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Transmission Reassembly

Special Tools Required 

NOTE: When you reassemble the transmission, soak the start clutch assembly, the forward clutch assembly, and the reverse brake disks in Honda Genuine CVTF for at least 30 minutes prior to installation.
  1. Install new O-rings (A) on the CVTF feed pipes (10.9 x 56 mm) (B), then install them with the filter ends into the transmission housing (C).
    Fig 1: Locating O-Rings, CVTF Feed Pipes (10.9 x 56 mm) And Transmission Housing Components
    G06951234Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Install the two dowel pins (D) and a new gasket (E) on the transmission housing.
  3. Push the selector control shaft (F) toward the outside of the transmission housing, then install the intermediate housing (G).
  4. Pull the selector control shaft back, then install the roller (H) in the intermediate housing by aligning the groove on the selector control shaft.
  5. Install two new O-rings (A) on the reverse brake piston (B), then install the piston in the intermediate housing (C).
    Fig 2: Locating O-Rings, Reverse Brake Piston And Intermediate Housing Components
    G06951235Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install the spring retainer/return spring assembly (D); install the return springs on the spring guides (E) of the reverse brake piston.
  7. The snap ring (F) is installed by compressing the spring retainer/return spring assembly by the reverse brake spring compressor on and after the next step.
  8. Install the reverse brake spring compressor through the drive pulley shaft (A) to compress the spring retainer/return spring assembly (B).
    Fig 3: Locating Reverse Brake Spring Compressor, Drive Pulley Shaft And Spring Retainer/Return Spring Assembly
    G06951236Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Compress the spring retainer/return spring assembly, and make sure that the reverse brake spring compressor is set over the return springs, and the reverse brake spring compressor tabs (A) do not ride on the reverse brake piston (B).
    Fig 4: Locating Reverse Brake Spring Compressor Tabs And Reverse Brake Piston
    G06951237Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the snap ring in the intermediate housing above the spring retainer, then remove the reverse brake spring compressor.
  11. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the intermediate housing, and that the ring end gap (A) is 15 mm (0.59 in) or more.
    Fig 5: Identifying Ring End Gap
    G06951238Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Install the disc spring (A) on the spring retainer (B) in the direction shown.
    Fig 6: Locating Disc Spring And Spring Retainer Components
    G06951239Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Starting with one of the reverse brake plate (C), alternately install the two reverse brake plates and the reverse brake discs (D). Install the reverse brake end-plate (E), then install the snap ring (F).
  14. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the intermediate housing, and that the snap ring inside diameter (A) is 143.5 mm (5.650 in) or more, and also check that the snap ring end gap (B) is 8.7 mm (0.343 in) or more.
    Fig 7: Checking Snap Ring Inside Diameter And Snap Ring End Gap
    G06951240Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Set up a dial indicator (A) on the reverse brake end-plate (B).
    Fig 8: Setting Up Dial Indicator On Reverse Brake End-Plate
    G06951241Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Zero the dial indicator by lifting the top disc (C) up against the reverse brake end-plate and the reverse brake end-plate up against the snap ring (D).
  17. Release the reverse brake end-plate (A) to lower the reverse brake end-plate, and place a steel plate (B) across width of the reverse brake end-plate.

    Standard: 0.55-0.70 mm (0.0217-0.0276 in) 

    Fig 9: Pressing Steel Plate Down With 49 n (5.0 kgf, 11.0 lbf) Using Force Gauge, And Read Dial Indicator
    G06951242Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Press the steel plate down with 49 N (5.0 kgf, 11.0 lbf) (C) using a force gauge, and read the dial indicator (D). The dial indicator reads the clearance (E) between the reverse brake end-plate and the top-disc (F). Take measurements in at least three places, and use the average as the actual clearance.
  19. If the clearance is out of standard, remove the reverse brake end-plate, and measure it thickness.
  20. Select a new reverse brake end-plate from the following table and install it, then recheck that the clearance is within the standard.

