Caja Automática Mitsubishi CVT
Caja Automática Mitsubishi CVT
Caja Automática Mitsubishi CVT
GROUP 23B
CONTINUOUSLY
VARIABLE
TRANSAXLE
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . .
23B-2
23B-3
23B-57
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
23B-60
FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
23B-3
23B-61
GENERAL SPECIFICATION . . . . . . . . . . .
23B-3
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
23B-64
SERVICE SPECIFICATIONS . . . . . . . . . . .
23B-4
23B-6
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .
23B-6
SPECIAL TOOLS. . . . . . . . . . . . . . . .
23B-6
TRANSAXLE . . . . . . . . . . . . . . . . . . .
23B-10
FORWARD CLUTCH . . . . . . . . . . . . .
23B-10
23B-57
REDUCTION GEAR
SUB-ASSEMBLY . . . . . . . . . . . . . . . . 23B-64
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
23B-64
DIFFERENTIAL. . . . . . . . . . . . . . . . . . 23B-66
DISASSEMBLY AND ASSEMBLY . . . . . . .
23B-66
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
23B-68
23B-69
23B-2
GENERAL INFORMATION
M1233201400014
Applicable engine
Vehicle model
F1CJA-2-BBZ
4B11 MIVEC
CY4A
SECTIONAL VIEW
AK603120
TSB Revision
23B-3
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1233205000115
Item
Specifications N m
Detent spring
Plug
Clip
Oil pump
19 (14 ft-lb)
Oil pump
28 (21 ft-lb)
Manual lever
Bracket
Oil strainer
Oil pan
Drain plug
Baffle plate
Bracket
26 (19 ft-lb)
Baffle plate
26 (19 ft-lb)
26 (19 ft-lb)
Converter housing
45 (33 ft-lb)
Shift lever
Inhibitor switch
Plug
11 1 (97 9 in-lb)
23 3 (17 2 ft-lb)
Harness bracket
23 3 (17 2 ft-lb)
90 10 (66 7 ft-lb)
90 10 (66 7 ft-lb)
Final gear
GENERAL SPECIFICATION
Transaxle model
Torque converter
M1233201000191
F1CJA
type
lockup
available
Transaxle type
Gear ratio
2.349 0.394
Reverse
1.750
6.120
TSB Revision
23B-4
SERVICE SPECIFICATIONS
M1233202000149
Item
Standard value mm
1.2 1.5
0.25 0.55
Differential preload
0.17 0.29
0.13 0.19
0.10 0.23
61.949 61.979
84.941 84.976
67.949 67.979
30.008 30.029
60.032 60.078
40.026 40.051
Identification
Thickness mm
Identification
2.2
2.8
2.4
3.0
2.6
Identification
Thickness mm
Identification
3.58
4.26
3.75
4.43
3.92
4.60
4.09
4.77
Identification
Thickness mm
Identification
0.40
0.96
0.44
1.00
0.48
1.04
0.52
1.08
0.56
1.12
0.60
1.16
0.64
1.20
TSB Revision
M1233204000145
Thickness mm
Identification
Thickness mm
Identification
0.68
1.24
0.72
1.28
0.76
1.32
Identification
Thickness mm
Identification
0.64
1.48
0.68
1.52
0.72
1.56
0.76
1.60
0.80
1.64
0.84
1.68
0.88
1.72
0.92
1.76
0.96
1.80
1.00
1.84
1.04
1.88
1.08
1.92
1.12
1.96
1.16
2.00
1.20
2.04
1.24
2.08
1.28
2.12
1.32
2.16
1.36
2.20
1.40
2.24
1.44
Adjusting shims (for adjustment of oil pump drive sprocket / converter housing clearance)
Thickness mm
Identification
Thickness mm
Identification
0.64
0.92
0.68
0.96
0.72
1.00
0.76
1.04
0.80
1.08
0.84
1.12
0.88
TSB Revision
23B-5
23B-6
M1233206000099
Transaxle
Converter housing
Loctite 509
LUBRICANT(S)
M1233200400033
Item
Specified lubricant
Transaxle
CVT fluid application parts
Diaqueen CVTF-J1
SPECIAL TOOLS
TOOL
B
M1233207000155
SUPERSESSION
APPLICATION
MB990590
Real axle shaft oil seal
remover
MB990211-01
MB992039
Slide hammer puller
MB992039-01
MB992139
Spring compressor
MB991168
Differential oil seal
installer
MB991168-01
Installation of differential
side bearing outer race
(converter housing side)
MB991702
Adapter
Installation of differential
