Part 1
DISASSEMBLY AND ASSEMBLY
CAUTION:
- Only use transmission fluid of the specified brand. Use of transmission fluid other than specified will impair driveability and CVT endurance, and may lead to breakage of CVT.
- Only use the specified Vaseline. Use of Vaseline other than specified will impair driveability and CVT endurance, and may lead to breakage of CVT.
- Disassembly work should be done in a clean dust-proof room.
- Prior to disassembly, clean any sand or dirt adhered to the outer parts of transaxle using steam, washing oil or another solvent, outside the clean room, so as not to contaminate inner parts of transaxle during disassembly or assembly. (Do not allow steam to get inside the transaxle, and do not clean rubber parts with washing oil.)
- After cleaning, remove the torque converter, and drain the transmission fluid.
- Disassembly and assembly work should be done with bare hands or using plastic gloves.
- Do not touch inner parts of the transaxle after touching its outer parts. (Wash hands after touching the outer parts.)
- Do not use cotton gloves and rags to prevent from lint; instead, use paper rags.
- Prior to assembly or disassembly work, make sure conditions are appropriate.
- Do not re-use the drained transmission fluid.
- MB990590: Real axle shaft oil seal remover
- MB992039: Slide hammer puller
- MB992139: Spring compressor
- MB990779: Bar
- MB990780: Real axle shaft bushing installer
- MB990932: Installer adapter
- MB990938: Installer bar
- MB992075: Handle
- MB992141: Oil seal installer
- MB992206: Oil seal installer
- MB992140: Oil seal installer
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 manual control lever from the manual shaft.
11. Remove the inhibitor switch from the transaxle.
12.
CAUTION:
Be careful not to cause damage to the terminal body.
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.
16.
CAUTION:
Be careful because adjusting shim of the drive sprocket may depart.
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:
dia. 61.949 - 61.979 mm (dia. 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:
dia. 67.949 - 67.979 mm (dia. 2.6752 - 2.6763 in)
21.
CAUTION:
When removing the oil seal, be careful not to cause damage to the converter housing.
Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.
22. Remove the clip.
23.
CAUTION:
When removing the pipe, be careful not to bend it.
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 chain cover.
28. Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.
29. Remove the thrust washer from the oil pump cover.
30. Remove the snap ring from the oil pump.
31. Remove the reduction gear assembly from the transaxle case.
32. Remove the differential assembly from the transaxle case.
33. Remove the bracket.
34. Remove the oil guide.
35. Remove the baffle plate.
36. Remove the oil pump cover from the transaxle case.
37. Remove the seal rings from the oil pump cover.
38. Remove the needle bearing from the forward clutch assembly.
39. Remove the oil pan from the transaxle case.
40. Remove the magnet from the oil pan.
41. Remove the oil pan gasket from the transaxle case.
42. Remove the oil strainer
43. Remove the O-ring from the oil strainer.
44. Remove the bracket from the control valve assembly.
45. Remove the manual valve lever.
46. Remove the control valve assembly from the transaxle case as follows:
(1) Insert pins etc. (dia. 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.
47. Remove the bush from the control valve.
48. Remove the lip seal from the transaxle case.
49. Remove the valve body harness from the control valve.
50. Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)
