Continuously Variable Transaxle Overhaul - Except Lancer Evolution Mitsubishi Lancer Evolution X

TRANSAXLE MODELS

TRANSAXLE MODELS

Scheme 134

GENERAL SPECIFICATION

GENERAL SPECIFICATION

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

SNAP RING, SPACER AND THRUST WASHER FOR ADJUSTMENT

Snap rings (For adjustment of reverse brake)

SNAP RINGS SPECIFICATIONS (FOR ADJUSTMENT OF REVERSE BRAKE)

Needle bearings (For adjustment of total end play)

NEEDLE BEARINGS SPECIFICATIONS (FOR ADJUSTMENT OF TOTAL END PLAY)

Adjusting shims (For adjustment of differential preload)

ADJUSTING SHIMS SPECIFICATIONS (FOR ADJUSTMENT OF DIFFERENTIAL PRELOAD)

Adjusting shims (For adjustment of reduction gear preload)

ADJUSTING SHIMS SPECIFICATIONS (FOR ADJUSTMENT OF REDUCTION GEAR PRELOAD)

SEALANTS AND ADHESIVES

SEALANTS AND ADHESIVES

LUBRICANTS

LUBRICANTS SPECIFICATIONS

SPECIAL TOOLS

SPECIAL TOOLS TOOL 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 MB990779 Bar MB990779-01 Installation of differential side bearing outer race (converter housing side) 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 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 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)

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

DISASSEMBLY AND ASSEMBLY

Scheme 142

Scheme 143

Scheme 144

Required special tools

1. MB990590: Real axle shaft oil seal remover
2. MB992039: Slide hammer puller
3. MB992139: Spring compressor
4. MB990779: Bar
5. MB990780: Real axle shaft bushing installer
6. MB990932: Installer adapter
7. MB990938: Installer bar
8. MB992075: Handle
9. MB992141: Oil seal installer
10. MB992206: Oil seal installer
11. MB992140: Oil seal installer

DISASSEMBLY SERVICE POINT

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

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.
6. Remove the plug from the transaxle case.
7. Remove the O-ring from the plug.
8. Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.
9. Remove the primary pulley speed sensor from the transaxle case, and detach the O-ring from the sensor.
10. Remove the manual control lever from the manual shaft.
11. Remove the inhibitor switch from the 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.
13. Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.
14. Remove the transmission fluid filter from the transaxle case.
15. Remove the fastening bolts of converter housing. CONVERTER HOUSING BOLT SPECIFICATIONS Bolt symbol A B Shank length mm (in) 30 (1.18) 35 (1.38) Quantity 18 5 CAUTION: Be careful because adjusting shim of the drive sprocket may depart.
16. Remove the converter housing by tapping with a plastic hammer etc.
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: ø 61.949 - 61.979 mm (ø2.4389 - 2.4401 in)
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: ø67.949 - 67.979 mm (ø2.6752 - 2.6763 in) 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.
22. Remove the clip. CAUTION: When removing the pipe, be careful not to bend it.
23. Remove the pipe from the converter housing.
24. Remove the plug from the converter housing.
25. Remove the O-ring from the plug.
26. Remove the O-ring from the input shaft.
27. Remove the chain cover.
28. Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.
29. Remove the thrust washer from the oil pump cover.
30. Remove the snap ring from the oil pump.
31. Remove the reduction gear assembly from the transaxle case.
32. Remove the differential assembly from the transaxle case.
33. Remove the bracket.
34. Remove the oil guide.
35. Remove the baffle plate.
36. Remove the oil pump cover from the transaxle case.
37. Remove the seal rings from the oil pump cover.
38. Remove the needle bearing from the forward clutch assembly.
39. Remove the oil pan from the transaxle case.
40. Remove the magnet from the oil pan.
41. Remove the oil pan gasket from the transaxle case.
42. Remove the oil strainer OIL STRAINER BOLT SPECIFICATIONS Bolt symbol A B C Shank length mm (in) 12 (0.47) 44 (1.73) 12 (0.47) Quantity 1 1 1
43. Remove the O-ring from the oil strainer.
44. Remove the bracket from the control valve assembly.
45. Remove the manual valve lever.
46. Remove the control valve assembly from the transaxle case as follows: Insert pins etc. (ø3 mm (0.12 in)) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage. Remove fastening bolts of the control valve assembly. CONTROL VALVE ASSEMBLY BOLT SPECIFICATIONS Bolt symbol A B Shank length mm (in) 54 (2.13) 44 (1.73) Quantity 10 1 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.
47. Remove the bush from the control valve.
48. Remove the lip seal from the transaxle case.
49. Remove the valve body harness from the control valve.
50. Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)
51. Remove the O-ring from the oil pump fastening bolt.
52. Remove the lip seal from the transaxle case.
53. Using the special tools MB990590 and MB992039, remove outer race of the differential side bearing from the transaxle case.
54. 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: ø67.949 - 67.979 mm (ø2.6752 - 2.6763 in)
55. Remove the adjusting shim from the transaxle case.
56. Using the special tools MB990590 and MB992039, remove outer race of the reduction gear bearing from the transaxle case.
57. 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: ø61.949 - 61.979 mm (ø2.4389 - 2.4401 in)
58. Remove the adjusting shim from the transaxle case. CAUTION: When removing the side oil seal, be careful not to cause damage to the transaxle case.
59. Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.
60. Remove the detent spring from the transaxle case.
61. Remove the forward clutch assembly from the transaxle case.
62. Remove the needle bearing on forward clutch drum side from the sun gear.
63. Remove the sun gear from the planet carrier.
64. Remove the needle bearing on primary pulley side from the sun gear.
65. Remove the planet carrier from the transaxle case.
66. Remove the needle bearing from the planet carrier. 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.
67. Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case. 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.
68. Using the special tool MB992139, compress the return spring, and remove the snap ring from the transaxle case.
69. Remove the retaining plate and return spring assembly. CAUTION: Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.
70. Feed the air in the oil hole shown in the illustration, and remove the reverse brake piston from the transaxle case.

