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Continuously Variable Automatic Transmission (Cvt): Maintenance Honda Insight ZE1

Automatic Trans 73 illustrations ~4824 words

CVT Fluid Level Check

Note. Keep all foreign particles out of the transmission.

Scheme 379

Scheme 379: CVT Fluid Level Check

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Scheme 381
  1. Warm up the engine to normal operating temperature (the radiator fan comes on).
  2. Park the vehicle on level ground, and turn the engine off. NOTE: Check the fluid level within 60-90 seconds after turning the engine off.
  3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth.
  4. Insert the dipstick back into the transmission.
  5. Remove the dipstick and check the fluid level in 60-90 seconds after the engines is turned off. It should be between the upper mark (A) and lower mark (B) on the Hot portion of the gauge (C). Do not check the fluid level when the engine is cold. NOTE: Some dipstick do not have HOT and COLD printed on them.
  6. If the level is below the lower mark, check for fluid leaks at the transmission, hose and line joints, and cooler lines.
  7. if the level exceeds the upper mark (A), drain the fluid for proper level.
  8. Pour the recommended fluid into the opening of the dipstick pipe (A) to bring it to the upper mark. Always use Honda Continuously Variable Transmission Fluid (CVT Fluid). Using a non-Honda CVT Fluid can affect shift quality.
  9. Insert the dipstick back into the transmission.

Tool Maintenance

Follow these instructions to keep the ATF cooler cleaner working properly

Scheme 382

Scheme 382: Tool Maintenance
  1. Replace the two magnetic non bypass spin-on filters once a year or when you notice a restriction in the CVTF flow.
  2. Check the level and condition of the fluid in the tank before each use.
  3. Replace the CVTF in the tank when it looks dark or dirty.

Scheme 383

Scheme 383: ATF Cooler Hose Replacement
  1. Lubricate hose and line joints with CVTF, then install the ATF cooler hoses (A) to the ATF cooler lines (B).
  2. Secure the ATF cooler hoses with the clips (C) in the position shown.

Scheme 384

Scheme 384: Shift Lever Removal

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Scheme 386
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Shift the transmission into the R position.
  3. Remove the nut securing the shift cable end, then separate the cable end from the shift lever.
  4. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the projection (C) on the socket holder faces direction to remove. Then slide the holder to remove the shift cable from the shift cable bracket base (D). Do not remove the shift cable by twisting the shift cable guide (E).
  5. Disconnect the shift lock solenoid connector (A) and park pin switch/indicator lamp connector (B).
  6. Remove the shift lever assembly.

Scheme 387

Scheme 387: Shift Lever Installation

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Scheme 392
  1. Install the shift lever assembly.
  2. Turn the ignition switch ON (II), and verify that the R position indicator comes on.
  3. If necessary, push the shift cable (A) until it stops, then release it. Pull the shift cable back one step so that the shift position is in the R position. Do not push and pull the shift cable by holding the shift cable guide (B).
  4. Turn the ignition switch OFF.
  5. Insert a 6.0 mm (0.24 in.) pin (A) through the positioning hole (B) on the shift lever bracket base and into the positioning hole (C) on the shift lever. The shift lever is secured in the R position.
  6. Align the socket holder (A) on the shift cable (B) with the slot in the bracket base (C), then slide the holder into the base. Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square fitting (G) at the bottom of the stud. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (H).
  7. Verify that the shift cable end (A) is properly installed on the mounting stud (B).
  8. If improperly installed, remove the shift cable from the shift cable bracket base, and reinstall the shift cable. Do not install the shift cable end on the mounting stud while the shift cable is on the shift cable bracket base.
  9. Install and tighten the nut.
  10. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.
  11. Connect the shift lock solenoid connector and park pin switch/indicator lamp connector.
  12. Move the shift lever to each position, and verify that the A/T gear position indicator follows the transmission range switch.
  13. Push the shift lock release, and verify that the shift lever releases.
  14. Reinstall the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).