side bearing outer race
(converter housing side)
MB990590
MB991168
TSB Revision
TOOL
23B-7
SUPERSESSION
APPLICATION
MB990780
Real axle shaft bushing
installer
Installation of differential
side bearing outer race
(transaxle case side)
MB990932
Installer adapter
MB990938
Installer bar
MB992075
Handle
MB992141
Oil seal installer
Installation of converter
housing oil seal
MB992206
Oil seal installer
Installation of converter
housing side oil seal
MB992140
Oil seal installer
TSB Revision
23B-8
TOOL
SUPERSESSION
APPLICATION
MB990810
Side bearing puller
MB990947
Lower arm push arbor
MB990947-01
MD999566
Crow
MB990984
Mount bushing lower roll
insulator arbor
MD998917
Bearing remover
MD998812
Installer cap
MIT304180-A or
General service tool
Installation of reduction
gear bearing inner race
(converter housing side
and transaxle case side),
installation of differential
side bearing outer race
(converter housing side),
installation of differential
side bearing inner race
(converter housing side),
installation of reduction
pinion gear
MB990810
MB990947
TSB Revision
TOOL
23B-9
SUPERSESSION
APPLICATION
MD998813
Installer-100
MIT304180-A or
General service tool
Installation of reduction
gear bearing inner race
(converter housing side
and Transaxle case side),
installation of differential
side bearing outer race
(converter housing side),
installation of differential
side bearing inner race
(converter housing side),
installation of reduction
pinion gear
MD998819
Installer adapter (40)
Installation of reduction
gear bearing inner race
(converter housing side
and Transaxle case side),
installation of reduction
pinion gear
MB991452
Oil seal installer
Removal of differential
side bearing inner race
(converter housing side)
MB992138
Bearing Installer
Installation of differential
side bearing inner race
(converter housing side)
MD998823
Installer adapter (48)
Installation of differential
side bearing inner race
(transaxle case side)
TSB Revision
23B-10
TRANSAXLE
DISASSEMBLY AND ASSEMBLY
M1233208000192
CAUTION
Only use CVT fluid of the specified brand. Use of CVT fluid other than specified will impair driveability and CVT endurance, and may lead to breakage of CVT.
Only use the specified vaseline. Use of vaseline other than specified will impair driveability and
CVT endurance, and may lead to breakage of CVT.
Disassembly work should be done in a clean dust-proof room.
Prior to disassembly, clean any sand or dirt adhered to the outer parts of transaxle using steam,
white gasoline or another solvent, outside the clean room, so as not to contaminate inner parts of
transaxle during disassembly or assembly. (Do not allow steam to get inside the transaxle, and do
not clean rubber parts with gasoline).
After cleaning, remove the torque converter, and drain the CVT fluid.
Disassembly and assembly work should be done with bare hands or using plastic gloves.
Do not touch inner parts of the transaxle after touching its outer parts. (Wash hands after touching
the outer parts).
Do not use cotton gloves and rags to prevent from lint; instead, use paper rags.
Prior to assembly or disassembly work, make sure conditions are appropriate.
Do not re-use the drained CVT fluid.
Refer to "HOW TO USE THIS MANUAL" for the symbols in the schematic.
TSB Revision
23B-11
11 1 Nm
97 9 in-lb
23 3 Nm
17 2 ft-lb
4
5
11 1 Nm
97 9 in-lb
23 3 Nm
17 2 ft-lb
90 10 Nm
66 7 ft-lb
90 10 Nm
66 7 ft-lb
1
AK603121AB
1.
2.
3.
4.
5.
6.
7.
