Caja Automática Mitsubishi CVT

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23B-1

GROUP 23B

CONTINUOUSLY
VARIABLE
TRANSAXLE
OVERHAUL
CONTENTS
GENERAL INFORMATION . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . .

23B-2
23B-3

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-57

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

23B-60

REDUCTION GEAR . . . . . . . . . . . . . . 23B-61

FASTENER TIGHTENING
SPECIFICATIONS . . . . . . . . . . . . . . . . . . .

23B-3

DISASSEMBLY AND ASSEMBLY . . . . . . .

23B-61

GENERAL SPECIFICATION . . . . . . . . . . .

23B-3

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

23B-64

SERVICE SPECIFICATIONS . . . . . . . . . . .

23B-4

SNAP RING, SPACER AND THRUST WASHER


FOR ADJUSTMENT . . . . . . . . . . . . . . . . . .
23B-4
SEALANTS AND ADHESIVES . . . . . . . . . .

23B-6

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .

23B-6

SPECIAL TOOLS. . . . . . . . . . . . . . . .

23B-6

TRANSAXLE . . . . . . . . . . . . . . . . . . .

23B-10

DISASSEMBLY AND ASSEMBLY . . . . . . .

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

DIFFERENTIAL SUB-ASSEMBLY. . . 23B-69


ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

23B-69

23B-2

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


GENERAL INFORMATION

GENERAL INFORMATION

M1233201400014

AUTOMATIC TRANSAXLE MODEL


Transaxle model

Applicable engine

Vehicle model

F1CJA-2-BBZ

4B11 MIVEC

CY4A

SECTIONAL VIEW

AK603120

TSB Revision

23B-3

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIFICATIONS

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

M1233205000115

Item

Specifications N m

Detent spring

6.9 (61 in-lb)

Plug

7.5 (66 in-lb)

Clip

6.9 (61 in-lb)

Oil pump

19 (14 ft-lb)

Oil pump

28 (21 ft-lb)

Control valve assembly

7.9 (70 in-lb)

Manual lever

22.1 (16 ft-lb)

Bracket

7.9 (70 in-lb)

Oil strainer

7.9 (70 in-lb)

Oil pan

7.9 (70 in-lb)

Drain plug

34.3 (25 ft-lb)

Baffle plate

5.9 (52 in-lb)

Bracket

26 (19 ft-lb)

Baffle plate

26 (19 ft-lb)

Oil pump cover

26 (19 ft-lb)

Converter housing

45 (33 ft-lb)

Shift lever

17.2 (13 ft-lb)

Inhibitor switch

5.5 (49 in-lb)

Primary pulley speed sensor

5.9 (52 in-lb)

Secondary pulley speed sensor

5.9 (52 in-lb)

CVT fluid cooler

4.2 (37 in-lb)

Plug

7.5 (66 in-lb)

Oil filter tube

11 1 (97 9 in-lb)

Control cable bracket

23 3 (17 2 ft-lb)

Harness bracket

23 3 (17 2 ft-lb)

FR roll stopper bracket

90 10 (66 7 ft-lb)

RR roll stopper bracket

90 10 (66 7 ft-lb)

Reduction gear nut

250 (184 ft-lb)

Final gear

154 (114 ft-lb)

