Continuously Variable Transmission (CVT) (Service Information): Assembly: Automatic-CVT

Fig 1: CVT EXTERNALS - EXPLODED VIEW

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1- WASHER	16 - OIL STRAINER
2 - SHIFT LEVER	17 - PLAIN WASHER
3 - INHIBITOR SWITCH	18 - MANUAL LEVER
4 - CVT FLUID FILTER	19 - BUSHING
5 - O-RING	20 - MANUAL VALVE
6 - CVT FLUID COOLER	21 - STEPPER MOTOR
7 - SHIM	22 - LIP SEAL
8 - OUTPUT SPEED SENSOR	23 - SNAP RING
9 - O-RING	24 - VALVE BODY HARNESS
10 - TRANSAXLE	25 - OIL PAN GASKET
11 - PULLEY RATIO LINKAGE	26 - OIL PAN
12 - SPRING	27 - TORQUE CONVERTER
13 - CONTROL VALVE	28 - O-RING
14 - BRACKET	29 - INPUT SPEED SENSOR
15 - O-RING	30 - O-RING

Fig 2: CVT INTERNALS - EXPLODED VIEW.

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1 - O-RING	24 - BAFFLE PLATE
2 - SIDE OIL SEAL	25 - DRIVEN SPROCKET (OIL PUMP)
3 - ADJUSTABLE SHIM	26 - BAFFLE PLATE
4 - OUTER RACE	27 - OIL PUMP
5 - REDUCTION GEAR ASSEMBLY	28 - LIP SEAL
6 - OUTER RACE	29 - SNAP RING
7 - ADJUSTABLE SHIM	30 - DRIVEN PLATES
8 - OUTER RACE	31 - NEEDLE BEARING
9 - DIFFERENTIAL ASSEMBLY	32 - SUN GEAR
10 - OUTER RACE	33 - NEEDLE BEARING
11 - FORWARD CLUTCH ASSEMBLY	34 - PLANETARY CARRIER
12 - NEEDLE BEARING	35 - NEEDLE BEARING
13 - SEAL RING	36 - SNAP RING
14 - OIL PUMP COVER	37 - RETAINING PLATE
15 - BAFFLE PLATE	38 - DRIVEN PLATES
16 - BRACKET	39 - DISH PLATE
17 - ADJUSTABLE SHIM	40 - SNAP RING
18 - ADJUSTABLE SHIM	41 - RETAINING PLATE
19 - CONVERTER HOUSING	42 - SPRING RETAINER ASSEMBLY
20 - CONVERTER HOUSING OIL SEAL	43 - REVERSE PLATE PISTON
21 - OIL PUMP CHAIN	44 - DETENT SPRING
22 - DRIVE SPROCKET	45 - TRANSAXLE CASE
23 - THRUST WASHER	-

1. Refer to the exploded views as necessary when performing the following steps.
   Fig 3: PIN AT SHEAVE HEIGHT SENSOR

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2. Install the primary sheave (2) with the sheave height sensor, (3) spring and pin (1) into the belt side case.
   Fig 4: SHIM UNDER SHEAVE

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3. Install the secondary sheave positioning shim (3) into the belt side cover.
   Fig 5: Install Puller 9874

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4. Install Puller 9874 (1) and Insert 8513 A, (2) onto secondary sheave.
   Fig 6: Drive Belt

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5. Move the secondary sheave (3) close enough to the primary (2) sheave to allow the drive belt (1) to be put around both secondary and primary sheaves.
   NOTE: The drive belt is directional and will need to be installed in the same direction as noted in disassembly. if installed incorrectly failure will occur.
6. Install the drive belt (1).
   CAUTION: Do not over tighten the compressor tool. Tighten to no more than 7 N.m (50 in. lbs.).
7. Compress the secondary (3) sheave to the stop.
8. Install the drive belt (1) around both secondary (3) and primary (2) sheaves.
9. Install the primary sheave into place.
10. Remove Puller 9874 and Insert 8513A from the primary sheave.
    Fig 7: SHEAVE RETAINING BOLTS