TSB Revision
23B-12
17.2 Nm
13 ft-lb
13
8
12
5.5 Nm
49 in-lb
11
9
10
40
5.9 Nm
52 in-lb
38
39
7.5 Nm
66 in-lb
15
5.9 Nm
52 in-lb
14
36
37
18
34
35
16
27
28
26
17
7.5 Nm
66 in-lb
29
19
25
20
24
23
7.9 Nm
70 in-lb
33
22.1 Nm
16 ft-lb
21
7.9 Nm
70 in-lb
22
7.9 Nm
70 in-lb
31
30
32
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Washer
Shift lever
Inhibitor switch
CVT fluid filter
O-ring
CVT fluid cooler
Secondary pulley speed sensor
O-ring
O-ring
Plug
Transaxle
Control valve
Bracket
O-ring
Oil strainer
Spring washer
Manual lever
TSB Revision
34.3 Nm
25 ft-lb
Bush
Lip seal
Snap ring
Valve body harness
Oil pan gasket
Magnet
Drain plug gasket
Drain plug
Oil pan
Torque converter
O-ring
Primary pulley speed sensor
O-ring
O-ring
Plug
Stud bolt
AK603122AB
23B-13
88
87
6.9 Nm
61 in-lb
41
86
85 84
83
82
81 80
42
79
71
77
75
72
74
5.9 Nm
52 in-lb
67
70
73
69 68
76
19 Nm
14 ft-lb
43
78
5.9 Nm
52 in-lb
26 Nm
19 ft-lb
54
44
66
46
45
63
45 Nm
33 ft-lb
65 64
51
52
47
61
53
56
48
49
57
50
55
26 Nm
19 ft-lb
58
6.9 Nm
61 in-lb
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
O-ring
Side oil shim
Adjusting shim
Outer race
Reduction gear assembly
Outer race
Adjusting shim
Outer race
Differential assembly
Outer race
Forward clutch assembly
Needle bearing
Seal ring
Oil pump cover
Baffle plate
Bracket
Adjusting shim
Clip
Pipe
Converter housing
Converter housing oil seal
Converter housing side oil seal
Oil pump chain
Adjusting shim
TSB Revision
59
Drive sprocket
Thrust washer
Baffle plate
Driven sprocket
Baffle plate
Oil pump
Lip seal
Snap ring
Driven plate
Needle bearing
Sun gear
Needle bearing
Planet carrier
Needle bearing
Snap ring
Retaining plate
Drive plate
Dish plate
Snap ring
Retaining plate
Spring retainer assembly
Reverse brake piston
Detent spring
Transaxle
60
62
AK603123 AB
23B-14
CAUTION
Do not disassemble parts other than specified in this manual.
1. Remove the RR roll stopper bracket and FR roll stopper
bracket from the transaxle.
2. Remove the harness bracket from the transaxle.
3. Remove the oil filler tube and oil level gage from the
transaxle.
4. Remove the control cable bracket and breather hose from
the transaxle.
5. Remove the torque converter from the transaxle.
AK603124
AK502775
AK502774AD
TSB Revision
23B-15
AK502193AD
AK502194AD
AK502195AD
AK502196
TSB Revision
23B-16
CAUTION
Be careful not to cause damage to the terminal body.
12.Remove the snap ring from the terminal body, and press the
terminal body into the transaxle case.
Snap ring
Terminal body
AK502197AF
13.Remove the CVT fluid cooler from the transaxle case, and
detach the O-ring from the cooler.
AK502198
14.Remove the CVT fluid cooler filter from the transaxle case.
AK502199
B A
A
B
A
B
B
A
A A A
A
AK502200 AD
TSB Revision
Bolt symbol
Bolt length mm
30
35
Quantity
18
23B-17
CAUTION
Be careful because adjusting shim of the drive sprocket
may depart.
16.Remove the converter housing by tapping with a plastic
hammer etc.
AK502201
MB990590
MB992039
AK502819AD
MB990590
MB992039
AK502820AD
CAUTION
When removing the oil seal, be careful not to cause damage to the converter housing.
21.Using a flat blade screwdriver etc., remove the converter
housing oil seal from the housing.
AK502204
TSB Revision
23B-18
AK502975AD
CAUTION
When removing the pipe, be careful not to bend it.
23.Remove the pipe from the converter housing.
AK502976
AK603125AB
AK502774AD
TSB Revision
23B-19
AK502206AF
AK502206AG
AK502207AE
29.Expand the snap ring, and remove the driven sprocket, oil
pump chain, and drive sprocket.