GENERAL SPECIFICATION
Transaxle model
Torque converter

M1233201000191

F1CJA
type

3-element 1-stage 2-phase

lockup

available

Transaxle type

forward: continuously variable (with steel belt), reverse: 1 gear

Gear ratio

2.349 0.394

Reverse

1.750

Final reduction ratio

6.120

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23B-4

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIFICATIONS

SERVICE SPECIFICATIONS

M1233202000149

Item

Standard value mm

Reverse brake clearance

1.2 1.5

Total end play

0.25 0.55

Differential preload

0.17 0.29

Reduction gear preload

0.13 0.19

Oil pump drive sprocket to converter housing clearance

0.10 0.23

Mounting bore diameter of reduction gear


bearing outer race

converter housing side

61.949 61.979

Mounting bore diameter of differential side


bearing outer race

converter housing side

84.941 84.976

transaxle case side

67.949 67.979

Mounting bore diameter of reduction gear


bearing inner race

converter housing side

30.008 30.029

Mounting bore diameter of differential side


bearing inner race

converter housing side

60.032 60.078

transaxle case side

40.026 40.051

transaxle case side

transaxle case side

SNAP RING, SPACER AND THRUST WASHER FOR ADJUSTMENT


Snap rings (for adjustment of reverse brake)
Thickness mm

Identification

Thickness mm

Identification

2.2

2.8

2.4

3.0

2.6

Needle bearings (for adjustment of total end play)


Thickness mm

Identification

Thickness mm

Identification

3.58

4.26

3.75

4.43

3.92

4.60

4.09

4.77

Adjusting shims (for adjustment of differential preload)


Thickness mm

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

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M1233204000145

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIFICATIONS

Thickness mm

Identification

Thickness mm

Identification

0.68

1.24

0.72

1.28

0.76

1.32

Adjusting shims (for adjustment of reduction gear preload)


Thickness mm

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

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23B-5

23B-6

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIAL TOOLS

SEALANT(S) AND ADHESIVE(S)


Item

M1233206000099

Specified sealant and adhesive

Transaxle
Converter housing

Loctite 509

LUBRICANT(S)

M1233200400033

Item

Specified lubricant

Transaxle
CVT fluid application parts

Diaqueen CVTF-J1

Vaseline application parts

White vaseline (main ingredient: isoparaffinic


hydrocarbon)

SPECIAL TOOLS
TOOL
B

M1233207000155

TOOL NUMBER AND


NAME

SUPERSESSION

APPLICATION

MB990590
Real axle shaft oil seal
remover

MB990211-01

Removal of outer race of


reduction gear bearing
and differential side
bearing

MB992039
Slide hammer puller

MB992039-01

Removal of outer race of


reduction gear bearing
and differential side
bearing

MB992139
Spring compressor

Removal and installation


of reverse brake

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIAL TOOLS

TOOL

23B-7

TOOL NUMBER AND


NAME

SUPERSESSION

APPLICATION

MB990780
Real axle shaft bushing
installer

Installation of differential
side bearing outer race
(transaxle case side)

MB990932
Installer adapter

Reduction gear bearing


outer race

MB990938
Installer bar

Reduction gear bearing


outer race

MB992075
Handle

Installation of oil seal

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

Installation of side oil seal

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23B-8

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIAL TOOLS

TOOL

TOOL NUMBER AND


NAME

SUPERSESSION

APPLICATION

MB990810
Side bearing puller

Removal of reduction gear


bearing inner race
(converter housing side),
removal of differential side
bearing inner race
(converter housing side),
removal of differential side
bearing inner race
(transaxle case side)

MB990947
Lower arm push arbor

MB990947-01

Removal of reduction gear


bearing inner race
(converter housing side)

MD999566
Crow

Removal of reduction gear


bearing inner race
(converter housing side)

MB990984
Mount bushing lower roll
insulator arbor

Removal of reduction gear


bearing inner race
(transaxle case side)

MD998917
Bearing remover

Removal of reduction gear


bearing inner race
(transaxle case side)

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


SPECIAL TOOLS

TOOL

23B-9

TOOL NUMBER AND


NAME

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)

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23B-10

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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.