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11. Install the bolts (2) that hold both sheaves to the case (1).
    Fig 8: BOLTS AT DRIVE BELT ASSEMBLY

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    CAUTION: Remove moisture, oil, and used sealant from the sealant application surface. Make sure that the starting point and the ending point are between two bolt holes.
12. Apply Loctite 509 sealer onto the belt side of the transaxle case.
13. Install the belt side assembly to the transaxle case.
14. Install the case bolts (1) to hold the drive belt assembly (2) to the transaxle. tighten to 45 N.m (33 ft. lbs.).
    Fig 9: REVERSE BRAKE PISTON

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    CAUTION: Inspect the reverse brake piston and, if damaged, replace it before installation. Apply CVT fluid to the seal when installing the reverse brake piston.
    NOTE: Rotate reverse brake piston into place.
15. Rotate and install the reverse brake piston (1) into the transaxle case. See Fig 9.
    Fig 10: RETAINER ASSEMBLY RETURN SPRING

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16. Align the return springs (3) of the spring retainer assembly (1) to the locating posts (2) of the reverse clutch piston. See Fig 10.
    Fig 11: RETAINING PLATE AT TRANSAXLE

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    NOTE: There is a notch in the retaining plate that points to the top of the case.
17. Install the retaining plate (1) into the transaxle case with the notch on the plate to the top (2). See Fig 11.
    Fig 12: COMPRESS FORWARD CLUTCH

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    CAUTION: Set the spring compressor on top of the spring retainer assembly.
18. Compress the reverse brake return spring using Compressor 5058 A (1) and Compressor 9875 and install the snap ring into the transaxle case using a screwdriver. See Fig 12.
    Fig 13: CLUTCH DISC STACK UP

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19. Install the dish plate (1) with the convex side down onto the reverse brake piston.
20. Install driven plate (2) and then a drive plate (6) until all the driven and drive plates are installed.
21. Install the retaining plate (3) into the reverse brake assembly.
22. Install the reverse brake snap ring (4) into the transaxle case.
    Fig 14: MEASURE CLEARANCE

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    CAUTION: When conducting measurements, measure two or more places and calculate the average value.
23. Measure the clearance between the snap ring and the retaining plate (1). See Fig 14. The correct clutch clearance is 1.2-1.5 mm (0.047-0.059 in.). If the clutch clearance is not within specifications, measure the existing retaining plate and select the correct retaining plate.
    Fig 15: Needle Bearing At Reverse Brake Piston

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    CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.
    NOTE: The inner race will need to face down.
24. Install the needle bearing (1) onto the reverse brake piston. Check for the direction of the needle bearing while installing. See Fig 15.
    Fig 16: PLANETARY CARRIER ASSEMBLY

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    NOTE: The inner race will need to face down
25. Install the planetary carrier assembly (1) onto the reverse brake. See Fig 16.
    Fig 17: NEEDLE BEARING AT SUN GEAR

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    CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.
26. Install the needle bearing (1) onto the primary pulley side of the sun gear. See Fig 17.
    Fig 18: SUN GEAR AT PLANETARY CARRIER

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27. Install the sun gear (1) onto the planetary carrier. See Fig 18.
    Fig 19: Needle Bearing At Forward Clutch

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    CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.
    NOTE: The inner race will need to face up.
28. Install the needle bearing (1) on the forward clutch drum side of the sun gear. See Fig 19.
    Fig 20: FORWARD CLUTCH ASSEMBLY

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29. Install the forward clutch assembly (1) into the transaxle case. See Fig 20.
    Fig 21: END PLAY

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30. Measure the total end play (2) in the following steps. Total end play should be 0.25 - 0.55 mm (0.010 - 0.022 in).
    Fig 22: Measurement One

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
31. Measure the distance (1) from the oil pump cover installation surface of the transaxle case to the needle bearing installation surface of the forward clutch drum. Call this measurement one.
    Fig 23: Measurement Two