Snap ring
AK502208AD
Drive
sprocket
TSB Revision
23B-20
AK502210AD
AK502211AD
AK502212
AK502213
AK502214AD
TSB Revision
23B-21
AK502215AE
AK502216AE
AK502217AD
AK502218AD
AK502219
TSB Revision
23B-22
AK502220
AK502221
Bolt symbol
Bolt length mm
12
44
12
Quantity
B
C
AK502222AD
AK502780
AK502223AD
TSB Revision
23B-23
AK502224AD
Pin
AK502225AD
B
A
A
Bolt symbol
Bolt length mm
54
44
Quantity
10
A
A A
A
A
AK502226AD
AK502227
TSB Revision
23B-24
AK502228
AK502229AD
AK502233
AK502235AD
TSB Revision
23B-25
AK502236
AK502237AD
MB990590
MB992039
AK502821AD
AK502239
MB990590
MB992039
AK502822 AD
TSB Revision
23B-26
AK502241
CAUTION
When removing the side oil seal, be careful not to cause
damage to the transaxle case.
60.Using a flat blade screwdriver etc., remove the side oil seal
from the transaxle case.
AK502242
AK502243AD
AK502244
TSB Revision
23B-27
AK502245
AK502246
AK502247
AK502248
AK502249
TSB Revision
23B-28
CAUTION
Check if there is damage, deformation, burn marks or permanent sets of the dish plate, driven plate, snap ring, and
drive plate. Replace any defective part.
68.Using a flat blade screwdriver etc., remove the reverse
brake retaining plate, drive plate, driven plate, and dish plate
from the transaxle case.
AK502250
CAUTION
Set the spring compressor right on top of the spring of
spring retainer assembly.
Do not remove the return spring from the spring
retainer assembly.
69.Using the Special Tool MB992139, compress the return
spring, and remove the snap ring from the transaxle case.
70.Remove the retaining plate and return spring assembly.
MB992139
AK502251AE
TSB Revision
23B-29
CAUTION
Be careful. Do not use to much air pressure as this may
cause the reverse brake piston be stuck.
71.Feed the air in the oil hole shown in the diagram, and
remove the reverse brake piston from the transaxle case.
AK502252AD
AK502253
TSB Revision
23B-30
B
C
AK502299AD
TSB Revision
23B-31
AK502253
Spring
Protrusion
AK502254AI
TSB Revision
23B-32
CAUTION
When installing the retaining plate, align the tangs at positions A, B, C in the diagram.
3. Install the retaining plate on the transaxle case.
AK502255
B
A
C
AK502770AD
CAUTION
Set the spring compressor right on top of the spring of
spring retainer assembly.
Do not re-use the snap ring.
When installing the snap ring, make sure that the joint
falls in the area A in the diagram.
4. Using the Special Tool MB992139, compress the return
spring, and install the snap ring on the transaxle case by
means of a flat blade screwdriver etc.
MB992139
AK502251AE
AK502771AD
TSB Revision
23B-33
Dish plate
Retaining plate
Reverse brake
piston
Drive plate
AK502256AD
CAUTION
When conducting measurements, measure two or more
places, and find the average value.
Do not re-use the snap ring.
When installing the snap ring, make sure that the joint
falls in the area A in the diagram.
6. Using a flat blade screwdriver etc., install the snap-ring on
the transaxle case, and measure clearance between the
snap ring and retaining plate. Select the snap ring so as to
obtain standard value of the clearance. For selection of the
snap ring, refer to "SERVICE SPECIFICATIONS".
Standard value: 1.2 1.5 mm
AK502257
AK502771AD
TSB Revision
23B-34
CAUTION
Apply vaseline when installing the needle bearing.
Be careful to attach the needle bearing in right direction.
7. Install the needle bearing on the reverse brake piston. Refer
to A in the "IDENTIFICATION OF NEEDLE BEARINGS" for
right direction.
AK502258
AK502248
CAUTION
Apply vaseline when installing the needle bearing.
Be careful to attach the needle bearing in right direction.
9. Install the needle bearing on the primary pulley side of the
sun gear. Refer to B in the "IDENTIFICATION OF NEEDLE
BEARINGS" for right direction.
AK502247
AK502246
TSB Revision
23B-35
CAUTION
Apply vaseline when installing the needle bearing.
Be careful to attach the needle bearing in right direction.