RR roll stopper bracket


FR roll stopper bracket
Harness bracket
Oil level gage

TSB Revision

Oil filler tube


Control cable bracket
Breather hose

23B-12

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE
4.2 Nm
37 in-lb

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

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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

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE
28 Nm
21 ft-lb

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

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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

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

Required Special Tools:


MB990590: Real axle shaft oil seal remover
MB990932: Installer adapter
MB992039: Slide hammer puller
MB990938: Installer bar
MB992139: Spring compressor
MB992075: Handle
MB991168: Differential oil seal installer
MB992141: Oil seal installer
MB991702: Adapter
MB992206: Oil seal installer
MB990780: Real axle shaft bushing installer
MB992140: Oil seal installer
DISASSEMBLY SERVICE POINT

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

6. Remove the plug from the transaxle case.

AK502775

7. Remove the O-ring from the plug.

AK502774AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-15

8. Remove the secondary pulley speed sensor from the


converter housing, and detach the O-ring from the sensor.

AK502193AD

9. Remove the primary pulley speed sensor from the transaxle


case, and detach the O-ring from the sensor.

AK502194AD

10.Remove the shift lever from the manual shaft.

AK502195AD

11.Remove the inhibitor switch from the transaxle.

AK502196

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23B-16

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

15.Remove the fastening bolts of converter housing.


B

B A

A
B
A

B
B

A
A A A

A
AK502200 AD

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Bolt symbol

Bolt length mm

30

35

Quantity

18

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

17.Using the Special Tools MB990590 and MB992039, remove


the outer race of reduction gear bearing from the converter
housing.
18.Using cylinder gage etc., measure the mounting bore
diameter of reduction gear bearing outer race at the
converter housing side; if the standard value is not satisfied,
then replace the converter housing.
Standard value: 61.949 61.979 mm

AK502819AD

19.Using the Special Tools MB990590 and MB992039, remove


the outer race of differential side bearing from the converter
housing.
20.Using cylinder gage etc., measure the mounting bore
diameter of differential side bearing outer race at the
converter housing side; if the standard value is not satisfied,
then replace the converter housing.
Standard value: 84.941 84.976 mm

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

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23B-18

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

22.Remove the clip.

AK502975AD

CAUTION
When removing the pipe, be careful not to bend it.
23.Remove the pipe from the converter housing.

AK502976

24.Remove the plug from the converter housing.

AK603125AB

25.Remove the O-ring from the plug.

AK502774AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-19

26.Remove the O-ring from the input shaft.

AK502206AF

27.Remove the adjusting shim from the drive sprocket.

AK502206AG

28.Remove the baffle plate.

AK502207AE

29.Expand the snap ring, and remove the driven sprocket, oil
pump chain, and drive sprocket.

Snap ring
AK502208AD

Drive
sprocket

Oil pump chain


Drive sprocket
AK502209AD

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23B-20

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

30.Remove the thrust washer from the oil pump cover.

AK502210AD

31.Remove the snap ring from the oil pump.

AK502211AD

32.Remove the reduction gear assembly from the transaxle


case.

AK502212

33.Remove the differential assembly from the transaxle case.

AK502213

34.Remove the bracket.

AK502214AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-21

35.Remove the baffle plate.

AK502215AE

36.Remove the baffle plate.

AK502216AE

37.Remove the oil pump cover from the transaxle case.

AK502217AD

38.Remove the seal rings from the oil pump cover.

AK502218AD

39.Remove the needle bearing from the forward clutch


assembly.

AK502219

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23B-22

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

40.Remove the oil pan from the transaxle case.


41.Remove the magnet from the oil pan.

AK502220

42.Remove the oil pan gasket from the transaxle case.

AK502221

43.Remove the oil strainer


A

Bolt symbol

Bolt length mm

12

44

12

Quantity

B
C
AK502222AD

44.Remove the O-ring from the oil strainer.

AK502780

45.Remove the bracket from the control valve assembly.

AK502223AD

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23B-23

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

46.Remove the manual lever.

AK502224AD

47.Remove the control valve assembly from the transaxle case


as follows:
(1) Insert pins etc. (3 mm) into linkage stopper holes of the
control valve assembly to fix the pulley ratio linkage.

Pulley ratio linkage

Pin

AK502225AD

(2) Remove fastening bolts of the control valve assembly.


