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DISASSEMBLY AND REASSEMBLY
caution
  • Only use transmission fluid of the specified brand. Use of transmission fluid 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, washing oil 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 washing oil).
  • After cleaning, remove the torque converter, and drain the transmission 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 transmission fluid.
  • When the transaxle assembly or the valve body assembly is replaced, follow the initialization procedure for CVT learned value (Refer to GROUP 23A, Diagnosis - Initialization Procedure for CVT Learned Value ).
 
 
1.Drain plug
2.Drain plug gasket
3.Harness bracket
4.Harness bracket
5.Harness bracket
6.Harness bracket
7.Transmission fluid dipstick
8.Oil filler tube
9.O-ring
10.Control cable bracket
11.Breather hose
12.Stud
13.Secondary pulley speed sensor
14.O-ring
15.Primary pulley speed sensor
16.O-ring
17.Output speed sensor
18.O-ring
19.Washer
20.Manual control lever
21.Transmission range switch
22.Transmission fluid cooler
23.O-ring
24.Side oil seal
25.Side oil seal
26.Oil pan
27.Oil pan gasket
28.Magnet
29.Fluid strainer
30.O-ring
31.Spring washer
32.Manual plate
33.Valve body assembly
34.Torque converter
35.O-ring
36.Converter housing oil seal
37.Fluid filter cover
38.Transmission fluid filter
39.O-ring
40.Plug
41.O-ring
42.Plug
43.O-ring
44.Transaxle assembly
45.Plug
46.O-ring
 
 
DISASSEMBLY SERVICE POINT
caution
  • Do not disassemble parts other than specified in this manual.
  • Be careful not to drop the torque converter during servicing work.
1. Remove the drain plug from the oil pan.
2. Remove the drain plug gasket from the drain plug.
3. Remove the harness bracket from the transaxle assembly.
4. Remove the oil filler tube and transmission fluid dipstick from the transaxle assembly.
5. Remove the control cable bracket and breather hose from the transaxle assembly.
6. Remove the secondary pulley speed sensor from the transaxle assembly.
7. Remove the O-ring from the secondary pulley speed sensor.
8. Remove the primary pulley speed sensor from the transaxle assembly.
9. Remove the O-ring from the primary pulley speed sensor.
10. Remove the output speed sensor from the transaxle assembly.
11. Remove the O-ring from the output speed sensor.
12. Remove the manual control lever from the manual shaft.
13. Remove the transmission range switch from the transaxle assembly.
14. Remove the transmission fluid cooler from the transaxle assembly, and detach the O-ring from the transmission fluid cooler.

15.
cautionWhen removing the side oil seal, be careful not to cause damage to the transaxle assembly.
Using a flat-tipped screwdriver, remove the side oil seal from the transaxle assembly.

16.
cautionWhen removing the side oil seal, be careful not to cause damage to the transaxle assembly.
Using a flat-tipped screwdriver, remove the side oil seal from the transaxle assembly.
17. Remove the oil pan mounting bolts from the transaxle assembly.
18. Remove the oil pan and oil pan gasket from the transaxle assembly.
19. Remove the magnet from the oil pan.
20. Remove the fluid strainer mounting bolts to remove the fluid strainer from the valve body assembly.
21. Remove the O-ring from the fluid strainer.

22.
caution
  • To remove the manual plate, use a flat-tipped screwdriver to counterhold the plate so that excessive torque is not applied to it.
  • Do not apply any fixture such as a screwdriver directly to the manual valve to protect it from deformation.
Remove the manual plate mounting nuts, and remove the manual plate and the spring washer from the manual shaft.
23.
caution
  • To remove the bolts securing the valve body assembly and the oil temperature sensor bracket together, use a flat-tipped screwdriver to counterhold the bracket to avoid it from deformation.
  • Be careful not to drop the manual valve.
Remove the valve body assembly mounting bolts, and remove the valve body assembly.
 