11.Install the needle bearing on the forward clutch drum side of
the sun gear. Refer to C in the "IDENTIFICATION OF
NEEDLE BEARINGS" for right direction.
AK502245
AK502244
CAUTION
When conducting measurements, measure two or more
places, and find the average value.
13.Measure the total end play as follows:
A
Forward clutch drum
Needle bearing
AK502259AD
M1
AK502260 AD
TSB Revision
23B-36
(2) Measure the distance M2 from the edge of oil pump cover
to the mounting surface on the transaxle case.
(3) Calculate the total end play by the following expression.
Select the needle bearing so that the total end play meets
its standard value.
Total end play = M1 M2 bearing thickness
Standard value: 0.25 0.55 mm
M2
AK502261AD
CAUTION
Apply vaseline when installing the needle bearing.
Be careful to attach the needle bearing in right direction.
14.Install the selected needle bearing on the forward clutch
assembly. Refer to D in the "IDENTIFICATION OF NEEDLE
BEARINGS" for right direction.
AK502219
CAUTION
Do not re-use the seal rings.
Apply vaseline when installing the seal rings.
15.Install the seal rings on the oil pump cover.
AK502218AD
CAUTION
Do not re-use the bolt.
16.Install the detent spring on the transaxle case and tighten
the bolt to the specified torque.
Tightening torque: 6.9 N m (61 in-lb)
AK502243AD
TSB Revision
23B-37
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
17.Install the O-ring on the plug.
AK502774AD
18.Install the plug on the converter housing and tighten the bolt
to the specified torque.
Tightening torque: 7.5 N m (66 in-lb)
AK603125AB
CAUTION
Do not bend the pipe when attaching it.
19.Install the pipe on the converter housing.
AK502976
20.Install the clip and tighten the bolt to the specified torque.
Tightening torque: 6.9 N m (61 in-lb)
AK502975AD
TSB Revision
23B-38
CAUTION
Do not re-use the outer race.
Replace the outer race together with the inner race.
21.Using the Special Tools MB991168 and MB991702, Install
the differential bearing outer race.
MB991168
MB991702
AK502847AD
CAUTION
When adjusting the preload, apply CVT fluid to the
bearing to make it roll smoothly.
When conducting measurements, measure two or more
places, and find the average value.
22.Measure the preload A of the differential assembly as
follows:
Converter housing
A
Transmission case
Differential assembly
AK502263AD
M3
AK502264AD
M4
AK502265 AD
TSB Revision
23B-39
M5
AK502266 AD
CAUTION
Do not re-use the adjusting shim.
23.Install the selected shim on the transaxle case. For selection
of the adjusting shim, refer to "SERVICE
SPECIFICATIONS".
AK502239
CAUTION
Do not re-use the outer race.
Replace the outer race together with the inner race.
24.Using the Special Tool MB990780, install the outer race of
differential side bearing on the transaxle case.
MB990780
AK502846AD
CAUTION
Do not re-use the outer race.
Replace the outer race together with the inner race.
25.Using the Special Tools MB990932 and MB990938, install
the outer race of reduction gear bearing on the converter
housing.
MB990938
MB990932
AK604111AC
TSB Revision
23B-40
CAUTION
When adjusting the preload, apply CVT fluid to the
bearing to make it roll smoothly.
When conducting measurements, measure two or more
places, and find the average value.
26.Measure the preload A of the reduction gear assembly in
the following way.
Bearing
outer race
Reduction gear
A
Transmission case
AK502269AD
AK502270 AD
M8
AK502271AD
M9
AK502272AD
TSB Revision
23B-41
CAUTION
Do not re-use the adjusting shim.
27.Install the selected adjusting shim on the transaxle case.
For selection of the adjusting shim, refer to "SERVICE
SPECIFICATIONS".
AK502241
CAUTION
Do not re-use the outer race.
Replace the outer race together with the inner race.
28.Using the Special Tools MB990932 and MB990938, install
the outer race of reduction gear bearing on the transaxle
case.
MB990938
MB990932
AK502951AD
CAUTION
Do not re-use the lip seal.
Apply CVT fluid when installing the lip seal.
29.Install the lip seal on the transaxle case.
AK502237AD
TSB Revision
23B-42
CAUTION
Do not re-use the O-rings.