A
A

B
A
A

Bolt symbol

Bolt length mm

54

44

Quantity

10

A
A A

A
A
AK502226AD

(3) Remove the control valve assembly from the transaxle


case.
NOTE: Tilt the control valve assembly, and after removing from the manual shaft side, remove the terminal body
from the transaxle case.

AK502227

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23B-24

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

48.Remove the bush from the control valve.

AK502228

49.Remove the lip seal from the transaxle case.

AK502229AD

50.Remove the valve body harness from the control valve.

AK502233

51.Remove the oil pump from the transaxle case. (One


fastening bolt is installed at the backside from the transaxle
case side).

AK502235AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-25

52.Remove the O-ring from the oil pump fastening bolt.

AK502236

53.Remove the lip seal from the transaxle case.

AK502237AD

54.Using the Special Tools MB990590 and MB992039, remove


outer race of the differential side bearing from the transaxle
case.
55.Using cylinder gage etc., measure the mounting bore
diameter of differential side bearing outer race at the
transaxle case side; if the standard value is not satisfied,
then replace the CVT assembly.
Standard value: 67.949 67.979 mm

MB990590

MB992039

AK502821AD

56.Remove the adjusting shim from the transaxle case.

AK502239

57.Using the special tools MB990590 and MB992039, remove


outer race of the reduction gear bearing from the transaxle
case.
58.Using cylinder gage etc., measure the mounting bore
diameter of reduction gear bearing outer race at the
transaxle case side; if the standard value is not satisfied,
then replace the CVT assembly.
Standard value: 61.949 61.979 mm

MB990590

MB992039

AK502822 AD

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23B-26

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

59.Remove the adjusting shim from the transaxle case.

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

61.Remove the detent spring from the transaxle case.

AK502243AD

62.Remove the forward clutch assembly from the transaxle


case.

AK502244

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-27

63.Remove the needle bearing on forward clutch drum side


from the sun gear.

AK502245

64.Remove the sun gear from the planet carrier.

AK502246

65.Remove the needle bearing on primary pulley side from the


sun gear.

AK502247

66.Remove the planet carrier from the transaxle case.

AK502248

67.Remove the needle bearing from the planet carrier.

AK502249

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23B-28

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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23B-30

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

IDENTIFICATION OF NEEDLE BEARINGS

B
C

AK502299AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-31

ASSEMBLY SERVICE POINT


CAUTION
When the outer races of reduction gear bearing and differential side bearing are removed, measure the mounting
bore diameters of outer race in the converter housing and
transaxle case, and replace the housing case or the CVT
assembly if the standard value is not satisfied. The standard values are listed in "SERVICE SPECIFICATIONS".
CAUTION
Do not re-use the reverse brake piston.
Apply CVT fluid when installing the reverse brake piston.
1. Install the reverse brake piston, while turning it, on the
transaxle case.

AK502253

Spring retainer assembly

2. Align the spring portion of spring retainer assembly with the


projections of the reverse brake piston, and install the spring
retainer assembly.

Spring
Protrusion

AK502254AI

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23B-32

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE
Driven plate Snap ring

23B-33

5. Install the reverse brake retaining plate, drive plate, driven


plate, and dish plate on the transaxle case.

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

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23B-34

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

8. Install the planet carrier on the reverse brake.

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

10.Install the sun gear on the planet carrier.

AK502246

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

12.Install the forward clutch assembly on the transaxle case.

AK502244

Oil pump cover

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

(1) Measure the distance M1 from the oil pump cover


mounting surface of the transaxle case to the needle
bearing mounting surface of the forward clutch drum.

M1

AK502260 AD

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23B-36

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

(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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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23B-38

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

(1) Measure the distance M3 from the edge of transaxle case


to the mounting surface of adjusting shim.

M3

AK502264AD

(2) Install the differential assembly on the converter case,


and measure the distance M4 from the differential case to
the edge of converter housing.