    REVERSE BRAKE END-PLATE 

    REVERSE BRAKE END-PLATE REFERENCE CHART

    Mark Thickness
    2 3.8 mm (0.150 in)
    B 3.9 mm (0.154 in)
    3 4.0 mm (0.157 in)
    C 4.1 mm (0.161 in)
    4 4.2 mm (0.165 in)
    D 4.3 mm (0.169 in)
    5 4.4 mm (0.173 in)
    E 4.5 mm (0.177 in)
    6 4.6 mm (0.181 in)
    F 4.7 mm (0.185 in)
    7 4.8 mm (0.189 in)
    8 5.0 mm (0.197 in)
  21. If the reverse brake end-plate is replaced, install the snap ring, and check that the snap ring inside diameter and end gap are within the tolerance.
  22. Install the snap ring retainer (A) over the drive pulley shaft (B).
    Fig 10: Locating Snap Ring Retainer And Drive Pulley Shaft Components
    G06951243Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Wrap the drive pulley shaft splines with tape to prevent O-ring damage. Install two new O-rings (C) in the drive pulley shaft O-ring grooves, then remove the tape.
  24. Install the forward clutch (D) on the drive pulley shaft, then install the snap ring (E) to secure the forward clutch.
  25. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the drive pulley shaft, and that the snap ring outside diameter (A) is 41.4 mm (1.630 in) or less.
    Fig 11: Identifying Snap Ring Outside Diameter
    G06951244Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Install the ring gear (A) on the forward clutch (B).
    Fig 12: Locating Ring Gear And Forward Clutch Components
    G06951245Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. Install the input shaft/planetary carrier assembly (C) through the drive pulley shaft (D) by aligning the sun gear (E) with the forward clutch discs (F) and aligning the planetary carrier with the reverse brake discs (G).
  28. Install the manual valve body separator plate (A) and the two dowel pins (B) on the intermediate housing (C), then install the manual valve body (D) and detent spring (E).
    Fig 13: Locating Manual Valve Body Separator Plate, Dowel Pins, Intermediate Housing, Manual Valve Body And Detent Spring Components With Torque Specifications
    G06951246Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. Install two new O-rings (A) on the 10.9 x 18.6 mm CVTF feed pipe (B), then install it on the manual valve body (C).
    Fig 14: Locating O-Rings, 10.9 x 18.6 mm CVTF Feed Pipe And Manual Valve Body Components With Torque Specifications
    G06951247Courtesy of AMERICAN HONDA MOTOR CO., INC.
  30. Install two new O-rings (D) on the 10.9 x 56 mm CVTF feed pipe (E), then install it with the filter end and the 8 mm CVTF pipe (F) in the intermediate housing (G).
  31. Install the two dowel pins (H) and a new gasket (I) on the intermediate housing.
  32. Install four new O-rings (J) on the two CVTF feed pipes (K), then install them on the manual valve body and the intermediate housing.
  33. Place the end cover (L) on the intermediate housing.
  34. Install the end cover bolts (sixteen), and tighten them to the specified torque in a crisscross pattern in at least two or three steps, then turn the transmission end cover down.
  35. Install the sealing ring (A) on a new secondary drive/park gear (B).
    NOTE: The secondary drive/park gear must be replaced when disassembling the transmission.
    Fig 15: Locating Sealing Ring And Secondary Drive/Park Gear
    G06951248Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Insert the secondary drive/park gear (A) into the start clutch (B). Wiggle the secondary drive/park gear back and forth as it goes into the start clutch, and push in the secondary drive/park gear until it bottoms out.
    Fig 16: Inserting Secondary Drive/Park Gear Into Start Clutch
    G06951249Courtesy of AMERICAN HONDA MOTOR CO., INC.
  37. Install the park pawl (A), the pawl spring (B), and the pawl shaft (C) on the transmission housing (D), then move the control lever to any position other than P.
    Fig 17: Locating Park Pawl, Pawl Spring, Pawl Shaft And Transmission Housing Components
    G06951250Courtesy of AMERICAN HONDA MOTOR CO., INC.
  38. Use the CVTF to lubricate the new O-rings (E) for the driven pulley shaft (F), then install the O-rings on the driven pulley shaft.
  39. Place the start clutch and secondary drive/park gear (G) onto the driven pulley shaft.
    NOTE: Make sure to hold the secondary drive/park gear engaged into the start clutch when you install the start clutch and secondary drive/park gear onto the driven pulley shaft.
  40. Seat the start clutch by aligning the tip of the start clutch installer with the driven pulley shaft hole (A) and then pushing down the handle (B).
    Fig 18: Seating Start Clutch By Aligning Tip Of Start Clutch Installer With Driven Pulley Shaft Hole And Then Pushing Down Handle
    G06951251Courtesy of AMERICAN HONDA MOTOR CO., INC.
  41. While holding the handle (A) down, push down the bottom part (B) of the start clutch installer until it contacts the seating surface of the start clutch (C).
    Fig 19: Pushing Down Bottom Part Of Start Clutch Installer Until It Contacts Seating Surface Of Start Clutch
    G06951252Courtesy of AMERICAN HONDA MOTOR CO., INC.
  42. Hold the upper hex section (A) of the start clutch installer with a 19 mm wrench (B), then use an adjustable wrench (C) to tighten the lower nut (D) of the start clutch installer until the start clutch (E) seats.
    NOTE: When using the start clutch installer, hold the upper hex section and then turn the lower nut. Turning the upper hex section could damage the start clutch installer.
    Fig 20: Tightening Lower Nut Of Start Clutch Installer Until Start Clutch Seats
    G06951253Courtesy of AMERICAN HONDA MOTOR CO., INC.
  43. Remove the start clutch installer.
  44. Reach under the start clutch to confirm that the clutch end-plate can move up and down slightly (less than 1.0 mm (0.039 in)).
  45. Install the 25.5 mm cotters (A) to the cotter groove on the driven pulley shaft (B), then measure the clearance between the cotters and the start clutch guide (C) using a feeler gauge (D). Take measurements in at least three places, and use the average as the actual clearance.