Apply CVT fluid when installing the O-rings.
30.Install the O-rings on the oil pump fastening bolts.
AK502236
31.Install the oil pump on the transaxle case and tighten the
bolt to the specified torque. (One fastening bolt is installed at
the backside from the transaxle case side. Only this bolt
should be tightened to the specified torque of 28 N m [21
ft-lb]).
Tightening torque: 19 N m (14 ft-lb)
AK502235AD
CAUTION
Do not re-use the snap ring.
32.Install the snap ring on the oil pump.
AK502211AD
TSB Revision
23B-43
CAUTION
Do not re-use the lip seal.
Apply CVT fluid or vaseline when installing the lip seal.
33.Install the lip seal on the transaxle case.
AK502229AD
AK502233
Pin
AK502225AD
TSB Revision
23B-44
Stopper
AK502274AD
TSB Revision
23B-45
CAUTION
Align the notch of pulley ratio linkage with the prong of
pulley sensor.
(3) Slide the control valve assembly from the bottom, and
install it on the transaxle case.
CAUTION
Apply CVT fluid when attaching the bush.
AK502227
Notch
Protrusion
AK502275 AD
AK502276
TSB Revision
23B-46
A
A
B
A
A
A
A A
A
A
Bolt length mm
54
44
Quantity
10
AK502226AD
36.Install the manual lever and tighten the bolt to the specified
torque.
Tightening torque: 22.1 N m (16 ft-lb)
AK502224AD
AK502223AD
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
38.Install the O-ring on the oil strainer.
AK502277
TSB Revision
23B-47
39.Install the oil strainer and tighten the bolt to the specified
torque.
Tightening torque: 7.9 N m (70 in-lb)
Bolt symbol
A
B
C
Bolt length mm
12
44
12
Quantity
C
AK502222AD
CAUTION
Do not re-use the oil pan gasket.
Remove any moisture, oil, and used gasket from the
mounting surface of oil pan gasket.
When installing the oil pan gasket, align the dowel pins
of transaxle case with dowel pin holes A of the oil pan
gasket.
40.Install the oil pan gasket on the transaxle case.
41.Install the magnet on the oil pan.
AK502278AE
CAUTION
When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
42.Install the oil pan on the transaxle case and tighten the bolts
to the specified torque.
Tightening torque: 7.9 N m (70 in-lb)
AK502220AD
CAUTION
Do not re-use the drain plug gasket.
43.Install the drain plug and drain plug gasket on the transaxle
case and tighten the bolt to the specified torque.
Tightening torque: 34.3 N m (25 ft-lb)
TSB Revision
23B-48
44.Install the oil pump cover on the transaxle case, and fix the
fastening bolts temporarily.
AK502217AD
AK502216AE
46.Install the baffle plate and tighten the bolt to the specified
torque.
Tightening torque: 5.9 N m (52 in-lb)
AK502215AE
47.Install the bracket, and tighten the fastening bolts of the oil
pump cover, baffle plate and tighten the bolts to the
specified torque.
Tightening torque: 26 N m (19 ft-lb)
AK502214AD
TSB Revision
23B-49
CAUTION
Make sure the tang of thrust washer is aligned with the
mounting hole of oil pump cover.
Apply vaseline when installing the thrust washer.
48.Install the thrust washer on the oil pump cover.
AK502210AD
CAUTION
Pull the driven sprocket up softly to make sure it is
securely attached.
49.Expand the snap ring, and install the driven sprocket, oil
pump chain, and drive sprocket.
Snap ring
AK502208AD
Drive
sprocket
Drive sprocket
Converter housing
Adjust shim
Oil pump cover
AK502279AD
TSB Revision
23B-50
M11
AK502280AD
M12
AK502281AD
CAUTION
Apply vaseline when installing the adjusting shim.
(4) Install the selected adjusting shim on the drive sprocket.
For selection of the adjusting shim, refer to "SERVICE
SPECIFICATIONS".
AK502206AG
51.Install the baffle plate, and tighten the fastening nuts to the
specified torque.
Tightening torque: 5.9 N m (52 in-lb)
AK502207AE
TSB Revision
23B-51
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
52.Install the O-ring on the input shaft.
