Part 2

DISASSEMBLY AND ASSEMBLY

33. Remove the differential assembly from the transaxle case.





34. Remove the bracket.





35. Remove the oil guide.





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. (dia.3 mm) 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
dia.67.949 - 67.979 mm (dia.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
dia.61.949 - 61.979 mm (dia.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.

IDENTIFICATION OF NEEDLE BEARINGS





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."

CAUTION:

- Do not re-use the reverse brake piston.

- Apply transmission fluid when installing the reverse brake piston.





1. 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.

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









3. Install the retaining plate on the transaxle case.

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.









4. 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.

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.









6. 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 clutch clearance)

CAUTION:

- Apply Vaseline when installing the needle bearing.

- Be careful to attach the needle bearing in right direction.





7. 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.

CAUTION:

- Apply Vaseline when installing the needle bearing.

- Be careful to attach the needle bearing in right direction.