Scheme 393

Scheme 393: Shift Lever Disassembly/Reassembly

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Scheme 394: Shift Cable Replacement

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Scheme 404
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Shift the transmission into the R position.
  3. Remove the nut securing the shift cable end, then separate the cable end from the shift lever.
  4. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the projection (C) on the socket holder faces direction to remove. Then slide the holder to remove the shift cable from the shift cable bracket base (D).
  5. Remove the shift cable bracket (A) in the cabin, under the dash.
  6. Remove the air cleaner housing.
  7. Loosen the locknut (A) on the shift cable (B).
  8. Remove the spring clip (C) and washers (D), and separate the shift cable from the control lever (E) and the shift cable bracket (F).
  9. Remove the grommet, and pull the shift cable out.
  10. Insert the new shift cable through the grommet hole, then install the grommet.
  11. Verify that the transmission is in the R position on the control lever.
  12. Install the shift cable end (A) on the control lever (B). Install the shift cable on its bracket (C), and tighten the locknut (D). Do not bend the shift cable excessively.
  13. Install the plastic washer (E), then the steel washer (F), and install the spring clip (G) in the direction shown.
  14. Turn the ignition switch ON (II), and verify that the R position indicator comes on.
  15. If necessary, push the shift cable (A) until it stops, then release it. Pull the shift cable back one step so that the shift position is in the R position. Do not push and pull the shift cable by holding the shift cable guide (B).
  16. Turn the ignition switch OFF.
  17. Insert a 6.0 mm (0.24 in.) pin (A) through the positioning hole (B) on the shift lever bracket base and into the positioning hole (C) on the shift lever. The shift lever is secured in the R position.
  18. Align the socket holder (A) on the shift cable (B) with the slot in the bracket base (C), then slide the holder into the base. Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square fitting (G) at the bottom of the stud. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (H).
  19. Verify that the shift cable end (A) is properly installed on the mounting stud (B).
  20. If improperly installed, remove the shift cable from the shift cable bracket base, and reinstall the shift cable. Do not install the shift cable end on the mounting stud while the shift cable is on the shift cable bracket base.
  21. Install and tighten the nut.
  22. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.
  23. Move the shift lever to each position, and verify that the A/T gear position indicator follows the transmission range switch.
  24. Allow the wheels to rotate freely.
  25. Start the engine, and check the shift lever operation in all gears.
  26. Reinstall the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).

Scheme 405

Scheme 405: Shift Cable Adjustment

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Scheme 411
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Shift the transmission into the R position.
  3. Remove the nut securing the shift cable end, then separate the cable end from the shift lever.
  4. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the projection (C) on the socket holder faces direction to remove. Then slide the holder to remove the shift cable from the shift cable bracket base (D). Do not remove the shift cable by twisting the shift cable guide (E).
  5. Push the shift cable (A) until it stops, then release it. Pull the shift cable back one step so that the shift position is in the R position. Do not push and pull the shift cable by holding the shift cable guide (B).
  6. Turn the ignition switch ON (II), and verify that the R position indicator light comes on.
  7. Turn the ignition switch OFF.
  8. Insert a 6.0 mm (0.24 in.) pin (A) through the positioning hole (B) on the shift lever bracket base and into the positioning hole (C) on the shift lever. The shift lever is secured in the R position.
  9. Align the socket holder (A) on the shift cable (B) with the slot in the bracket base (C), then slide the holder into the base. Install the shift cable end (D) over the mounting stud (E) by aligning its square hole (F) with the square fitting (G) at the bottom of the stud. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (H).
  10. Verify that the shift cable end (A) is properly installed on the mounting stud (B).
  11. If improperly installed, remove the shift cable from the shift cable bracket base, and reinstall the shift cable. Do not install the shift cable end on the mounting stud while the shift cable is on the shift cable bracket base.
  12. Install and tighten the nut.
  13. Remove the 6.0 mm (0.24 in.) pin that was installed to hold the shift lever.
  14. Move the shift lever to each position, and verify that the A/T gear position indicator follows the transmission range switch.
  15. Allow the wheels to rotate freely.
  16. Start the engine, and check the shift lever operation in all gears.
  17. Reinstall the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).