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
32. Measure the distance (1 to 2) as shown in illustration. Call this measurement two.
33. Calculate the bearing thickness required to achieve the necessary end play with the following formula. The bearing thickness is equal to measurement one, minus measurement two minus, the nominal end play (0.40 mm or 0.016 "in).
    Fig 24: Needle Bearing On The Forward Clutch Assembly

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    CAUTION: Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.
34. Install the selected needle bearing (1) on the forward clutch assembly. See Fig 24.
    Fig 25: DETENTE SPRING

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35. Install the detent spring (1) onto the transaxle case. Install the bolt to hold the detent spring to the transaxle case and tighten the mounting bolt to 7 N.m (61 in.lbs.). See Fig 25.
    Fig 26: Installing Outer Race Of Differential Bearing Into Converter Housing

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36. Install the outer race of the differential bearing (1) into the converter housing using Installer 9668 and Installer 4628 on 4WD, use Installer 4628 on 2WD and Handle C-4171. See Fig 26.
    Fig 27: Measuring For Differential Preload Shim

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    1 - PRELOAD SHIM

    2 - DIFFERENTIAL ASSEMBLY

    3 - TRANSAXLE CASE

    4 - CONVERTER HOUSING

    CAUTION: When adjusting the preload, apply CVT fluid on the bearing to make it roll smoothly. When conducting measurements, measure two or more places and calculate the average value.
37. Measure for the differential preload shim (1) in the following steps. Refer to the graphic as necessary when performing the steps. See Fig 27.
    Fig 28: DIFFERENTIAL MEASUREMENT ONE

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
38. The required differential preload is 0.17 to 0.29 mm (0.007 0.011 to in).
39. Measure the distance (1-3) from the edge of the transaxle case to the select shim installation surface. This is differential measurement one.
    Fig 29: DIFFERENTIAL MEASUREMENT TWO

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
40. Install the differential assembly on the converter case and measure the distance (differential measurement two) (1-2) from the differential hub to the surface of the converter housing. See Fig 29.
    Fig 30: DIFFERENTIAL MEASUREMENT THREE

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
41. Install the outer race for the differential side bearing and measure the distance (differential measurement three) (1-2) from the differential case to the outer race of the differential side bearing. See Fig 30.
42. The thickness of the required select shim is calculated as follows: differential measurement one, minus differential measurement two, plus differential measurement three, plus 0.23 mm (0.009 in).
    Fig 31: Select Shim At Transaxle Case

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    CAUTION: Do not re-use the select shim.
43. Install the chosen select shim (1) into the transaxle case. See Fig 31.
    Fig 32: Install Outer Race On Transaxle Case

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44. Install the outer race (1) of the differential bearing on the transaxle case using the Installer D-129 and Handle C-4171.
    Fig 33: Install Outer Race Reduction Gear Into Converter Housing

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45. Install the outer race (1) of the reduction gear bearing into the converter housing using Installer C-4628 and Handle C-4171. See Fig 33.
    Fig 34: Measuring For Reduction Gear Preload Shim

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    1 - REDUCTION GEAR

    2 - TRANSAXLE CASE

    3 - PRELOAD SHIM

    4 - BEARING OUTER RACE

46. The required preload on the reduction gear assembly is 0.13-0.19 mm (0.005-0.0075 in). Measure for the required preload shim (3) as follows: See Fig 34.
    Fig 35: REDUCTION ASSEMBLY MEASUREMENT ONE

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
47. Measure the distance (reduction assembly measurement one) (1-2) from the edge of the transaxle case to the select shim installation surface.
    Fig 36: REDUCTION ASSEMBLY MEASUREMENT TWO

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
48. Install the reduction gear assembly on the converter housing and measure the distance (reduction assembly measurement two) (1-2) from the top of the reduction gear assembly to the edge of the converter housing. See Fig 36.
    Fig 37: REDUCTION ASSEMBLY MEASUREMENT THREE