Scheme 209

ASSEMBLY SERVICE POINT

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

1. Install the reverse brake piston, while turning it, on the transaxle case.
2. Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly. CAUTION: When installing the retaining plate, align the tangs at positions A, B, C in the illustration.
3. Install the retaining plate on the transaxle case. CAUTION: Set the spring compressor right on top of the spring of spring retainer assembly. Do not reuse the snap ring. When installing the snap ring, make sure that the joint falls in the area A in the illustration.
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.
5. Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case. CAUTION: When conducting measurements, measure two or more places, and find the average value. Do not reuse the snap ring. When installing the snap ring, make sure that the joint falls in the area A in the illustration.
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»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution__service-specifications) ." Standard value: 1.2 - 1.5 mm (0.05 - 0.06 in) (For reverse brake end play) 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»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution) " for right direction.
8. Install the planet carrier on the reverse brake. 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»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution) " for right direction.
10. Install the sun gear on the planet carrier. 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»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution) " for right direction.
12. Install the forward clutch assembly on the transaxle case. CAUTION: When conducting measurements, measure two or more places, and find the average value.
13. Measure the total end play as follows: 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. Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transaxle case. 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 (0.010 - 0.022 in) (For total end play) 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»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution) " for right direction. CAUTION: Do not reuse the seal rings. Apply vaseline when installing the seal rings.
15. Install the seal rings on the oil pump cover. CAUTION: Do not reuse 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) CAUTION: Do not reuse the O-ring. Apply transmission fluid when installing the O-ring.
17. Install the O-ring on the plug.
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) CAUTION: Do not bend the pipe when attaching it.
19. Install the pipe on the converter housing.
20. Install the clip and tighten the bolt to the specified torque. Tightening torque: 6.9 N.m (61 in-lb) CAUTION: Do not reuse the outer race. Replace the outer race together with the inner race.
21. Using the special tools MB990779 and MB990780, Install the differential bearing outer race of differential side bearing on the converter housing. CAUTION: When adjusting the preload, apply transmission 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: Measure the distance M3 from the edge of transaxle case to the mounting surface of adjusting shim. Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing. 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. 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 Using the following expression, calculate thickness of the adjusting shim. Thickness of adjusting shim = M3 - M6 + preload Standard value: 0.17 - 0.23 mm (0.007 - 0.009 in) (For differential preload) CAUTION: Do not reuse the adjusting shim.
23. Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to " «SERVICE SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution__service-specifications) ." CAUTION: Do not reuse 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. CAUTION: Do not reuse 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. CAUTION: When adjusting the preload, apply transmission 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. Measure the distance M7 from the edge of transaxle case to the mounting surface of adjusting shim. 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. 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. 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 Using the following expression, calculate the thickness of adjusting shim. Thickness of adjusting shim = M7 - M10 + preload Standard value: 0.11 - 0.17 mm (0.004 - 0.006 in) (For reduction gear preload) CAUTION: Do not reuse the adjusting shim.
27. Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to " «SERVICE SPECIFICATIONS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/automatic-trans/#continuously-variable-transaxle-overhaul-except-lancer-evolution__service-specifications) ." CAUTION: Do not reuse 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. CAUTION: Do not reuse the lip seal. Apply transmission fluid when installing the lip seal.
