Part 3

DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY SERVICE POINT

CAUTION:
When the outer races of reduction gear bearing and differential side bearing are removed, measure the mounting bore diameters of outer race in the converter housing and transaxle case, and replace the housing case or the CVT assembly if the standard value is not satisfied. The standard values are listed in "SERVICE SPECIFICATIONS."





1.
CAUTION:

- Do not re-use the reverse brake piston.
- Apply transmission fluid when installing the reverse brake piston.

Install the reverse brake piston, while turning it, on the transaxle case.





2. Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.









3.
CAUTION:
When installing the retaining plate, align the tangs at positions A, B, C in the diagram.

Install the retaining plate on the transaxle case.









4.
CAUTION:

- Set the spring compressor right on top of the spring of spring retainer assembly.
- Do not re-use the snap ring.
- When installing the snap ring, make sure that the joint falls in the area A in the diagram.

Using the special tool MB992139, compress the return spring, and install the snap ring on the transaxle case by means of a flat blade screwdriver etc.





5. Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case.









6.
CAUTION:

- When conducting measurements, measure two or more places, and find the average value.
- Do not re-use the snap ring.
- When installing the snap ring, make sure that the joint falls in the area A in the diagram.

Using a flat blade screwdriver etc., install the snap-ring on the transaxle case, and measure clearance between the snap ring and retaining plate. Select the snap ring so as to obtain standard value of the clearance. For selection of the snap ring, refer to "SERVICE SPECIFICATIONS."
Standard value: 1.2 - 1.5 mm (0.05 - 0.06 in)
(For reverse brake end play)






7.
CAUTION:

- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.

Install the needle bearing on the reverse brake piston. Refer to A in the "IDENTIFICATION OF NEEDLE BEARINGS" for right direction.





8. Install the planet carrier on the reverse brake.





9.
CAUTION:

- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.

Install the needle bearing on the primary pulley side of the sun gear. Refer to B in the
"IDENTIFICATION OF NEEDLE BEARINGS" for right direction.





10. Install the sun gear on the planet carrier.





11.
CAUTION:

- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.

Install the needle bearing on the forward clutch drum side of the sun gear. Refer to C in the "IDENTIFICATION OF NEEDLE BEARINGS" for right direction.





12. Install the forward clutch assembly on the transaxle case.













13.
CAUTION:
When conducting measurements, measure two or more places, and find the average value.

Measure the total end play as follows:
(1) Measure the distance M1 from the oil pump cover mounting surface of the transaxle case to the needle bearing mounting surface of the forward clutch drum.
(2) Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transaxle case.
(3) Calculate the total end play by the following expression. Select the needle bearing so that the total end play meets its standard value.
Total end play = M1 - M2 - bearing thickness
Standard value: 0.25 - 0.55 mm (0.010 - 0.022 in)
(For total end play)






14.
CAUTION:

- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.

Install the selected needle bearing on the forward clutch assembly. Refer to D in the
"IDENTIFICATION OF NEEDLE BEARINGS" for right direction.





15.
CAUTION:

- Do not re-use the seal rings.
- Apply Vaseline when installing the seal rings.

Install the seal rings on the oil pump cover.





16.
CAUTION:
Do not re-use the bolt.

Install the detent spring on the transaxle case and tighten the bolt to the specified torque.
Tightening torque: 6.9Nm (61 in-lb)






17.
CAUTION:

- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.

Install the O-ring on the plug.





18. Install the plug on the converter housing and tighten the bolt to the specified torque.
Tightening torque: 7.5Nm (66 in-lb)






19.
CAUTION:
Do not bend the pipe when attaching it.

Install the pipe on the converter housing.





20. Install the clip and tighten the bolt to the specified torque.
Tightening torque: 6.9Nm (61 in-lb)






21.
CAUTION:

- Do not re-use the outer race.
- Replace the outer race together with the inner race.

Using the special tools MB990779 and MB990780, Install the differential bearing outer race of differential side bearing on the converter housing.

















22.
CAUTION:

- When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
- When conducting measurements, measure two or more places, and find the average value.