Length beneath the head mm (in)87 (3.4)
Quantity11
24.
cautionTo remove the torque converter, be careful not to scratch the bushing inside the sleeve.
Remove the torque converter.
25. Remove the O-ring from the input shaft.

26.
cautionTo remove the converter housing oil seal, be careful not to scratch the converter housing and the input shaft.
Use a flat-tipped screwdriver to remove the converter housing oil seal from the transaxle assembly.
27. Remove the fluid filter cover mounting bolt.
28. Rotate the fluid filter cover counterclockwise to remove it from the transaxle assembly.
29. Remove the transmission fluid filter and the O-ring from the transaxle assembly.
30. Remove the plug from the transaxle assembly.
31. Remove the O-ring from the plug.
32. Remove the plug from the transaxle assembly.
33. Remove the O-ring from the plug.
 
 
 
ASSEMBLY SERVICE POINT
1.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
Install the O-ring to the plug.
2. Tighten the plug to the specified torque.
Tightening torque:
23 ± 2 N·m (17 ± 1 ft-lb)

3.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
Install the O-ring to the plug.
4. Tighten the plug to the specified torque.
Tightening torque:
7.5 ± 2.5 N·m (66 ± 22 in-lb)

5.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
Install the transmission fluid filter and the O-ring to the transaxle assembly.
6. Install the fluid filter cover to the transaxle assembly, and then rotate it clockwise to secure it.
7. Tighten the fluid filter cover mounting bolt to the specified torque.
Tightening torque:
7.0 ± 0.4 N·m (62 ± 3 in-lb)

8.
caution
  • Do not re-use the converter housing oil seal.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Apply the transmission fluid around the circumference of the converter housing oil seal. Then use the special tool MD998375 to install the converter housing oil seal so that the dimension (A) shown meets the standard value.
Standard value (A): 1.3 ± 0.5 mm (0.05 ± 0.02 inch)

9.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
Install the O-ring to the input shaft.

10.
caution
  • Fit the torque converter fully into position by twisting it back and forth.
  • To install the torque converter, be careful not to scratch the bushing inside the sleeve.
Align (A) on the torque converter with the (B) on the drive sprocket at the transaxle assembly.

11.
cautionMeasure at two points or more to determine an average value.
The dimension (A) should meet the standard value.
Standard value (A): approximately 12.2 mm (0.48 inch)
12. Apply the transmission fluid to the terminal assembly mount on the transaxle assembly.

13.
cautionWhen the wire(s) on the valve body assembly are pinched, loose or twisted, correct them.
The wire (A) on the terminal assembly should not be trapped in the terminal assembly bracket (B).
14.
caution
  • To install the valve body assembly to the transaxle assembly, be careful not to scratch the O-ring seated in the connector on the valve body assembly.
  • Push in the valve body assembly so that it butts up tight to the case.
Install the valve body assembly to the transaxle assembly.
15. Tighten the two mounting bolts by hand.
 
Length beneath the head mm (in)87 (3.4)
Quantity2
16. Then tighten nine mounting bolts by hand.
 
Length beneath the head mm (in)87 (3.4)
Quantity9
17. Tighten 11 bolts to the specified torque.
Tightening torque:
7.9 ± 1.0 N·m (70 ± 8 in-lb)

18.
caution
  • To install the manual plate, use a flat-tipped screwdriver to counterhold the plate so that excessive torque is not applied to it.
  • Do not apply any fixture such as a screwdriver directly to the manual valve to protect it from deformation.
Install the manual plate and the spring washer, and tighten the mounting nuts to the specified torque.
Tightening torque:
22 ± 0.4 N·m (16 ± 0.2 ft-lb)

19.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
Install the O-ring to the fluid strainer.

20.
cautionThe fluid strainer should butt tight to the valve body.
Install the fluid strainer to the valve body assembly, and then tighten the mounting bolts to the specified torque.
 