M4

AK502265 AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-39

(3) Install the outer race on differential side bearing, and


measure the distance M5 from the differential case to the
outer race of differential side bearing.
(4) Using the following expression, calculate the distance M6
from the edge of converter housing to the outer race of
differential side bearing.
M6 = M4 M5

M5

AK502266 AD

(5) Using the following expression, calculate thickness of the


adjusting shim.
Thickness of adjusting shim = M3 M6 + preload
Preload standard value: 0.17 0.29 mm

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

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23B-40

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

(1) Measure the distance M7 from the edge of transaxle case


to the mounting surface of adjusting shim.
M7

AK502270 AD

(2) Install the reduction gear assembly on the converter


housing, and measure the distance M8 from the edge of
reduction gear assembly to the edge of converter
housing.

M8
AK502271AD

(3) Install the outer race of reduction gear side bearing on


the bearing, and measure the distance M9 from the edge
of reduction gear assembly to the outer race of reduction
gear bearing.
(4) Using the following expression, calculate the difference
M10 from the outer race of reduction gear bearing to the
edge of converter housing.
M10 = M8 M9

M9
AK502272AD

(5) Using the following expression, calculate the thickness of


adjusting shim.
Thickness of adjusting shim = M7 M10 +preload
Preload standard value: = 0.13 0.19 mm

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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23B-42

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

34.Install the valve body harness on the control valve.

AK502233

35.Install the control valve assembly on the transaxle case as


follows:
(1) Insert pins etc. ( 3 mm) into linkage stopper holes of the
control valve assembly to fix the pulley ratio linkage.

Pulley ratio linkage

Pin

AK502225AD

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23B-44

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

(2) Install the terminal body on the transaxle case, while


aligning the detent of terminal body with the transaxle
case as shown in the diagram.

Stopper

AK502274AD

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

(4) Install the bush on the control valve assembly.

AK502276

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23B-46

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

A
A

(5) Install the fastening bolts of control valve assembly and


tighten the bolt to the specified torque.
Tightening torque: 7.9 N m (70 in-lb)
Bolt symbol
A
B

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

37.Install the bracket on the control valve assembly and tighten


the bolt to the specified torque.
Tightening torque: 7.9 N m (70 in-lb)

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

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23B-47

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

Oil pan gasket

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)

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23B-48

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

44.Install the oil pump cover on the transaxle case, and fix the
fastening bolts temporarily.

AK502217AD

45.Install the baffle plate, and fix the fastening bolts


temporarily.

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

Oil pump chain


Drive sprocket
AK502209AD

Drive sprocket

Converter housing

50.Measure the clearance A between the oil pump drive


sprocket and the converter housing as follows:

Adjust shim
Oil pump cover
AK502279AD

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23B-50

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

(1) Measure the distance M11 between the edge of transaxle


case and the adjusting shim mounting surface of drive
sprocket.

M11

AK502280AD

M12

AK502281AD

(2) Measure the distance M12 between the edge of


converter housing and the surface contacting the
adjusting shim.
(3) Use the following expression, to select the adjusting shim
having the standard value.
Standard value of clearance = M11 + M12 thickness of
adjusting shim
Standard value: 0.10 0.23 mm

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

53.Install the differential assembly on the transaxle case.

AK502213

54.Install the reduction gear assembly on the transaxle case.

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

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23B-52

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

58.Install the converter housing on the transaxle case, and


tighten the fastening bolts to the specified torque of 45 N m.
Tightening torque: 45 N m (33 ft-lb)
Bolt symbol
A
B

A
B
A

B
B

A
A A A

A
AK502200 AD

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Bolt length mm

30

35

Quantity

18

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

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23B-54

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE
Installing bolt

(4) Insert pins etc. ( 5 mm) in adjusting holes in both


inhibitor switch and shift lever, and after alignment,
tighten the fastening bolts to the specified torque.
Tightening torque: 5.5 N m (49 in-lb)

CAUTION
Do not re-use the O-ring.
Apply CVT fluid when installing the O-ring.