Scheme 412

Scheme 412: Component Location Index

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Scheme 413: Circuit Diagram

Scheme 414

Scheme 414: Indicator Input Test

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Scheme 415
  1. If the D indicator or MIL has been reported on, check for a DTC, and repair the system as indicated by the DTC.
  2. If the D indicator does not come on, and the A/T gear position indicator light does not come on, remove the gauge assembly from the dashboard, then disconnect the gauge assembly connectors B (22P) and C (10P).
  3. Inspect the connectors and connector terminals to be sure they are making good contact.
  4. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system.
  5. Shift to the P position, and check for continuity between C1 terminal (BLU/BLK) and ground. There should be continuity in the P position and no continuity in any other shift lever position. If the test results are different, check for a faulty transmission range switch or an open in the wire.
  6. Turn the ignition switch ON (II), and shift to the R position by pressing the brake pedal. Check for voltage between C2 terminal (WHT) and ground. There should be 0 V in the R position, and about 5 V in any other position. If the test results are different, check for a faulty transmission range switch or an open in the wire.
  7. Shift to the N position, and check for continuity between C3 terminal (RED/BLK) and ground. There should be continuity in the N position and no continuity in any other position. If the test results are different, check for a faulty transmission range switch or an open in the wire.
  8. Shift to the D position, and check for voltage between C10 terminal (GRN/BLK) and ground. There should be battery voltage in the D position, and 5 V in any other position. If the test results are different, check for faulty transmission range switch and TCM, or an open in the wire.
  9. Shift to the L position, and check for voltage between C4 terminal (BLU) and ground. There should be 0 V in the L position, and about 5 V in any other position. If the test results are different, check for a faulty transmission range switch or an open in the wire.
  10. Shift to the D position and check for voltage between B1 terminal (LT GRN) and ground. There should be 10 V while pressing the S mode switch and 0 V when the switch is released. If the test results are different, check for a faulty mode switch and TCM, or an open in the wire.
  11. Check for voltage between the B8 terminal (YEL) and ground. There should be battery voltage. If the test result is different, check for a blown No. 6 (7.5 A) fuse in the under-dash fuse/relay box or an open in the wire.
  12. Check for continuity between the B16 terminal (BRN) and ground. There should be continuity under all conditions. If the test result is different, check for a poor ground (G401) or an open in the wire.
  13. If the input test found nothing wrong, but the indicator is faulty, replace the printed circuit board.

Scheme 416

Scheme 416: Transmission Range Switch Test
  1. Remove the air cleaner housing.
  2. Remove the transmission range switch connector from the connector bracket, then disconnect it. Connector Terminal Specifications CONNECTOR TERMINAL SPECIFICATIONS Terminal signal 1 GND 2 L 3 D 4 N 5 R 6 P
  3. Check for continuity between terminals at the connector. There should be continuity between terminals listed for each switch position. In the P position: Between terminals No. 1 and No. 6 In the R position: Between terminals No. 1 and No. 5 In the N position: Between terminals No. 1 and No. 4 In the D position: Between terminals No. 1 and No. 3 In the L position: Between terminals No. 1 and No. 2
  4. If there is no continuity between any terminals, adjust the transmission range switch. If the transmission range switch adjustment is OK, replace the transmission range switch.

Scheme 417

Scheme 417: Transmission Range Switch Replacement

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Scheme 420
  1. Remove the air cleaner housing.
  2. Remove the transmission range switch connector from the connector bracket (A), then disconnect it.
  3. Remove the transmission range switch (B).
  4. Shift the transmission into the N position by turning the control lever (A). Do not squeeze the end (B) of the control shaft tips together when shifting. If the tips are squeezed together it will cause a faulty signal or position due to the play between the control shaft and the switch.
  5. Set the transmission range switch to the N position. The switch clicks in the N position.
  6. Install the transmission range switch gently over the control shaft, then tighten the bolts. Do not move the switch when tightening the bolts.
  7. Connect the connector securely, then install it on its bracket.
  8. Turn the ignition switch ON (II). Move the shift lever through all positions, and check the transmission range switch synchronization with the A/T gear position indicator.
  9. Check that the engine can start in the P and N positions, and will not start in any other shift lever position.
  10. Check that the back-up lights come on when the shift lever is in the R position.
  11. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation.