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    CAUTION: When adjusting the preload, apply CVT fluid on the bearing to make it roll smoothly. When conducting measurements, measure two or more places and calculate the average value.
    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
49. Install the outer race of the reduction gear bearing and measure the distance (reduction assembly measurement three) (1-2) from the top of the reduction gear assembly to the outer race of the reduction gear bearing. See Fig 37.
50. The thickness of the required select shim is calculated as follows: reduction assembly measurement one, minus reduction assembly measurement two, plus reduction assembly measurement three, plus 0.16 mm (0.006 in).
    Fig 38: SELECT SHIM AT TRANSAXLE CASE

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    CAUTION: Do not re-use the select shim.
51. Install the chosen select shim (1) into the transaxle case. See Fig 38.
    Fig 39: Install Outer Race On Transaxle Case

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52. Install the outer race (1) of the reduction gear bearing on the transaxle case using Installer C-4628 and Handle C-4171. See Fig 39.
    Fig 40: LIP SEAL AT THE TRANSAXLE CASE

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    CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
53. Install the new lip seal (1) on the transaxle case. See Fig 40.
    Fig 41: O-RING AT THE OIL PUMP MOUNTING

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    CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the O-ring.
54. Install the new o-ring (1) onto the oil pump mounting bolts. (Only for bolts installed from the outside of the transaxle case). See Fig 41.
    Fig 42: OIL PUMP RETAINING BOLTS

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    NOTE: One of the oil pump retaining bolts is installed from the outside of the transaxle case in the rear part of the oil pump.
55. Install the oil pump on the transaxle case. Install and tighten the mounting bolts (1) to 19 N.m (14 ft. lbs.) Install and tighten the mounting bolt (2) to 28 N.m (20 ft. lbs.). See Fig 42.
    Fig 43: LIP SEAL AT TRANSAXLE CASE

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    CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
56. Install the new lip seal (1) into the transaxle case. See Fig 43.
    Fig 44: PIN AT MANUAL SHAFT

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57. Install the manual shaft (1) into the case.
58. Install the pin at the manual shaft using a punch (2).
59. To install the valve body assembly on to the transaxle case, insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of the valve body assembly to set the pulley ratio linkage (1) in position. See Fig 44.
    Fig 45: POSITION TERMINAL BODY

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60. Position the locating tab (1) of the terminal body and install the terminal body into the transaxle case. See Fig 45.
    Fig 46: Control Valve Assembly

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61. Install the valve body assembly (1) up from the bottom side and install it into the transaxle case. See Fig 46.
    Fig 47: Aligning Notch Of Pulley Ratio Linkage

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62. Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2). See Fig 47.
    Fig 48: BUSHING AT THE CONTROL VALVE

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    CAUTION: Apply CVT fluid when installing the bushing.
63. Install the bushing (1) into the valve body assembly. See Fig 48.
    Fig 49: BOLTS FOR VALVE BODY ASSEMBLY

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64. Tighten the mounting bolts of the valve body assembly to 8 N.m (70 in. lbs).
    Fig 50: MANUAL LEVER

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65. Install the manual lever (1) onto the manual shaft. Install and tighten the mounting nut to 22 N.m 194 in. lb. See Fig 50.
    Fig 51: BRACKET AT VALVE BODY ASSEMBLY

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66. Install the bracket (1) onto the valve body assembly. Install and tighten the mounting bolts to 8 N.m (70 in. lbs.). See Fig 51.
    Fig 52: OIL STRAINER O - RING

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    CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.
67. Install the new o-ring (1) onto the new oil strainer. See Fig 52.
    Fig 53: OIL STRAINER

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68. Install the new oil strainer (1) onto the valve body assembly. Install and tighten the mounting bolts to 8 N.m (70 in. bs.). See Fig 53.
    Fig 54: OIL PAN GASKET.