AK502206AF
AK502213
AK502212
CAUTION
Do not re-use the converter housing oil seal.
Apply CVT fluid when installing the converter housing
oil seal.
55.Using the Special Tools MB992141 and MB992075, install
the converter housing oil seal on the converter housing.
Depth from the case edge: within 1.0 0.5 mm
(recessed).
MB992075
MB992141
Oil seal
AK603128AB
TSB Revision
23B-52
CAUTION
Do not re-use the converter housing side oil seal.
Apply CVT fluid when installing the converter housing
side oil seal.
56.Using the Special Tools MB992206 and MB992075, install
the converter housing side oil seal on the converter housing.
MB992075
MB992206
AK603129AB
CAUTION
Remove any moisture, oil and oil sealant from the application surface.
Make sure the starting point and the ending point are
about the middle between the bolts.
57.Apply the sealant on the converter housing mounting
surface of the transaxle case in the following way.
Specified sealant: Loctite 509
L1
9 mm
L4
L2
L5
L3
L1
L6
AK502283AD
L7
L2
5 mm
L3
1.5 mm
L4
R 8.5 mm
L5
R 5 8 mm
L6
R 3 5 mm
L7
17 mm
L8
3.5 mm
L8
AK502284AD
B A
A
B
A
B
B
A
A A A
A
AK502200 AD
TSB Revision
Bolt length mm
30
35
Quantity
18
23B-53
CAUTION
Do not re-use the snap ring.
59.Install the snap ring on the terminal body.
Snap ring
Terminal body
AK502197AF
Oil seal
CAUTION
Do not re-use the side oil seal.
Apply CVT fluid when installing the side oil seal.
60.Using the Special Tool MB992140 and MB992075, install
the side oil seal on the transaxle case.
Depth from the case edge: within 1.8 0.5 mm
(recessed).
MB992140
MB992075
AK502285AE
CAUTION
Do not re-use the inhibitor switch.
61.Install the inhibitor switch on the transaxle case as follows:
(1) Install the inhibitor switch on the transaxle case.
AK502196
(2) Install the shift lever on the manual shaft, and tighten the
fastening nuts to the specified torque.
Tightening torque: 17.2 N m (13 ft-lb)
(3) Set the manual shaft at N position.
AK502195AD
TSB Revision
23B-54
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
Installing bolt
Adjustment hole
AK502773AD
AK502287AD
AK502194AD
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
64.Install the O-ring on the secondary pulley speed sensor.
AK502288AD
TSB Revision
23B-55
AK502193AD
CAUTION
Apply CVT fluid or vaseline when installing the CVT
fluid cooler filter.
Do-not re-use the CVT fluid cooler filter.
66.Install the CVT fluid cooler filter on the transaxle case.
AK502199
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
When installing O-ring, make sure that projection of the
O-ring is put into the groove on the filter.
67.Install the O-ring on the CVT fluid filter.
AK502289
AK502198
TSB Revision
23B-56
CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.
69.Install the O-ring on the plug.
AK502774AD
70.Fasten the plug on the transaxle case and tighten the bolt to
the specified torque.
Tightening torque: 7.5 N m (66 in-lb)
AK502775
CAUTION
When conducting measurements, measure two or more
places, and find the average value.
71.Install the converter on the transaxle, and measure the size
A to check if it meets the standard value.
Standard value: 15.9 mm.
A
AK603131AB
TSB Revision
23B-57
FORWARD CLUTCH
DISASSEMBLY AND ASSEMBLY
M1233209000184
CAUTION
Refer to "HOW TO USE THIS MANUAL" for the symbols in the schematic.
5
7
1
2
3
AK502291AD
<<A>>
<<B>>
<<C>>
<<D>>
>>E<<
>>D<<
>>C<<
>>B<<
1.
2.
3.
4.
Disassembly steps
Snap ring
Internal gear
Snap ring
Snap ring
TSB Revision
<<E>>
<<E>>
>>A<<
>>A<<
5.
6.
7.
8.
23B-58
AK502292
AK502293
AK502294
AK502296
TSB Revision
23B-59
AK502296
TSB Revision
23B-60
AK502294
AK502293
AK502292
INSPECTION
M1233200200040
TSB Revision
23B-61
REDUCTION GEAR
DISASSEMBLY AND ASSEMBLY
M1233200600059
CAUTION
Refer to "HOW TO USE THIS MANUAL" for the symbols in the schematic.
