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

Fig 1: CVT Externals - Exploded View
GC0084462Courtesy of CHRYSLER LLC
1- WASHER 16 - OIL STRAINER
2 - SHIFT LEVER 17 - PLAIN WASHER
3 - INHIBITOR SWITCH 18 - MANUAL LEVER
4 - CVT FLUID FILTER (Certain Models) 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
GC0084463Courtesy of CHRYSLER LLC
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
    GC0084464Courtesy of CHRYSLER LLC
  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. Refer to Fig 3.
    Fig 4: Stand, Transmission Case & Mount Bolts
    GC0084465Courtesy of CHRYSLER LLC
  5. Install Transmission Service Stand (special tool #9878, Stand, Transmission Service) (1) to the belt side of the transmission case (3) using the upper transmission mount bolts (2).
    Fig 5: Output Speed Sensor
    GC0084466Courtesy of CHRYSLER LLC
  6. Remove the output speed sensor (1) from the converter housing. Refer to Fig 5. Remove and discard the o-ring from the output speed sensor.
    CAUTION:

    Set aside and reuse any adjusting shim found between the output speed sensor and the converter housing.

    Fig 6: Input Speed Sensor
    GC0084467Courtesy of CHRYSLER LLC
  7. Remove the input speed sensor (1) from the transaxle case. Refer to Fig 6. Remove and discard the o-ring from the input speed sensor.
    Fig 7: Shift Lever
    GC0084468Courtesy of CHRYSLER LLC
  8. Remove the nut (1) holding the shift lever (2) to the manual shaft.
  9. Remove the shift lever from the manual shaft. Refer to Fig 7.
    Fig 8: Transmission Range Sensor
    GC0084469Courtesy of CHRYSLER LLC
  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. Refer to Fig 8.
    Fig 9: Terminal Body
    GC0084470Courtesy of CHRYSLER LLC
  12. Remove the snap ring (1) from the terminal body (2) and press the terminal body into the transaxle case. Refer to Fig 9.
    CAUTION:

    Be careful not to cause damage to the terminal body.