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    CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket.
69. Install the oil pan gasket (1) onto the transaxle case. See Fig 54.
    Fig 55: OIL PAN

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    CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan.
70. Install the oil pan on the transaxle case (1). See Fig 55. Install and tighten the mounting bolts to 8 N.m (70 in. lbs.).
    Fig 56: TERMINAL BODY

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71. Install the snap ring (1) onto the terminal body. See Fig 56.
    Fig 57: SEAL RINGS

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    CAUTION: Do not re-use the seal rings. Apply Vaseline or assembly lube when installing the seal rings.
72. Install the new seal rings (1) onto the reaction shaft support. See Fig 57.
    Fig 58: REACTION SHAFT SUPPORT

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73. Install the reaction shaft support (1) onto the transaxle case temporarily with the mounting bolts. See Fig 58.
    Fig 59: BAFFLE PLATE 3

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74. Install the baffle plate (1) temporarily with the mounting bolts. See Fig 59.
    Fig 60: BAFFLE PLATE 2

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75. Install the baffle plate (1). See Fig 60. Install and tighten the mounting bolts to 6 N.m (52 in. lbs.).
    Fig 61: BRACKET

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76. Install the bracket (1) as shown in illustration. Tighten the mounting bolts of the oil pump cover, baffle plate, and brackets to 26 N.m (19 in. lbs.). See Fig 61.
    Fig 62: SNAP RING AT OIL PUMP

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77. Install the snap ring (1) into the oil pump. See Fig 62.
    Fig 63: THRUST WASHER AT OIL PUMP COVER

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    CAUTION: Be sure to align the pawl of the thrust washer with the alignment hole of the oil pump cover. Apply Vaseline or assembly lube when installing the thrust washer.
78. Install the thrust washer (1) onto the oil pump cover. See Fig 63.
    Fig 64: OIL PUMP CHAIN

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    CAUTION: When necessary to replace any of the driven sprocket, oil pump chain, or drive sprocket, replace all components as a matched set. Pull the driven sprocket up softly and check that the driven sprocket is securely installed.
79. Expand the snap ring (1).
80. Install the driven sprocket, oil pump chain (2) and drive sprocket (3).
    Fig 65: Measuring Clearance Between Oil Pump Drive Sprocket And Converter Housing

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81. The required clearance for the oil pump drive sprocket is 0.10-0.23 mm (0.004-0.009 in.). Measure the clearance (1) between the oil pump drive sprocket (4) and the converter housing (5) in the following procedure: See Fig 65.
    Fig 66: OIL PUMP DRIVE SPROCKET MEASUREMENT ONE

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
82. Measure the distance (1-2) from the edge of the transaxle case to the select shim installation surface of the drive sprocket. This is the oil pump drive sprocket measurement one. See Fig 66.
    Fig 67: OIL PUMP DRIVE SPROCKET MEASUREMENT TWO

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    NOTE: Gauge Bar 6311 can be used for doing the following measurement.
83. Measure the distance (1-2) from the edge of the converter housing to the surface touching the select shim contact surface. This is the oil pump drive sprocket measurement two. See Fig 67.
84. Calculate the thickness of the required select shim with the following formula: The select shim is equal to the oil pump drive sprocket measurement one, plus the oil pump drive sprocket measurement two, minus 0.16 mm (0.0065 in.).
    Fig 68: ADJUSTING SHIM AT DRIVE SPROCKET

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85. Install the chosen select shim (1) onto the drive sprocket. See Fig 68.
    Fig 69: BAFFLE PLATE

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86. Install the baffle plate (1) over the oil pump driven sprocket. Install and tighten the mounting nut to 6 N.m (52 in. lbs.). See Fig 69.
    Fig 70: Input Shaft O-Ring

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    CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.
87. Install the new o-ring (1) onto the input shaft. See Fig 70.
    Fig 71: DIFFERENTIAL ASSEMBLY

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88. Install the differential assembly (1) into the transaxle case. See Fig 71.
    Fig 72: REDUCTION GEAR ASSEMBLY

