detach the O-ring from the sensor.





10. Remove the shift lever from the manual shaft.





11. Remove the inhibitor switch from the transaxle.

CAUTION:
Be careful not to cause damage to the terminal body.





12. Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.





13. Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.








14. Remove the transmission fluid filter from the transaxle case.





15. Remove the fastening bolts of converter housing.





CAUTION:
Be careful because adjusting shim of the drive sprocket may depart.





16. Remove the converter housing by tapping with a plastic hammer etc.





17. Using the special tools MB990590 and MB992039, remove the outer race of reduction gear bearing from the converter housing.
18. Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.

Standard value: diameter 61.949 - 61.979 mm (diameter 2.4389 - 2.4401 in)





19. Using the special tools MB990590 and MB992039, remove the outer race of differential side bearing from the converter housing.
20. Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.

Standard value: diameter 67.949 - 67.979 mm (diameter 2.6752 - 2.6763 in)

CAUTION:
When removing the oil seal, be careful not to cause damage to the converter housing.





21. Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.





22. Remove the clip.

CAUTION:
When removing the pipe, be careful not to bend it.





23. Remove the pipe from the converter housing.





24. Remove the plug from the converter housing.





25. Remove the O-ring from the plug.





26. Remove the O-ring from the input shaft.





27. Remove the adjusting shim from the drive sprocket.





28. Remove the baffle plate.





29. Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.








30. Remove the thrust washer from the oil pump cover.





31. Remove the snap ring from the oil pump.





32. Remove the reduction gear assembly from the transaxle case.





33. Remove the differential assembly from the transaxle case.





34. Remove the bracket.





35. Remove the baffle plate.





36. Remove the baffle plate.





37. Remove the oil pump cover from the transaxle case.





38. Remove the seal rings from the oil pump cover.





39. Remove the needle bearing from the forward clutch assembly.





40. Remove the oil pan from the transaxle case.
41. Remove the magnet from the oil pan.





42. Remove the oil pan gasket from the transaxle case.





43. Remove the oil strainer








44. Remove the O-ring from the oil strainer.





45. Remove the bracket from the control valve assembly.





46. Remove the manual lever.





47. Remove the control valve assembly from the transaxle case as follows:
1) Insert pins etc. (diameter 3 mm (0.12 in) ) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.





2) Remove fastening bolts of the control valve assembly.








3) Remove the control valve assembly from the transaxle case.

NOTE: Tilt the control valve assembly, and after removing from the manual shaft side, remove the terminal body from the transaxle case.





48. Remove the bush from the control valve.





49. Remove the lip seal from the transaxle case.





50. Remove the valve body harness from the control valve.





51. Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)





52. Remove the O-ring from the oil pump fastening bolt.





53. Remove the lip seal from the transaxle case.





54. Using the special tools MB990590 and MB992039, remove outer race of the differential side bearing from the transaxle case.
55. Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the transaxle case side; if the standard value is not satisfied, then replace the CVT assembly.

Standard value: diameter 67.949 - 67.979 mm (diameter 2.6752 - 2.6763 in)





56. Remove the adjusting shim from the transaxle case.





57. Using the special tools MB990590 and MB992039, remove outer race of the reduction gear bearing from the transaxle case.
58. Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the transaxle case side; if the standard value is not satisfied, then replace the CVT assembly.

Standard value: diameter 61.949 - 61.979 mm (diameter 2.4389 - 2.4401 in)





59. Remove the adjusting shim from the transaxle case.

CAUTION:
When removing the side oil seal, be careful not to cause damage to the transaxle case.





60. Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.





61. Remove the detent spring from the transaxle case.





62. Remove the forward clutch assembly from the transaxle case.





63. Remove the needle bearing on forward clutch drum side from the sun gear.





64. Remove the sun gear from the planet carrier.





65. Remove the needle bearing on primary pulley side from the sun gear.





66. Remove the planet carrier from the transaxle case.





67. Remove the needle bearing from the planet carrier.

CAUTION:
Check if there is damage, deformation, burn marks or permanent sets of the dish plate, driven plate, snap ring, and drive plate. Replace any defective part.





68. Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case.

CAUTION:
^ Set the spring compressor right on top of the spring of spring retainer assembly.
^ Do not remove the return spring from the spring retainer assembly.





69. Using the special tool MB992139, compress the return spring, and remove the snap ring from the transaxle case.
70. Remove the retaining plate and return spring assembly.

CAUTION:
Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.





71. Feed the air in the oil hole shown in the diagram, and remove the reverse brake piston from the transaxle case.