Scheme 421

Scheme 421: Component Location Index

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Scheme 422: Circuit Diagram

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Scheme 423: Shift Lock System Circuit Troubleshooting

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  1. Press the brake pedal. Are the brake lights ON? YES -Go to step 2. NO -Repair faulty brake light circuit.
  2. Turn the ignition switch ON (II), and shift to the P position.
  3. Press the brake pedal, and release the accelerator.
  4. Measure the voltage between ECM connector terminal A28 and body ground. Is there battery voltage? YES -Check for an open in the wire between ECM connector terminal A28 and the gauge assembly interlock control system circuit, and check for loose terminal fit in the gauge assembly connectors. If necessary, substitute a known-good gauge assembly and recheck. NO -Go to step 5.
  5. Turn the ignition switch OFF.
  6. Disconnect TCM connectors A (26P) and B (22P).
  7. Press the brake pedal, and measure the voltage between TCM connector terminals B12 and A4. Is there battery voltage while pressing the brake pedal? YES -Release the brake pedal, and go to step 8. NO -Repair an open in the wire between TCM connector terminal B12 and the brake pedal position switch.
  8. Reconnect TCM connectors A (26P) and B (22P).
  9. Turn the ignition switch ON (II).
  10. Measure the voltage between TCM connector terminals B4 and A4. Is there about 0.5 V? YES -Go to step 15 . NO -Go to step 11.
  11. Turn the ignition switch OFF.
  12. Disconnect the throttle position (TP) sensor connector.
  13. Turn the ignition switch ON (II).
  14. Measure the voltage between TP sensor connector terminals No. 1 and No. 3. Is there about 5 V? YES -Check for an open or a short in the wire between TCM connector terminal B4 and the TP sensor. If the wire is OK, replace the TP sensor. NO -Go to step 15.
  15. Turn the ignition switch OFF.
  16. Disconnect ECM connector B (25P).
  17. Check for continuity between TP sensor connector terminal No. 3 and body ground. Is there continuity? YES -Check for a short to ground in the wire between TP sensor connector terminal No. 3 and ground. If the wire is OK, replace the TP sensor. NO -Go to step 18.
  18. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  19. Disconnect the shift lock solenoid connector.
  20. Turn the ignition switch ON (II).
  21. Press the brake pedal, and check the voltage between shift solenoid connector terminals. Is there battery voltage? YES -Go to step 21. NO -Check for an open or short in the wires between the shift lock solenoid connector and the gauge assembly. If wires are OK, check for a loose terminal fit in the gauge assembly connector. If necessary, substitute a known-good gauge assembly and recheck.
  22. Connect the battery positive terminal to shift lock solenoid connector terminal No. 1, and connect the battery negative terminal to connector terminal No. 2. Do not connect the battery positive terminal to connector terminal No. 2 or you will damage the diode inside the shift lock solenoid.
  23. Check that the shift lock solenoid operates. Does the shift lock solenoid operate properly? YES -Check for loose gauge assembly connectors. If necessary, substitute a known-good gauge assembly and recheck. NO -Replace the shift lock solenoid.

Scheme 430

Scheme 430: Key Interlock System Circuit Troubleshooting

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  1. Disconnect steering lock assembly 5P connector.
  2. Turn the ignition switch to ACC (I) or ON (II).
  3. Connect the battery positive terminal to steering lock assembly 5P connector terminal No. 4, and connect the battery negative terminal to connector terminal No. 5.
  4. Check the key interlock solenoid operation. A clicking sound should be heard when pushing the ignition key in, and you should not be able to turn it to OFF (0) position. Does the key interlock solenoid operate properly? YES -Go to step 5. NO -Faulty key interlock solenoid/switch. Replace the ignition key cylinder/steering lock assembly.
  5. Check for continuity between steering lock assembly 5P connector terminals No. 3 and No. 4. Is there continuity while pushing the key in, and no continuity when the key is released? YES -Go to step 6. NO -Replace the ignition key cylinder/steering lock assembly.
  6. Measure the voltage between steering lock assembly 5P connector terminal No. 4 and body ground. Is there battery voltage? YES -Go to step 7. NO -Check for a blown No. 6 (10 A) fuse in the under-hood fuse/relay box. If the fuse is OK, repair open or short in the wire between steering lock assembly 5P connector terminal No. 4 and the under-hood fuse/relay box.
  7. Measure the voltage between steering lock assembly 5P connector terminals No. 3 and No. 4. (shift lever must be in the P position) Is there battery voltage when the shift lever is in the P position, and 0 V when the shift lever is out of the P position? YES -Go to step 8. NO -Check for an open or a short in the wire between steering lock assembly connector terminal No. 3 and the gauge assembly. If the wire is OK, check loose terminal fit in the gauge assembly connectors. If necessary, substitute a known-good gauge assembly and recheck.
  8. Shift the shift lever back to the P position, and measure the voltage between steering lock assembly connector terminals No. 4 and No. 5. Is there battery voltage when the shift lever is in the P position, and 0 V when the shift lever is out of the P position? YES -Check for loose terminal fit in the gauge assembly connectors, substitute a known-good gauge assembly and recheck. NO -Go to step 9.
  9. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  10. Disconnect the park pin switch connector.
  11. Check for continuity between park pin switch connector terminals No. 3 and No. 4 while you move the shift lever in and out of the P position. Is there continuity with the shift lever in the P position, and no continuity with the shift lever is out of the P position? YES -Repair an open or short in the wire between steering lock assembly connector terminal No. 5 and park pin switch connector, and repair open in the wire between the park pin switch connector and ground. NO -Replace the park pin switch.