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89. Install the reduction gear assembly (1) into the transaxle case. See Fig 72.
    Fig 73: INSTALL CONVERTER HOUSING OIL SEAL

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    CAUTION: Do not re-use the converter housing oil seal (1). Apply CVT fluid when installing the converter housing oil seal (1).
90. Install the converter housing oil seal (1) into the converter housing with Installer 9858. See Fig 73.
    Fig 74: Apply MOPAR gasket sealer

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91. Apply MOPAR gasket sealer (1) on the converter housing installation surface of the transaxle case. See Fig 74.
    CAUTION: Remove moisture, oil, and used sealant from the sealant application surface. Make sure that the starting point and the ending point are between two bolt holes.
    Fig 75: CONVERTER HOUSING MOUNTING BOLTS

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92. Install the converter housing on the transaxle case and tighten the bolts to 45 N.m (33 ft. lbs.).
    Fig 76: TRANSMISSION RANGE SENSOR

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93. Install the transmission range sensor (TRS) (1) over the manual shaft and onto the transaxle case. See Fig 76.
    Fig 77: TRS ADJUSTMENT TOOL

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    CAUTION: Do not re-use the TRS transmission range sensor.
94. Put the manual shaft in the N position (3). See Fig 77. Install Park Neutral Switch Adjustment Tool 9876 (2) and adjust the position of the TRS (1).
    Fig 78: BOLTS AT TRS

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95. Install and tighten the mounting bolts of the TRS to 6 N.m (49 in. lbs.).
96. Remove the TRS alignment tool from the TRS.
    Fig 79: SHIFT LEVER

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97. Install the shift lever (1) onto the manual shaft. Install and tighten the mounting nut to 17 N.m (150 in. lbs.). See Fig 79.
    Fig 80: INPUT SPEED SENSOR O-RING

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    CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.
98. Install the o-ring (1) onto the input speed sensor. See Fig 80.
    Fig 81: INPUT SPEED SENSOR

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99. Install the input speed sensor (1) into the transaxle case. Install and tighten the mounting bolt to 6 N.m (52 in. lbs.). See Fig 81.
    Fig 82: OUTPUT SPEED SENSOR O-RING

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    CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.
100. Install the new o-ring (1) onto the output speed sensor. See Fig 82.
     Fig 83: OUTPUT SPEED SENSOR

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     CAUTION: Be sure to install the select shim between the secondary speed sensor and the converter housing before installing the secondary speed sensor.
101. Install the output speed sensor (1) into the converter housing. Install and tighten the mounting bolt to 6 N.m (52 in lbs.). See Fig 83.
     Fig 84: FLUID FILTER

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     CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter.
102. Install the CVT fluid filter (1) into the transaxle case. See Fig 84.
     Fig 85: CVT FLUID FILTER O-RING

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     CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.
103. Install the new o-ring (1) onto the CVT fluid filter.
     Fig 86: FLUID COOLER

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104. Install the CVT fluid cooler (1) onto the transaxle case. Install and tighten the mounting bolts to 4 N.m (37 in.lbs.). See Fig 86.
     Fig 87: 9878 TRANSMISSION SERVICE STAND

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105. Remove the Transmission Service Stand 9878 (1) from the Belt side of the transmission case.
     Fig 88: MEASURE TORQUE CONVERTER TO TRANSMISSION

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     NOTE: Gauge Bar 6311 can be used for doing the following measurement.
     NOTE: When conducting measurements, measure two or more places and calculate the average value.
106. Install the torque converter on the transaxle and measure the dimension (1) to see if it is at least 13 mm. If the measurement is less than 13 mm, the torque converter is not fully installed. See Fig 88.
     NOTE: Use the designated brand of CVT fluid. Use of other brands of CVT fluid other than the designated brand will deteriorate the driveability and the durability of the CVT, and will cause damage to the CVT.
107. Fill the transaxle with CVT fluid. See STANDARD PROCEDURE .