Installing bolt

Adjustment hole

AK502773AD

62.Install the oil ring on the primary pulley speed sensor.

AK502287AD

63.Install the primary pulley speed sensor on the transaxle


case, and tighten the fastening bolts to the specified torque.
Tightening torque: 5.9 N m (52 in-lb)

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

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CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

23B-55

65.Install the secondary pulley speed sensor on the transaxle


case, and tighten the fastening bolts to the specified torque.
Tightening torque: 5.9 N m (52 in-lb)

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

68.Install the CVT fluid cooler on the transaxle case, and


tighten the fastening bolts to the specified torque.
Tightening torque: 4.2 N m (37 in-lb)

AK502198

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23B-56

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


TRANSAXLE

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

72.Install the control cable bracket and breather hose on the


transaxle.
73.Install the oil filler tube and oil level gage on the transaxle.
74.Install the harness bracket on the transaxle.
75.Install the RR roll stopper bracket and FR roll stopper
bracket on the transaxle.

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23B-57

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


FORWARD CLUTCH

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.

Disassembly steps (Continued)


Seal ring (small)
Seal ring (big)
Input shaft
Forward clutch sub-assembly

23B-58

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


FORWARD CLUTCH

DISASSEMBLY SERVICE POINT


.

<<A>>SNAP RING REMOVAL


Using a flat blade screwdriver etc., remove the snap ring from
the forward clutch drum.

AK502292

<<B>>INTERNAL GEAR REMOVAL


Remove the internal gear from the forward clutch drum.

AK502293

<<C>>SNAP RING REMOVAL


Using a flat blade screwdriver etc., remove the snap ring from
the forward clutch drum.

AK502294

<<D>>SNAP RING REMOVAL


Remove the snap ring using snap ring pliers, and remove the
input shaft from the forward clutch drum.

AK502296

TSB Revision

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


FORWARD CLUTCH

23B-59

<<E>>SEAL RING REMOVAL


Remove the seal rings (small and big) from the input shaft.
Seal ring (small)

Seal ring (big)


AK502776AD

REASSEMBLY SERVICE POINT


.

>>A<<SEAL RING INSTALLATION


CAUTION
Apply vaseline when installing the seal rings.
Do not re-use the seal rings.
Install the seal rings (small and big) on the input shaft.

Seal ring (small)

Seal ring (big)


AK502776AD

>>B<<SNAP RING INSTALLATION


CAUTION
Be careful not to strain the snap ring by expanding it
excessively.
Do not re-use the snap ring.
Install the input shaft on the forward clutch drum, and attach the
snap ring.

AK502296

TSB Revision

23B-60

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


FORWARD CLUTCH

>>C<<SNAP RING INSTALLATION


CAUTION
Do not re-use the snap ring.
Install the snap ring on the forward clutch drum.

AK502294

>>D<<INTERNAL GEAR INSTALLATION


Install the internal gear on the forward clutch drum.

AK502293

>>E<<SNAP RING INSTALLATION


CAUTION
Do not re-use the snap ring.
Install the snap ring on the forward clutch drum.

AK502292

INSPECTION

M1233200200040

FORWARD CLUTCH SUB-ASSEMBLY


Check if there is a damage, deformation, or burn marks, and
replace the forward clutch sub-assembly if any defect is found.

INPUT SHAFT AND INTERNAL GEAR


Check if there is a damage or deformation, and replace if any
defect is found.

TSB Revision

23B-61

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


REDUCTION GEAR

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

Required Special Tools:


MB990810: Side bearing puller
MB990947: Lower arm push arbor
MD999566: Crow
MB990984: Mount bushing lower roll insulator
arbor

TSB Revision

4.
5.