Measure the preload A of the differential assembly as follows:
(1) Measure the distance M3 from the edge of transaxle case to the mounting surface of adjusting shim.
(2) Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing.
(3) Install the outer race on differential side bearing, and measure the distance M5 from the differential case to the outer race of differential side bearing.
(4) Using the following expression, calculate the distance M6 from the edge of converter housing to the outer race of differential side bearing.
M6 = M4 - M5
(5) Using the following expression, calculate thickness of the adjusting shim.
Thickness of adjusting shim = M3 - M6 + preload
Standard value: 0.17 - 0.23 mm (0.007 - 0.009 in)
(For differential preload)






23.
CAUTION:
Do not re-use the adjusting shim.

Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS."





24.
CAUTION:

- Do not re-use the outer race.
- Replace the outer race together with the inner race.

Using the special tool MB990780, install the outer race of differential side bearing on the transaxle case.





25.
CAUTION:

- Do not re-use the outer race.
- Replace the outer race together with the inner race.

Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the converter housing.

















26.
CAUTION:

- When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
- When conducting measurements, measure two or more places, and find the average value.

Measure the preload A of the reduction gear assembly in the following way.
(1) Measure the distance M7 from the edge of transaxle case to the mounting surface of adjusting shim.
(2) Install the reduction gear assembly on the converter housing, and measure the distance M8 from the edge of reduction gear assembly to the edge of converter housing.
(3) Install the outer race of reduction gear side bearing on the bearing, and measure the distance M9 from the edge of reduction gear assembly to the outer race of reduction gear bearing.
(4) Using the following expression, calculate the difference M10 from the outer race of reduction gear bearing to the edge of converter housing.
M10 = M8 - M9
(5) Using the following expression, calculate the thickness of adjusting shim.
Thickness of adjusting shim = M7 - M10 + preload
Standard value: 0.11 - 0.17 mm (0.004 - 0.006 in)
(For reduction gear preload)






27.
CAUTION:
Do not re-use the adjusting shim.

Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS."





28.
CAUTION:

- Do not re-use the outer race.
- Replace the outer race together with the inner race.

Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the transaxle case.





29.
CAUTION:

- Do not re-use the lip seal.
- Apply transmission fluid when installing the lip seal.

Install the lip seal on the transaxle case.





30.
CAUTION:

- Do not re-use the O-rings.
- Apply transmission fluid when installing the O-rings.

Install the O-rings on the oil pump fastening bolts.





31. Install the oil pump on the transaxle case and tighten the bolt to the specified torque.
(One fastening bolt is installed at the backside from the transaxle case side. Only this bolt should be tightened to the specified torque of 28 Nm [21 ft-lb]).
Tightening torque: 19Nm (14 ft-lb)






32.
CAUTION:
Do not re-use the snap ring.

Install the snap ring on the oil pump.





33.
CAUTION:

- Do not re-use the lip seal.
- Apply transmission fluid or Vaseline when installing the lip seal.

Install the lip seal on the transaxle case.





34. Install the valve body harness on the control valve.

























35. Install the control valve assembly on 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) Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the diagram.
(3)

CAUTION:
Align the notch of pulley ratio linkage with the prong of pulley sensor.

Slide the control valve assembly from the bottom, and install it on the transaxle case.
(4)

CAUTION:
Apply transmission fluid when attaching the bush.

Install the bush on the control valve assembly.
(5) Install the fastening bolts of control valve assembly and tighten the bolt to the specified torque.
Tightening torque: 7.9Nm (70 in-lb)











36. Install the manual valve lever and tighten the bolt to the specified torque.
Tightening torque: 22.1Nm (16 ft-lb)






37. Install the bracket on the control valve assembly and tighten the bolt to the specified torque.
Tightening torque: 7.9Nm (70 in-lb)






38.
CAUTION:

- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.

Install the O-ring on the oil strainer.





39. Install the oil strainer and tighten the bolt to the specified torque.
Tightening torque: 7.9Nm (70 in-lb)