Continuously Variable Transmission (CVT) (Service Information): Disassembly: 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: TORQUE CONVERTER

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2. Drain the CVT fluid from the transaxle assembly.
3. Remove the power transfer unit assembly and o-ring (4WD only).
4. Remove the torque converter (1) from the transaxle. See Fig 3.
   Fig 4: 9878 TRANSMISSION SERVICE STAND

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5. Install Transmission Service Stand 9878 (1) to the belt side of the transmission case (3) using the upper transmission mount bolts (2).
   Fig 5: OUTPUT SPEED SENSOR

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6. Remove the output speed sensor (1) from the converter housing. Remove and discard the o-ring from the output speed sensor. See Fig 5.
   CAUTION: Set aside and reuse any adjusting shim found between the output speed sensor and the converter housing.
   Fig 6: INPUT SPEED SENSOR

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7. Remove the input speed sensor (1) from the transaxle case. Remove and discard the o-ring from the input speed sensor. See Fig 6.
   Fig 7: SHIFT LEVER

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8. Remove the nut (1) holding the shift lever (2) to the manual shaft.
9. Remove the shift lever from the manual shaft. See Fig 7.
   Fig 8: TRANSMISSION RANGE SENSOR

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10. Remove the bolts (2) holding the transmission range sensor (TRS) (1) to the transaxle case.
11. Remove the (TRS) transmission range sensor (1) from the transaxle case and the manual shaft. See Fig 8.
    Fig 9: TERMINAL BODY

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12. Remove the snap ring (1) from the terminal body (2) and press the terminal body into the transaxle case. See Fig 9.
    CAUTION: Be careful not to cause damage to the terminal body.
    Fig 10: FLUID COOLER

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13. Remove CVT fluid cooler (1) from transaxle case. Remove and discard the CVT fluid cooler o-ring. See Fig 10.
    Fig 11: FLUID FILTER

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14. Remove the bolts holding the CVT fluid filter to the transaxle case.
15. Remove the CVT fluid filter (1) from the transaxle case. See Fig 11.
    Fig 12: CONVERTER HOUSING MOUNTING BOLTS

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16. Remove the converter housing mounting bolts. See Fig 12.
    Fig 13: CONVERTER HOUSING

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17. Remove the converter housing (1) by tapping with plastic hammer. See Fig 13.
    CAUTION: There is a possibility that the drive sprocket adjusting shim may be dislodged and fall out.
    Fig 14: PULL OUTER RACE REDUCTION GEAR

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18. Remove outer race of reduction gear bearing (1) from the converter housing using Puller 7794-A and Puller C-637. See Fig 14.
    Fig 15: REMOVE DIFFERENTIAL SIDE OIL SEAL

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19. Remove differential side oil seal (1) from converter housing using a screwdriver. (2WD) See Fig 15.
    Fig 16: REMOVE CONVERTER HOUSING OIL SEAL

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20. Remove converter housing oil seal (1) from converter housing using a screwdriver. See Fig 16.
    Fig 17: OUTER RACE OF DIFFERENTIAL SIDE BEARING

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21. Remove outer race (1) of differential side bearing from converter housing using a suitable punch. See Fig 17.
    CAUTION: When removing the outer race, tap the outer race on both sides evenly. When removing the outer race, do not damage the converter housing.
    Fig 18: Input Shaft O-Ring

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22. Remove and discard the O-ring (1) from the input shaft. See Fig 18.
    Fig 19: ADJUSTING SHIM AT DRIVE SPROCKET

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23. Remove the adjusting shim (1) from the drive sprocket, if necessary. See Fig 19.
    Fig 20: BAFFLE PLATE

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24. Remove the nuts holding the baffle plate (1) to the transaxle. See Fig 20.
25. Remove the baffle plate.
    Fig 21: SNAP RING AT DRIVEN SPROCKET

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26. Expand the snap ring (1) and remove the driven sprocket (3), the oil pump chain (2), and the drive sprocket. See Fig 21.
    Fig 22: THRUST WASHER AT OIL PUMP COVER

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27. Remove the thrust washer (1) from the oil pump cover. See Fig 22.
    Fig 23: SNAP RING AT OIL PUMP

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28. Remove the snap ring (1) from the oil pump. See Fig 23.
    Fig 24: REDUCTION GEAR ASSEMBLY

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29. Remove the reduction gear assembly (1) from the transaxle case. See Fig 24.
    Fig 25: DIFFERENTIAL ASSEMBLY