    Standard: 0-0.13 mm (0-0.0051 in) 

    Fig 21: Measuring Clearance Between Cotters And Start Clutch Guide Using Feeler Gauge
    G06951254Courtesy of AMERICAN HONDA MOTOR CO., INC.
  46. If the clearance is out of standard, remove the cotters, and measure its thickness.
  47. Select new 25.5 mm cotters from the following table and install its, then recheck that the clearance is within the standard.

    COTTERS, 25.5 mm 

    COTTERS REFERENCE CHART

    No. Thickness
    A 2.90 mm (0.1142 in)
    B 3.00 mm (0.1181 in)
    C 3.10 mm (0.1220 in)
    D 3.20 mm (0.1260 in)
  48. Install the cotter retainer (A) and the snap ring (B) to the driven pulley shaft (C).
    Fig 22: Locating Cotter Retainer, Snap Ring And Driven Pulley Shaft
    G06951255Courtesy of AMERICAN HONDA MOTOR CO., INC.
  49. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the driven pulley shaft, and that the snap ring outside diameter (A) is 33.9 mm (1.335 in) or less.
    Fig 23: Checking Snap Ring Outside Diameter
    G06951256Courtesy of AMERICAN HONDA MOTOR CO., INC.
  50. Install the thrust washer (A), the thrust needle bearing (B), the thrust washer (C), the CVTF pump drive sprocket hub (D), and the 22 x 28 mm thrust shim (E) on the input shaft (F), and install the snap ring (G) to secure them.
    Fig 24: Locating Thrust Washer, Thrust Needle Bearing, Thrust Washer, CVTF Pump Drive Sprocket Hub And 22 x 28 mm Thrust Shim Components
    G06951257Courtesy of AMERICAN HONDA MOTOR CO., INC.
  51. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the input shaft, and that the snap ring outside diameter (A) is 26.3 mm (1.035 in) or less.
    Fig 25: Checking Snap Ring Outside Diameter
    G06951258Courtesy of AMERICAN HONDA MOTOR CO., INC.
  52. Measure the clearance between the 22 x 28 mm thrust shim (A) and the snap ring (B) using a feeler gauge (C). Take measurements in at least three places, and use the average as the actual clearance.

    Standard: 0.37-0.65 mm (0.0146-0.0256 in) 

    Fig 26: Measuring Clearance Between 22 x 28 mm Thrust Shim And Snap Ring Using Feeler Gauge
    G06951259Courtesy of AMERICAN HONDA MOTOR CO., INC.
  53. If the clearance is out of standard, remove the 22 x 28 mm thrust shim, and measure its thickness.
  54. Select a new 22 x 28 thrust shim from the following table and install it, then recheck that the clearance is within the standard.