Disassembly steps (Continued)


Reduction gear sub-assembly
Adjusting shim

MD998917: Bearing remover


MD998812: Installer Cap
MD998813: Installer-100
MD998819: Installer adapter (40)

23B-62

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


REDUCTION GEAR

DISASSEMBLY SERVICE POINT


.

<<A>>NUT REMOVAL
Remove the nut from the reduction gear sub-assembly.

AK502979

<<B>>REDUCTION GEAR BEARING REMOVAL

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

<<C>>REDUCTION GEAR BEARING REMOVAL


MB990984

Using the Special Tools MB990984 and MD998917, remove


the outer race of reduction gear bearing (transaxle case side)
from the reduction gear sub-assembly.

MD998917

AK502841AD

TSB Revision

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


REDUCTION GEAR

23B-63

ASSEMBLY SERVICE POINT


.

>>A<<REDUCTION GEAR BEARING


INSTALLTION

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
.

>>B<<REDUCTION GEAR BEARING


INSTALLATION

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

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


REDUCTION GEAR SUB-ASSEMBLY

INSPECTION

M1233200700034

REDUCTION GEAR SUB-ASSEMBLY


Measure the inner race press-fit shaft diameter of reduction
gear sub-assembly, and replace the assembly if the diameter
does not meet the standard value.
Standard values
Converter housing side: 30.008 30.029 mm
transaxle case side: 30.008 30.029 mm

REDUCTION GEAR SUB-ASSEMBLY


ASSEMBLY

M1233200900038

CAUTION
The reduction gear sub-assembly can only be assembled, not disassembled.

AK503079 AD

Assembly steps

>>A<< 1. Idler gear


>>A<< 2. Reduction pinion gear
Required Special Tools:
MD998812: Installer Cap
MD998813: Installer-100

TSB Revision

MD998819: Installer adapter (40)

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


REDUCTION GEAR SUB-ASSEMBLY

23B-65

ASSEMBLY SERVICE POINT


.

>>A<<REDUCTION PINION GEAR / IDLER GEAR


INSTALLATION

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

Center boss portion B

Short

B
AK503080AD

MD998812

Using the Special Tools MD998812, MD998813 and


MD998819, attach the idler gear to the reduction pinion gear.

MD998813
MD998819

AK503032AD

TSB Revision

23B-66

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


DIFFERENTIAL

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

Required Special Tools:


MB990810: Side bearing puller
MB991452: Oil seal installer
MD998812: Installer Cap
MD998813: Installer-100

TSB Revision

3.
4.

Disassembly steps (Continued)


Differential sub-assembly
Adjusting shim

MD998819: Installer adapter (40)


MB992138: Bearing Installer
MD998823: Installer adapter (48)

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


DIFFERENTIAL

23B-67

DISASSEMBLY SERVICE POINT


.

<<A>>DIFFERENTIAL SIDE BEARING REMOVAL


Using the Special Tool MB990810, remove the inner race of differential side bearing (transaxle case side) from the differential
sub-assembly.
MB990810

AK502848AD
.

<<B>>DIFFERENTIAL SIDE BEARING REMOVAL


Using the Special Tools MB990810 and MB991452, remove the
inner race of differential side bearing (converter housing side)
from the differential sub-assembly.

MB990810
MB991452

AK502844AD

REASSEMBLY SERVICE POINT


.

>>A<<DIFFERENTIAL SIDE BEARING INSTALLATION

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

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


DIFFERENTIAL

>>B<<REDUCTION GEAR BEARING


INSTALLATION

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

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


DIFFERENTIAL SUB-ASSEMBLY

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

ASSEMBLY SERVICE POINT


.

>>A<<DIFFERNTIAL CASE/FINAL GEAR INSTALLATION


B

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

Distance from gear edge to flange A

Long

Distance from gear edge to flange B

Short

AK503083 AD

TSB Revision

23B-70

CONTINUOUSLY VARIABLE TRANSAXLE OVERHAUL


DIFFERENTIAL SUB-ASSEMBLY

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

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