Exploded View

Fig 1: Exploded View Of Intermediate Housing, Reverse Brake, And Forward Clutch

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required 

Reverse brake spring compressor 07TAE-P4V0110

1. Install 8 x 50 mm ATF feed pipe in the transmission housing, and install the 10.9 x 39.6 mm ATF feed pipes with new O-rings in the transmission housing.
2. Install the two dowel pins and new transmission housing gasket on the transmission housing.
3. Push the control shaft toward the outside of the transmission housing, then install the intermediate housing.
4. Install the manual valve body separator plate and two dowel pins on the intermediate housing, and install the manual valve body (four bolts) with the detent spring (one bolt).
5. Put the control shaft back, then install the roller in the intermediate housing with aligning the groove on the control shaft.
6. Install the new O-rings (A) on the reverse brake piston (B), then install the piston in the intermediate housing (C).
   Fig 2: Installing Reverse Brake Piston In Intermediate Housing

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7. Install the spring retainer/return spring assembly (D); Install the return springs on the spring guide (E) on the reverse brake piston.
8. Install the special tool through the drive pulley shaft to compress the return spring. Be sure the special tool (spring compressor attachment) is set over the return springs, not over the reverse brake piston.
   Fig 3: Installing Special Tool

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9. Compress the return springs, making sure that the special tool is set over the return springs and the spring retainer tabs do not ride on the reverse brake piston.
   Fig 4: Compressing Return Spring

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10. Install the snap ring in the intermediate housing above the spring retainer.
11. Verify that the snap ring end gap (A) is 15 mm (0.59 in.) or more.
    Fig 5: Identifying Snap Ring End Gap

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12. Inspect the brake discs, brake plates, and brake end-plate for wear, damage, and discoloration.
    • If the discs or plates are worn or damaged, replace the disc and plates as a set.
    • If the end-plate is worn, damaged, or discolored, replace the end-plate.
13. Soak the reverse brake discs thoroughly in CVTF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the brake is free of dirt and other foreign matter.
14. Install the disc spring (A) in the direction shown.
    Fig 6: Identifying Direction For Installing Disc Spring

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15. Starting with the reverse brake plate (B), alternately install the plates and discs (C). Install the reverse brake end-plate (D).
16. Install the snap ring by installing its end gap in the direction (A) shown.
    Fig 7: Installing Snap Ring

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17. Verify that the inside diameter (B) of the snap ring is 143.5 mm (5.65 in.) and above.
18. Verify that the snap ring end gap (A) is 18 mm (0.71 in.) and above.
    Fig 8: Identifying Snap Ring End Gap

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19. Set a dial indicator (A) on the reverse brake end-plate (B).
    Fig 9: Setting Dial Indicator On Reverse Brake End-Plate And Torque Specifications

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20. Zero the dial indicator with lifting the top disc (C) up to contact the reverse brake end-plate to the snap ring (D).
21. Release the end-plate to lower the end-plate, and place a steel plate across the width of the reverse brake end-plate.
22. Press the steel plate (A) down with 39 N (4 kgf, 9 lbf) using a force gauge, and read the dial indicator (B). the dial indicator reads the clearance (C) between the reverse brake end-plate (D) and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.

    Standard: 0.55-0.70 mm (0.022-0.028 in.) 

    Fig 10: Checking Clearance Between Reverse Brake End-Plate And Top Disc

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23. If the clearance is out of standard, select a new reverse brake end-plate from the following table, then recheck.
    NOTE: If the thickest end-plate is installed, but the clearance is still over the service limit, replace the reverse brake discs and plates as a set.

    REVERSE BRAKE END-PLATE 

    REVERSE BRAKE END-PLATE SPECIFICATIONS
    
    

    No.	Part Number	Thickness
    1	22551-P4V-003	3.6 mm (0.142 in.)
    A	22551 -PWR-003	3.7 mm (0.146 in.)
    2	22552-P4V-003	3.8 mm (0.150 in.)
    B	22552-PWR-003	3.9 mm (0.154 in.)
    3	22553-P4V-003	4.0 mm (0.157 in.)
    C	22553-PWR-003	4.1 mm (0.161 in.)
    4	22554-P4V-003	4.2 mm (0.165 in.)
    D	22554-PWR-003	4.3 mm (0.169 in.)
    5	22555-P4V-003	4.4 mm (0.173 in.)
    E	22555-PWR-003	4.5 mm (0.177 in.)
    6	22556-P4V-003	4.6 mm (0.181 in.)
    F	22556-PWR-003	4.7 mm (0.185 in.)
    7	22557-P4V-003	4.8 mm (0.189 in.)
    8	22558-P4V-003	5.0 mm (0.197 in.)

24. After replacing the reverse brake end-plate, make sure that the clearance is within tolerance.
25. Install the snap ring retainer (A) over the drive pulley shaft (B).
    Fig 11: Installing Snap Ring Retainer Over Drive Pulley Shaft

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26. Wrap the drive pulley shaft splines with tape to prevent O-ring damage. Install the new O-ring (C) in the drive pulley shaft O-ring grooves, then remove the tape.
27. Install the forward clutch (D) on the drive pulley shaft, then install the snap ring (E) to secure the forward clutch.
28. Verify that the snap ring outside diameter (A) is 41.4 mm (1.63 in.) or less.
    Fig 12: Identifying Snap Ring Outer Diameter

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29. Install the ring gear (A) on the forward clutch (B).
    Fig 13: Installing Ring Gear On Forward Clutch And Torque Specifications

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30. Install the planetary carrier/input shaft assembly (C) through the drive pulley shaft (D) with aligning the sun gear (E) to the clutch discs and aligning the planetary carrier to the reverse brake discs.
31. Install the manual valve body lines (A) with new 0-rings (B) on the manual valve body (C) and intermediate housing (D).
32. Install the ATF feed pipe (E) with new O-rings (F) on the manual valve body.
33. Install the two dowel pins (G) and the new end cover gasket (H) on the intermediate housing, and install the new O-rings (I) over the ATF feed pipes (J).
34. Install the end cover (K).
35. Install the CVT input shaft (drive pulley) speed sensor with a new O-ring.