    THRUST SHIM, 22 x 28 mm 

    THRUST SHIM REFERENCE CHART

    No. Thickness
    C 1.15 mm (0.0453 in)
    D 1.40 mm (0.0551 in)
    E 1.65 mm (0.0650 in)
    F 1.90 mm (0.0748 in)
    G 2.15 mm (0.0846 in)
    H 2.40 mm (0.0945 in)
  55. If the 22 x 28 mm thrust shim is replaced, install the snap ring, and check that the snap ring outside diameter is within the tolerance.
  56. Place the secondary driven gear (A) on the transmission housing (B) by aligning it with the secondary drive gear (C), then install the final drive shaft (D) through the secondary driven gear into the transmission housing.
    Fig 27: Locating Secondary Driven Gear, Transmission Housing And Final Drive Shaft Components With Torque Specifications
    G06951260Courtesy of AMERICAN HONDA MOTOR CO., INC.
  57. Install the 25 x 35 mm thrust shim (E) on the final drive shaft.
  58. Position the CVTF pump drive sprocket (F) on the CVTF pump drive sprocket hub (G), and put the CVTF pump drive chain (H) on the CVTF pump drive sprocket and the CVTF pump sprocket (I), then secure the CVTF pump drive sprocket with the three bolts.
  59. Install the lubrication pipe (J).
  60. Install the differential assembly (A) onto the transmission housing (B).
    Fig 28: Locating Differential Assembly And Transmission Housing With Torque Specifications
    G06951261Courtesy of AMERICAN HONDA MOTOR CO., INC.
  61. Install two new O-rings (C) on both ends of the CVTF passage pipe (D), then install the CVTF passage pipe in the pipe joint (E) of the transmission housing, and put the other end on the pipe guide (F).
  62. Install the three dowel pins (G) and a new gasket (H) on the transmission housing.
  63. Place the flywheel housing (I) on the transmission housing.
  64. Install the housing bolts (nineteen), and tighten them to the specified torque in a crisscross pattern in at least two or three steps, then turn the transmission flywheel housing down.
  65. Install a new O-ring (A) on the solenoid wire harness 7P connector (B).
    Fig 29: Locating O-Ring And Solenoid Wire Harness 7P Connector Components With Torque Specifications
    G06951262Courtesy of AMERICAN HONDA MOTOR CO., INC.
  66. Install the two CVTF pipes (C) on the lower valve body (D), then install the solenoid wire harness 7P connector and the lower valve body in the transmission housing (E).
  67. Install a new O-ring (F) on the CVTF strainer (G), then install the CVTF strainer (two bolts) on the lower valve body.
  68. Install the two dowel pins (A) and a new gasket (B) on the transmission housing (C).
    Fig 30: Locating Dowel Pins, Gasket And Transmission Housing Components With Torque Specifications
    G06951263Courtesy of AMERICAN HONDA MOTOR CO., INC.
  69. Place the CVTF pan (D) on the transmission housing.
  70. Install the CVTF pan bolts (eighteen), and tighten them to the specified torque in a crisscross pattern in at least two or three steps.
  71. Move the shift position from the P position to the N position by turning the selector control lever (A).
    NOTE: Do not squeeze the end (B) of the selector control shaft tips together when turning. If the tips are squeezed together it will cause a faulty control signal or position due to play between the selector control shaft and the transmission range switch.
    Fig 31: Moving Shift Position From P Position To N Position
    G06951264Courtesy of AMERICAN HONDA MOTOR CO., INC.
  72. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C). Then put a 2.0 mm (0.079 in) feeler gauge blade (D) in the cutouts to hold the transmission range switch in the N position.
    NOTE: Be sure to use a 2.0 mm (0.079 in) feeler gauge blade or equivalent to hold the transmission range switch in the N position.
    Fig 32: Locating Feeler Gauge Blade In Cutouts Components
    G06951265Courtesy of AMERICAN HONDA MOTOR CO., INC.
  73. Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position with the 2.0 mm (0.079 in) blade (C).
    Fig 33: Installing Transmission Range Switch Gently On Selector Control Shaft While Holding It In N Position
    G06951266Courtesy of AMERICAN HONDA MOTOR CO., INC.
  74. Tighten the bolts (A) on the transmission range switch (B) while you continue to hold it in the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge (C).
    Fig 34: Locating Bolts On Transmission Range Switch Components With Torque Specifications
    G06951267Courtesy of AMERICAN HONDA MOTOR CO., INC.
  75. Install the control shaft cover (A) on the transmission range switch (B).
    Fig 35: Locating Control Shaft Cover And Transmission Range Switch
    G06951268Courtesy of AMERICAN HONDA MOTOR CO., INC.
  76. Install the breather cap (A) on the breather pipe (B) with its arrow (C) pointing to the flywheel housing.
    Fig 36: Locating Breather Cap, Breather Pipe And Arrow
    G06951269Courtesy of AMERICAN HONDA MOTOR CO., INC.
  77. Install the CVT output shaft (driven pulley) speed sensor (A), and the vehicle speed sensor (B), with new O-rings (C).
    Fig 37: Locating CVT Output Shaft (Driven Pulley) Speed Sensor, Vehicle Speed Sensor And O-Rings Components With Torque Specifications
    G06951270Courtesy of AMERICAN HONDA MOTOR CO., INC.
  78. Install the dipstick tube (A) with a new O-ring (B).
    Fig 38: Locating Dipstick Tube And O-Ring Components With Torque Specifications
    G06951271Courtesy of AMERICAN HONDA MOTOR CO., INC.
  79. Install the CVT input shaft (drive pulley) speed sensor (C) with a new O-ring (D).
  80. Install the two CVTF cooler lines (E) with the line bolts (F) and new sealing washers (G).
  81. Install the CVTF dipstick in the tube.
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