    Fig 10: Fluid Cooler
    GC0084471Courtesy of CHRYSLER LLC
  13. Remove CVT fluid cooler (1) from transaxle case. Refer to Fig 10. Remove and discard the CVT fluid cooler o-ring.
    Fig 11: Fluid Filter
    GC0084472Courtesy of CHRYSLER LLC
  14. Remove the bolts holding the CVT fluid filter to the transaxle case.
  15. Remove the CVT fluid filter (1) from the transaxle case (certain models).
    Fig 12: Converter Housing Mounting Bolts
    GC0084473Courtesy of CHRYSLER LLC
  16. Remove the converter housing mounting bolts. Refer to Fig 12.
    Fig 13: Converter Housing
    GC0084474Courtesy of CHRYSLER LLC
  17. Remove the converter housing (1) by tapping with plastic hammer. Refer to 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
    GC0099041Courtesy of CHRYSLER LLC
  18. Remove outer race of reduction gear bearing (1) from the converter housing using Puller (special tool #7794-A, Remover, Seal) and Puller (special tool #C-637, Slide Hammer, Universal).
    Fig 15: Remove Differential Side Oil Seal
    GC0084475Courtesy of CHRYSLER LLC
  19. Remove differential side oil seal (1) from converter housing using a screwdriver. Refer to Fig 15. (2WD)
    Fig 16: Remove Converter Housing Oil Seal
    GC0084476Courtesy of CHRYSLER LLC
  20. Remove converter housing oil seal (1) from converter housing using a screwdriver. Refer to Fig 16.
    Fig 17: Outer Race Of Differential Side Bearing
    GC0084477Courtesy of CHRYSLER LLC
  21. Remove outer race (1) of differential side bearing from converter housing using a suitable punch. Refer to 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
    GC0084478Courtesy of CHRYSLER LLC
  22. Remove and discard the O-ring (1) from the input shaft. Refer to Fig 18.
    Fig 19: Adjusting Shim AT Drive Sprocket
    GC0084479Courtesy of CHRYSLER LLC
  23. Remove the adjusting shim (1) from the drive sprocket, if necessary. Refer to Fig 19.
    Fig 20: Baffle Plate
    GC0084480Courtesy of CHRYSLER LLC
  24. Remove the nuts holding the baffle plate (1) to the transaxle. Refer to Fig 20.
  25. Remove the baffle plate.
    Fig 21: Snap Ring AT Driven Sprocket
    GC0084481Courtesy of CHRYSLER LLC
  26. Expand the snap ring (1) and remove the driven sprocket (3), the oil pump chain (2), and the drive sprocket. Refer to Fig 21.
    Fig 22: Thrust Washer AT Oil Pump Cover
    GC0084482Courtesy of CHRYSLER LLC
  27. Remove the thrust washer (1) from the oil pump cover. Refer to Fig 22.
    Fig 23: Snap Ring AT Oil Pump
    GC0084483Courtesy of CHRYSLER LLC
  28. Remove the snap ring (1) from the oil pump. Refer to Fig 23.
    Fig 24: Reduction Gear Assembly
    GC0084484Courtesy of CHRYSLER LLC
  29. Remove the reduction gear assembly (1) from the transaxle case. Refer to Fig 24.
    Fig 25: Differential Assembly
    GC0084485Courtesy of CHRYSLER LLC
  30. Remove the differential assembly (1) from the transaxle case. Refer to Fig 25.
    Fig 26: Bracket
    GC0084486Courtesy of CHRYSLER LLC
  31. Remove the bolts holding the bracket (1) to the oil pump cover and the transaxle. Refer to Fig 26.
  32. Remove the bracket (1).
    Fig 27: Baffle Plate 2
    GC0084487Courtesy of CHRYSLER LLC
  33. Remove the bolts holding the baffle plate (1) to the transaxle. Refer to Fig 27.
  34. Remove the baffle plate.
    Fig 28: Reaction Shaft Support
    GC0084488Courtesy of CHRYSLER LLC
  35. Remove the bolts holding the reaction shaft support (1) to the transaxle. Refer to Fig 28.
  36. Remove the reaction shaft support from the transaxle case.
    Fig 29: Seal Rings
    GC0084489Courtesy of CHRYSLER LLC
  37. Remove and discard the seal rings (1) from the reaction shaft support. Refer to Fig 29.
    Fig 30: Oil Pan
    GC0084490Courtesy of CHRYSLER LLC
  38. Remove the bolts holding the oil pan (1) to the transaxle case. Refer to Fig 30.
  39. Remove the oil pan from the transaxle case.
    Fig 31: Oil Pan Gasket
    GC0084491Courtesy of CHRYSLER LLC
  40. Remove the oil pan gasket (1) from the transaxle case. Refer to Fig 31.
    Fig 32: Oil Strainer
    GC0084492Courtesy of CHRYSLER LLC
  41. Remove the bolts holding the oil strainer (1) to the valve body. Refer to Fig 32.
  42. Remove the oil strainer.
  43. Remove and discard the oil strainer o-ring.
    Fig 33: Oil Pump Retaining Bolts
    GC0084493Courtesy of CHRYSLER LLC
  44. Remove the bolt (2) holding the oil pump to the transaxle case from the rear of the transaxle. Refer to 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
    GC0084494Courtesy of CHRYSLER LLC
    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
    GC0084495Courtesy of CHRYSLER LLC
  48. Remove and discard the lip seal (1) from the transaxle case. Refer to Fig 35.
    Fig 36: Detente Spring
    GC0084496Courtesy of CHRYSLER LLC
  49. Remove the bolt holding the detent spring (1) to the transaxle case. Refer to Fig 36.
  50. Remove the detente spring from the transaxle case.
    Fig 37: Forward Clutch Assembly
    GC0084497Courtesy of CHRYSLER LLC
  51. Remove the forward clutch assembly (1) from the transaxle case. Refer to Fig 37.
    Fig 38: Needle Bearing AT Forward Clutch
    GC0084498Courtesy of CHRYSLER LLC
  52. Remove needle bearing (1) from forward clutch drum side of the sun gear. Refer to Fig 38.
    Fig 39: Sun Gear AT Planetary Carrier
    GC0084499Courtesy of CHRYSLER LLC
  53. Remove the sun gear (1) from the planetary carrier. Refer to Fig 39.
    Fig 40: Needle Bearing AT Sun Gear
    GC0084500Courtesy of CHRYSLER LLC
  54. Remove the needle bearing (1) from the sun gear. Refer to Fig 40.
    Fig 41: Planetary Carrier Assembly
    GC0084501Courtesy of CHRYSLER LLC
  55. Remove the planetary carrier assembly (1) from the transaxle case. Refer to Fig 41.
    Fig 42: Needle Bearing AT Planetary Carrier
    GC0084502Courtesy of CHRYSLER LLC
  56. Remove the needle bearing (1) from the planetary carrier. Refer to Fig 42.
    Fig 43: Bracket AT Valve Body Assembly
    GC0084503Courtesy of CHRYSLER LLC
  57. Remove the bolts holding the bracket (1) to the valve body assembly. Refer to Fig 43.
  58. Remove the bracket from the valve body assembly.
    Fig 44: Manual Lever
    GC0084504Courtesy of CHRYSLER LLC
  59. Remove the nut holding the manual lever (1) to the manual shaft. Refer to Fig 44.
  60. Remove the manual lever.
    Fig 45: Bolts For Valve Body Assembly
    GC0084505Courtesy of CHRYSLER LLC
  61. Use this picture when removing valve body attaching bolts.
    Fig 46: Control Valve Assembly
    GC0084506Courtesy of CHRYSLER LLC
    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:
    1. 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). Refer to Fig 46.
    2. Remove the bolts holding the valve body assembly to the transaxle case.
    3. Remove the valve body assembly from the transaxle case.
    Fig 47: Bushing AT The Control Valve
    GC0084507Courtesy of CHRYSLER LLC
  63. Remove and set aside the bushing (1) from the valve body. Refer to Fig 47.
    Fig 48: Pin AT Manual Shaft
    GC0084508Courtesy of CHRYSLER LLC
  64. Remove the pin at the manual shaft using a punch (2). Refer to Fig 48.
  65. Remove the manual shaft from case.
    Fig 49: Lip Seal AT Transaxle Case
    GC0084509Courtesy of CHRYSLER LLC
  66. Remove and discard the lip seal (1) from the transaxle case. Refer to Fig 49.
    Fig 50: Remove Outer Race
    GC0084510Courtesy of CHRYSLER LLC
  67. Remove outer race (1) of differential side bearing from converter main housing using Puller (special tool #9664, Remover, Bearing Cup) and Puller (special tool #C-637, Slide Hammer, Universal). Refer to Fig 50.
    Fig 51: Select Shim AT Transaxle Case
    GC0084511Courtesy of CHRYSLER LLC
  68. Remove the selective shim (1) from the transaxle case. Refer to Fig 51.
    Fig 52: Pull Outer Race Reduction Gear
    GC0099041Courtesy of CHRYSLER LLC
  69. Remove outer race of reduction gear bearing (1) from transaxle case using Puller (special tool #C-637, Slide Hammer, Universal) and Puller (special tool #7794-A, Remover, Seal). Refer to Fig 52.
    Fig 53: Select Shim AT Transaxle Case
    GC0084512Courtesy of CHRYSLER LLC
  70. Remove the selective shim (1) from the transaxle case. Refer to Fig 53.
    Fig 54: Side Oil Seal AT Transaxle Case
    GC0084513Courtesy of CHRYSLER LLC
    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. Refer to Fig 54.
    Fig 55: Retaining Plate Of The Reverse Brake
    GC0084514Courtesy of CHRYSLER LLC
    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. Refer toFig 55.
    Fig 56: Compress Clutches
    GC0084515Courtesy of CHRYSLER LLC
    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 (special tool #5058A, Compressor, Spring) (1) and Compressor (special tool #9875, Compressor). Refer to Fig 56. Remove the snap ring (2) from the transaxle case.
  74. Remove the retaining plate and the spring retainer assembly.
    Fig 57: Apply Compressed Air
    GC0084516Courtesy of CHRYSLER LLC
    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. Refer to Fig 57.
    Fig 58: Bolts AT Drive Belt Assembly
    GC0084517Courtesy of CHRYSLER LLC
  76. Remove the case bolts (1) at the drive belt assembly (2). Refer to 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
    GC0084518Courtesy of CHRYSLER LLC
  78. Remove the bolts (2) that hold both sheaves to the case (1). Refer to Fig 59.
    Fig 60: Install Puller 9874
    GC0084519Courtesy of CHRYSLER LLC
    CAUTION:

    Do not allow the Puller (special tool #9874, Compressor, Pulley) to come in contact with the belt at any time

  79. Install the Puller (special tool #9874, Compressor, Pulley) (1) and Insert (special tool #8513A, Insert, Crankshaft) (2) onto the secondary sheave (3).
    Fig 61: Compress Sheave
    GC0084520Courtesy of CHRYSLER LLC
    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
    GC0084521Courtesy of CHRYSLER LLC
    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
    GC0084522Courtesy of CHRYSLER LLC
  82. Remove the pin (1) from the sheave height sensor (3).
    Fig 64: Sheave Height Sensor
    GC0084523Courtesy of CHRYSLER LLC
  83. Lift the primary sheave (3) enough to remove the sheave height sensor (1).
    Fig 65: Drive Belt
    GC0084524Courtesy of CHRYSLER LLC
  84. Remove the drive belt (1) from both secondary (3) and primary sheaves (2).
  85. Remove the secondary sheave.
    Fig 66: Shim Under Sheave
    GC0084525Courtesy of CHRYSLER LLC
  86. Remove the shim (3) under the secondary sheave (1).
    Fig 67: Secondary Sheave
    GC0084526Courtesy of CHRYSLER LLC
  87. Remove the primary sheave.
  88. Remove bolts at the park pawl.
  89. Remove the park pawl.
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