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30. Remove the differential assembly (1) from the transaxle case. See Fig 25.
    Fig 26: BRACKET

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31. Remove the bolts holding the bracket (1) to the oil pump cover and the transaxle. See Fig 26.
32. Remove the bracket (1).
    Fig 27: BAFFLE PLATE 2

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33. Remove the bolts holding the baffle plate (1) to the transaxle. See Fig 27.
34. Remove the baffle plate.
    Fig 28: REACTION SHAFT SUPPORT

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35. Remove the bolts holding the reaction shaft support (1) to the transaxle. See Fig 28.
36. Remove the reaction shaft support from the transaxle case.
    Fig 29: SEAL RINGS

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37. Remove and discard the seal rings (1) from the reaction shaft support. See Fig 29.
    Fig 30: OIL PAN

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38. Remove the bolts holding the oil pan (1) to the transaxle case. See Fig 30.
39. Remove the oil pan from the transaxle case.
    Fig 31: OIL PAN GASKET

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40. Remove the oil pan gasket (1) from the transaxle case. See Fig 31.
    Fig 32: OIL STRAINER

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41. Remove the bolts holding the oil strainer (1) to the valve body. See Fig 32.
42. Remove the oil strainer.
43. Remove and discard the oil strainer o-ring.
    Fig 33: OIL PUMP RETAINING BOLTS

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44. Remove the bolt (2) holding the oil pump to the transaxle case from the rear of the transaxle. See Fig 33.
45. Remove the bolts (1) holding the oil pump to the transaxle case from inside the transaxle.
46. Remove the oil pump from the transaxle case.
    Fig 34: O-RING AT THE OIL PUMP MOUNTING

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    NOTE: One of the oil pump retaining bolts is installed from the outside of the transaxle case into the rear part of the oil pump.
47. Remove and discard the o-ring (1) from the oil pump mounting bolt. (Only on bolt installed from the outside of the transaxle case).
    Fig 35: LIP SEAL AT THE TRANSAXLE CASE

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48. Remove and discard the lip seal (1) from the transaxle case. See Fig 35.
    Fig 36: DETENTE SPRING

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49. Remove the bolt holding the detent spring (1) to the transaxle case. See Fig 36.
50. Remove the detente spring from the transaxle case.
    Fig 37: FORWARD CLUTCH ASSEMBLY

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51. Remove the forward clutch assembly (1) from the transaxle case. See Fig 37.
    Fig 38: NEEDLE BEARING - FORWARD CLUTCH

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52. Remove needle bearing (1) from forward clutch drum side of the sun gear. See Fig 38.
    Fig 39: SUN GEAR AT PLANETARY CARRIER

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53. Remove the sun gear (1) from the planetary carrier. See Fig 39.
    Fig 40: NEEDLE BEARING AT SUN GEAR

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54. Remove the needle bearing (1) from the sun gear. See Fig 40.
    Fig 41: PLANETARY CARRIER ASSEMBLY

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55. Remove the planetary carrier assembly (1) from the transaxle case. See Fig 41.
    Fig 42: NEEDLE BEARING AT PLANETARY CARRIER

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56. Remove the needle bearing (1) from the planetary carrier. See Fig 42.
    Fig 43: BRACKET AT VALVE BODY ASSEMBLY

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57. Remove the bolts holding the bracket (1) to the valve body assembly. See Fig 43.
58. Remove the bracket from the valve body assembly.
    Fig 44: MANUAL LEVER

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59. Remove the nut holding the manual lever (1) to the manual shaft. See Fig 44.
60. Remove the manual lever.
    Fig 45: BOLTS FOR THE VALVE BODY ASSEMBLY

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61. Use this picture when removing valve body attaching bolts.
    Fig 46: CONTROL VALVE ASSEMBLY

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    CAUTION: Tilt the valve body assembly away from the transaxle case on the manual shaft side to ease removal. Pay attention to completely remove the terminal body from the transaxle case.
62. Remove the valve body assembly from the transaxle case as follows:
    • 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 fix the pulley ratio linkage (1). See Fig 46.
    • Remove the bolts holding the valve body assembly to the transaxle case.
    • Remove the valve body assembly from the transaxle case.
    Fig 47: BUSHING AT THE CONTROL VALVE

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63. Remove and set aside the bushing (1) from the valve body. See Fig 47.
    Fig 48: PIN AT MANUAL SHAFT