Scheme 436

Scheme 436: Shift Lock Solenoid Test
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Disconnect the shift lock solenoid connector.
  3. Connect the battery positive terminal to shift lock solenoid connector terminal No. 1, and connect the battery negative terminal to connector terminal No. 2. Do not connect the battery positive terminal to connector terminal No. 2 or you will damage the diode inside the shift lock solenoid.
  4. Check that the shift lever can be moved from the P position. Release the battery terminals from the solenoid connector. Move the shift lever back to the P position, and check that it locks securely.
  5. Check that the shift lock releases when the shift lock release is pushed, and check that it locks when the shift lock release is released.
  6. If the shift lock solenoid does not work properly, replace it.

Scheme 437

Scheme 437: Shift Lock Solenoid Replacement
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Disconnect the shift lock solenoid connector.
  3. Pry the shift lock solenoid clamp (A) with a screwdriver, and remove it.
  4. Remove the shift lock solenoid.
  5. Install the shift lock solenoid plunger (B) and plunger spring (C) in the new shift lock solenoid (D).
  6. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger with the tip of the shift lock stop (E).
  7. Secure the shift lock solenoid with the solenoid clamp.
  8. Connect the shift lock solenoid connector.
  9. Install the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).

Scheme 438

Scheme 438: Park Pin Switch Test
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Disconnect the park pin switch connector.
  3. Shift to the P position, then check for continuity between connector terminals No. 3 and No. 4. There should be continuity.
  4. If there is no continuity between connector terminals No. 3 and No. 4, replace the parking pin switch.
  5. Shift out of the P position, and check for continuity between connector terminals No. 3 and No. 4. There should be no continuity.
  6. If there is continuity between connector terminals No. 3 and No. 4, replace the park pin switch.

Scheme 439

Scheme 439: Park Pin Switch Replacement
  1. Remove the front console (see «FRONT CONSOLE REMOVAL/INSTALLATION»(ref-219314-S17903802192006021300000) ).
  2. Remove the A/T gear position indicator panel light, and remove the bulb (A) from the socket (B).
  3. Separate the A/T gear position indicator panel from the shift lever bracket base (C).
  4. Disconnect the park pin switch connector (D), and remove it from the bracket base.
  5. Remove the park pin switch clamp (E) and the park pin switch (F).
  6. Install the new park pin switch in the shift lever bracket base, and install the park pin switch clamp to secure it.
  7. Install the removed parts in the reverse order of removal.

Scheme 440

Scheme 440: ATF Pan, ATF Strainer, and Lower Valve Body Assembly Removal

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Scheme 441
  1. Remove the bolt (A) securing the ATF cooler inlet line (B).
  2. Remove the ATF pan (C) (15 bolts).
  3. Remove the ATF strainer (D).
  4. Remove the lower valve body assembly (E) mounting bolts.
  5. Remove the bolt (F) securing the solenoid harness connector (G) with holding the lower valve body assembly, and remove the connector and valve body assembly.
  6. Clean the inlet opening (A) of the ATF strainer (B) thoroughly with compressed air, then check that it is in good condition, and that the inlet opening is not clogged.
  7. Test the ATF strainer by pouring clean CVT Fluid through the inlet opening, and replace it if it is clogged or damaged.