Length beneath the head mm (in)12 (0.47)
Quantity3
Tightening torque:
7.9 ± 1.0 N·m (70 ± 8 in-lb)
21. Install the magnet on the oil pan.

22.
cautionDo not re-use the oil pan gasket.
Install the oil pan and oil pan gasket on the transaxle assembly.
23. Tighten the front oil pan mounting bolts by hand.
24. Tighten the oil pan mounting bolts to the specified torque in the order shown.
Tightening torque:
5.9 ± 0.6 N·m (52 ± 5 in-lb)

25.
caution
  • Do not re-use the oil seal.
  • Apply transmission fluid to the outer circumference of the oil seal.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Using the special tool MB990982, install the side oil seal on the transaxle assembly.
Depth from the case edge: within - 1.8 ± 0.5 mm (0.07 ± 0.02 inch) (recessed).

26.
caution
  • Do not re-use the oil seal.
  • Apply transmission fluid to the outer circumference of the oil seal.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Using the special tool MB990982, install the side oil seal on the transaxle assembly.
Depth from the case edge: within - 1.8 ± 0.5 mm (0.07 ± 0.02 inch) (recessed).

27.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
  • The O-ring should be seated fully into the groove on the transmission fluid cooler.
Install the O-ring on the transmission fluid cooler.
28. Install the transmission fluid cooler on the transaxle assembly, and tighten the mounting bolts to the specified torque.
Tightening torque:
4.3 ± 0.5 N·m (38 ± 4 in-lb)

29.
cautionDo not re-use the transmission range switch.
Install the transmission range switch on the transaxle assembly as shown.
30. Install the transmission range switch on the transaxle assembly.
31. Tighten the transmission range switch mounting bolts by hand.
32. Install the manual control lever on the manual shaft.
33. Install the washer on the manual shaft, and tighten the mounting nut to the specified torque.
Tightening torque:
17 ± 2 N·m (13 ± 1 ft-lb)
34. Set the manual shaft at N position.
35. Insert a Φ5 mm (Φ0.2 inch) pin through the hole on the manual control lever down to the recess on the transmission range switch to align the transmission range switch.
36.
cautionThe pin should be engaged fully into the recess on the transmission range switch.
Tighten the transmission range switch mounting bolts to the specified torque.
Tightening torque:
5.9 ± 1.0 N·m (52 ± 8 in-lb)
37. Remove the pin.
38.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Install the O-ring on the output speed sensor.
39. Install the output speed sensor on the transaxle assembly, and tighten the mounting bolt to the specified torque.
Tightening torque:
5.9 ± 1.0 N·m (52 ± 8 in-lb)

40.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Install the O-ring on the primary pulley speed sensor.

41. Install the primary pulley speed sensor on the transaxle assembly, and tighten the mounting bolt to the specified torque.
Tightening torque:
5.9 ± 1.0 N·m (52 ± 8 in-lb)

42.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Install the O-ring on the secondary pulley speed sensor.
43. Install the secondary pulley speed sensor on the transaxle assembly, and tighten the mounting bolt to the specified torque.
Tightening torque:
5.9 ± 1.0 N·m (52 ± 8 in-lb)

44.
cautionMeasure at two or more points to determine an average value.
The dimension (A) should meet the standard value.
Standard value (A): approximately 12.2 mm (0.48 inch)
45. Install the control cable bracket and breather hose on the transaxle assembly.
46. Install the harness bracket on the transaxle assembly.
47.
caution
  • Do not re-use the O-ring.
  • Apply transmission fluid when installing the O-ring.
  • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
Install the oil filler tube and transmission fluid dipstick on the transaxle assembly.
48.
cautionDo not re-use the drain plug gasket.
Install the drain plug and drain plug gasket on the transaxle assembly, and tighten to the specified torque.
Tightening torque:
35 ± 4 N·m (26 ± 2 ft-lb)