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64. Remove the pin at the manual shaft using a punch (2). See Fig 48.
65. Remove the manual shaft from case.
    Fig 49: LIP SEAL AT TRANSAXLE CASE

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66. Remove and discard the lip seal (1) from the transaxle case. See Fig 49.
    Fig 50: REMOVE OUTER RACE

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67. Remove outer race (1) of differential side bearing from converter main housing using Puller 9664 and Puller C-637. See Fig 50.
    Fig 51: SELECT SHIM AT TRANSAXLE CASE

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68. Remove the selective shim (1) from the transaxle case. See Fig 51.
    Fig 52: PULL OUTER RACE REDUCTION GEAR

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69. Remove outer race of reduction gear bearing (1) from transaxle case using Puller C-637 and Puller 7794-A. See Fig 52.
    Fig 53: SELECTIVE SHIM AT TRANSAXLE CASE

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70. Remove the selective shim (1) from the transaxle case. See Fig 53.
    Fig 54: SIDE OIL SEAL AT TRANSAXLE CASE

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    CAUTION: When removing the side oil seal, do not damage the transaxle case.
71. Remove side oil seal (1) from transaxle case using a screwdriver. See Fig 54.
    Fig 55: RETAINING PLATE OF THE REVERSE BRAKE

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    CAUTION: Check if there is damage, deformation, or burning on the surface of any of the drive or driven plates. Check for permanent fatigue of the dish plate, driven plates, retaining plate, snap ring, and the drive plates. Replace all reverse brake components if any of these conditions exist.
72. Remove the reverse brake snap ring using a screwdriver. Then remove the reverse brake retaining plate, the drive plates, the driven plates, and the dish plate from the transaxle case. See Fig 55
    Fig 56: COMPRESS REAR CLUTCH

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    CAUTION: Set the spring compressor right on top of the return spring of the spring retainer assembly. Do not remove the return springs from the spring retainer assembly.
73. Compress the reverse brake return spring using Compressor 5058A (1) and Compressor 9875. Remove the snap ring (2) from the transaxle case. See Fig 56.
74. Remove the retaining plate and the spring retainer assembly.
    Fig 57: APPLY COMPRESSED AIR

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    CAUTION: There is a possibility that the reverse brake piston might be stuck if excessive pressure is required to remove.
75. Try removing the reverse brake piston from the transaxle case by hand if unable to remove by hand, apply compressed air to the fluid passage (1) and remove the reverse brake piston from the transaxle case. See Fig 57.
    Fig 58: BOLTS AT DRIVE BELT ASSEMBLY

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76. Remove the case bolts (1) at the drive belt assembly (2). See Fig 58.
    NOTE: Pin at pulley sensor stays with drive belt assembly case.
77. Separate drive belt assembly case from main housing.
    Fig 59: SHEAVE RETAINING BOLTS

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78. Remove the bolts (2) that hold both sheaves to the case (1). See Fig 59.
    Fig 60: Install Puller 9874

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    CAUTION: Do not allow the Puller 9874 to come in contact with the belt at any time
79. Install the Puller 9874 (1) and Insert 8513A (2) onto the secondary sheave (3).
    Fig 61: COMPRESS SHEAVE

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    CAUTION: Do not over tighten the compressor tool. Tighten to no more than 7 N.m (50 in. lbs.)
    NOTE: The belt is directional, look for an arrow indicating the direction of the belt for installation
80. Compress sheave (2) to the stop.
    Fig 62: REMOVE SHEAVE FROM CASE

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    CAUTION: Do not allow the primary sheave to contact the drive surface of the secondary sheave.
    NOTE: You may need to lightly tap case while holding secondary sheave.
81. Lift and move the secondary sheave (1) closer to the primary sheave.
    Fig 63: PIN AT SHEAVE HEIGHT SENSOR

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82. Remove the pin (1) from the sheave height sensor (3).
    Fig 64: SHEAVE HEIGHT SENSOR

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83. Lift the primary sheave (3) enough to remove the sheave height sensor (1).
    Fig 65: Drive Belt

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84. Remove the drive belt (1) from both secondary (3) and primary sheaves (2).
85. Remove the secondary sheave.
    Fig 66: SHIM UNDER SHEAVE

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86. Remove the shim (3) under the secondary sheave (1).
    Fig 67: SECONDARY SHEAVE

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87. Remove the primary sheave.
88. Remove bolts at the park pawl.
89. Remove the park pawl.