Scheme 442

Scheme 442: 2004-2006 Models
  1. Disconnect the CVT start clutch pressure control valve connector (A).
  2. Remove the CVT start clutch pressure control valve (B).
  3. Check that the filter (C) is in good condition, replace it if it is clogged or damaged.
  4. Install the CVT start clutch pressure control valve with the dowel pins (D) and separator plate (E) on the lower valve body (F).
  5. Connect the CVT start clutch pressure control valve connector.

Scheme 443

Scheme 443: 2004-2006 Models
  1. Remove the solenoid harness clamp (A).
  2. Disconnect the CVT drive pulley pressure control valve connector (B).
  3. Remove the seven bolts, and remove the CVT drive pulley pressure control valve (C). The CVT start clutch pressure control valve (D) also be removed, it uses those four bolts.
  4. Check that the filter (E) is in good condition, replace it if it is clogged or damaged.
  5. Install the CVT drive pulley pressure control valve with the dowel pins (F) and separator plate (G), and CVT start clutch pressure control valve with the dowel pins (H) and separator plate (I) on the lower valve body (J).
  6. Connect the CVT drive pulley pressure control valve connector.
  7. Install the solenoid harness clamp.

Scheme 444

Scheme 444: 2004-2006 Models
  1. Disconnect the CVT driven pulley pressure control valve connector (A) and the inhibitor solenoid connector (B).
  2. Remove the CVT driven pulley pressure control valve (C), and remove the inhibitor solenoid (D) from the CVT driven pulley pressure control valve.
  3. Check that the filter (E) is in good condition, replace it if it is clogged or damaged.
  4. Replace the O-rings (F) on the inhibitor solenoid, if necessary.
  5. Install the inhibitor solenoid on the new CVT driven pulley pressure control valve.
  6. Install the CVT driven pulley pressure control valve with the dowel pins (G) and separator plate (H) on the lower valve body (I).
  7. Connect the CVT driven pulley pressure control valve connector and the inhibitor solenoid connector.

Scheme 445

Scheme 445: 2004-2006 Models
  1. Disconnect the inhibitor solenoid connector (A).
  2. Remove the inhibitor solenoid (B).
  3. Install the inhibitor solenoid on the CVT driven pulley pressure control valve.
  4. Connect the inhibitor solenoid connector.

Scheme 446

Scheme 446: Exploded View

Special Tools Required

Start clutch remover 07TAE-P4VA120

Note. Refer to the EXPLODED VIEW as needed during the following procedure.

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Scheme 449
  1. Remove the flywheel housing (19 bolts).
  2. Remove the differential assembly.
  3. Remove the snap ring and thrust shim on the ATF pump drive sprocket, then remove the bolts securing the ATF pump drive sprocket.
  4. Remove the ATF pump drive chain, then remove the ATF pump drive sprocket, sprocket hub, thrust washers and thrust needle bearing from the input shaft.
  5. Remove the park pawl shaft, park pawl spring then and park pawl.
  6. Remove the snap ring securing the start clutch, and remove the cotter retainer and the cotters.
  7. Set the special tool on the start clutch (A), then attach the pawl (B) of the special tool to the park gear (C) securely. Do not place the pawl of the special tool on the start clutch guide. If the pawl contacts the start clutch guide, the clutch guide may be damaged. Do not allow dust or other foreign particles to enter into the driven pulley shaft.
  8. Remove the start clutch (A) and the secondary drive gear assembly (B) with the special tool.
  9. Remove the secondary gear shaft.
  10. Remove the secondary drive gear from the start clutch.
  11. Remove the sealing ring (A) from the secondary drive gear (B), and clean it; the ring will be reinstalled on the new secondary drive gear when assembling the transmission.

Scheme 450

Scheme 450: ATF Pump Replacement

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Scheme 451
  1. Remove the ATF pump drive sprocket mounting bolts, then remove the ATF pump drive chain.
  2. Expand the snap ring under the ATF pump driven sprocket, and remove the ATF pump driven sprocket from the ATF pump.
  3. Remove the ATF pump from the transmission housing.
  4. Install the 22 x 10 mm ATF pipe (A) and the 18 x 10 mm ATF pipe (B) in the transmission housing, then install the new O-rings (C) over the ATF pipes.
  5. Install the new ATF pump body (D) with the dowel pins (E). Do not pinch the O-rings.
  6. Install the snap ring (F) in the snap ring groove.
  7. Install the ATF pump driven sprocket.
  8. Install the ATF pump drive chain and ATF pump drive sprocket.