250 Nm
184 ft-lb
1
2
AK502978AD
<<A>>
<<B>>
<<C>>
>>C<<
>>B<<
>>A<<
1.
2.
3.
Disassembly steps
Nut
Reduction gear bearing
Reduction gear bearing
TSB Revision
4.
5.
23B-62
<<A>>NUT REMOVAL
Remove the nut from the reduction gear sub-assembly.
AK502979
MB990810
CAUTION
Align the tang of special tool as shown in the diagram.
Using the Special Tools MB990810, MB990947 and
MD999566, remove the inner race of reduction gear bearing
(converter housing side) from the reduction gear sub-assembly.
MD999566
MB990947
AK502839AD
AK502980
MD998917
AK502841AD
TSB Revision
23B-63
MD998812
MD998813
CAUTION
Do not re-use the inner race.
Replace the inner race together with the outer race.
Using the Special Tools MD998812, MD998813 and
MD998819, install the inner race of reduction gear bearing
(transaxle case side) on the reduction gear sub-assembly.
MD998819
AK502842AD
.
MD998812
MD998813
CAUTION
Do not re-use the inner race.
Replace the inner race together with the outer race.
Using the Special Tools MD998812, MD998813 and
MD998819, install the inner race of reduction gear bearing
(converter housing side) on the reduction gear sub-assembly.
MD998819
AK502840AD
.
>>C<<NUT INSTALLATION
Install the nut on the reduction gear sub-assembly to the specified torque.
Tightening torque: 250 N m (184 ft-lb)
AK502982
TSB Revision
23B-64
INSPECTION
M1233200700034
M1233200900038
CAUTION
The reduction gear sub-assembly can only be assembled, not disassembled.
AK503079 AD
Assembly steps
TSB Revision
23B-65
Reduction pinion
gear
Idler gear
CAUTION
When attaching the idler gear to the reduction pinion gear,
make sure the center boss portion A faces the reduction
pinion gear.
Center boss portion A
Long
Short
B
AK503080AD
MD998812
MD998813
MD998819
AK503032AD
TSB Revision
23B-66
DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY
M1233213000176
CAUTION
Refer to "HOW TO USE THIS MANUAL" for the symbols in the schematic.
1
4
AK502984 AD
<<A>>
<<B>>
>>B<<
>>A<<
1.
2.
Disassembly steps
Differential side bearing
Differential side bearing
TSB Revision
3.
4.
23B-67
AK502848AD
.
MB990810
MB991452
AK502844AD
MB992138
CAUTION
Do not re-use the inner race.
Replace the inner race together with the outer race.
Using the Special Tool MB992138, install the inner race of
reduction gear bearing (converter housing side) on the reduction gear sub-assembly.
AK502990AD
TSB Revision
23B-68
MD998812
MD998813
MD998823
CAUTION
Do not re-use the inner race.
Replace the inner race together with the outer race.
Using the Special Tools MD998812, MD998813 and
MD998823, install the inner race of reduction gear bearing
(transaxle case side) on the reduction gear sub-assembly.
AK502845AD
INSPECTION
M1233200800031
DIFFERENTIAL SUB-ASSEMBLY
Measure the inner race press-fit shaft diameter of differential
sub-assembly, and replace the assembly if the diameter does
not meet the standard value.
Standard values
Converter housing side: 60.032 60.078 mm
Transaxle case side: 40.026 40.051 mm
TSB Revision
23B-69
DIFFERENTIAL SUB-ASSEMBLY
ASSEMBLY
M1233201200032
CAUTION
The differential sub-assembly can only be assembled, not disassembled.
2
154 Nm
114 ft-lb
AK503081AD
>>A<<
>>A<<
1.
2.
Assembly steps
Differential case
Final gear
CAUTION
When attaching the final gear to the differential case, make
sure the side with the bigger distance from the edge to the
flange A face the differential case.
Differential case
Final gear
Long
Short
AK503083 AD
TSB Revision
23B-70
Install the final gear on the differential case, and tighten the fastening bolts to the specified torque.
Tightening torque: 154 N m (114 ft-lb)
AK503082
TSB Revision