29. Install the lip seal on the transaxle case. CAUTION: Do not reuse the O-rings. Apply transmission fluid when installing the O-rings.
30. Install the O-rings on the oil pump fastening bolts.
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) CAUTION: Do not reuse the snap ring.
32. Install the snap ring on the oil pump. CAUTION: Do not reuse the lip seal. Apply transmission fluid or vaseline when installing the lip seal.
33. Install the lip seal on the transaxle case.
34. Install the valve body harness on the control valve.
35. Install the control valve assembly on the transaxle case as follows: Insert pins etc. (ø3 mm (0.12 in)) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage. Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the illustration. CAUTION: Align the notch of pulley ratio linkage with the prong of pulley sensor. Slide the control valve assembly from the bottom, and install it on the transaxle case. CAUTION: Apply transmission fluid when attaching the bush. Install the bush on the control valve assembly. 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) CONTROL VALVE ASSEMBLY BOLTS SPECIFICATIONS Bolt symbol A B Shank length mm (in) 54 (2.13) 44 (1.73) Quantity 10 1
36. Install the manual valve lever and tighten the bolt to the specified torque. Tightening torque: 22.1 N.m (16 ft-lb)
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) CAUTION: Do not reuse the O-ring. Apply transmission fluid when installing the O-ring.
38. Install the O-ring on the oil strainer.
39. Install the oil strainer and tighten the bolt to the specified torque. Tightening torque: 7.9 N.m (70 in-lb) OIL STRAINER BOLT SPECIFICATIONS Bolt symbol A B C Shank length mm (in) 12 (0.47) 44 (1.73) 12 (0.47) Quantity 1 1 1 CAUTION: Do not reuse 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. 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) CAUTION: Do not reuse 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)
44. Install the oil pump cover on the transaxle case, and fix the fastening bolts temporarily.
45. Install the baffle plate, and fix the fastening bolts temporarily.
46. Install the oil guide and tighten the bolt to the specified torque. Tightening torque: 5.9 N.m (52 in-lb)
47. Install the bracket, and then tighten the fastening bolts of the bracket to the specified torque. Tightening torque: 26 N.m (19 ft-lb)
48. Tighten the fastening bolts of the oil pump cover and the baffle plate to the specified torque. Tightening torque: 19 N.m (14 ft-lb) 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.
49. Install the thrust washer on the oil pump cover. CAUTION: Pull the driven sprocket up softly to make sure it is securely attached.
50. Expand the snap ring, and install the driven sprocket, oil pump chain, and drive sprocket.
51. Install the chain cover, and tighten the fastening nuts to the specified torque. Tightening torque: 5.9 N.m (52 in-lb) CAUTION: Do not reuse the O-ring. Apply transmission fluid when installing the O-ring.
52. Install the O-ring on the input shaft.
53. Install the differential assembly on the transaxle case.
54. Install the reduction gear assembly on the transaxle case. CAUTION: Do not reuse the converter housing oil seal. Apply transmission 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). CAUTION: Do not reuse the converter housing side oil seal. Apply transmission 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. CAUTION: Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand. 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 SPECIFIED SEALANT - LOCTITE 509 L1 9 mm (0.35 in) L2 5 mm (0.20 in) L3 ø1.5 mm (0.059 in) L4 R8.5 mm (0.334 in) L5 R5 - 8 mm (0.20 - 0.31 in) L6 3 - 5 mm (0.12 - 0.20 in) L7 ø 17 mm (0.67 in) L8 3.5 mm (0.137 in)
58. Install the converter housing on the transaxle case, and tighten the fastening bolts to the specified torque. Tightening torque: 45 N.m (33 ft-lb) CONVERTER HOUSING BOLT SPECIFICATIONS Bolt symbol A B Shank length mm (in) 30 (1.18) 35 (1.38) Quantity 18 5 CAUTION: Do not reuse the snap ring.
59. Install the snap ring on the terminal body. CAUTION: Do not reuse the side oil seal. Apply transmission fluid when installing the side oil seal.
60. Using the special tools MB992140 and MB992075, install the side oil seal on the transaxle case. Depth from the case edge: within - 1.8 ± 0.5 mm (recessed). CAUTION: Do not reuse the inhibitor switch.
61. Install the inhibitor switch on the transaxle case as follows: Install the inhibitor switch on the transaxle case. Install the manual control lever on the manual shaft, and tighten the fastening nuts to the specified torque. Tightening torque: 17.2 N.m (13 ft-lb) Set the manual shaft at N position. Insert pins etc. (ø5 mm (0.20 in)) in adjusting holes in both inhibitor switch and manual control lever, and after alignment, tighten the fastening bolts to the specified torque. Tightening torque: 5.5 N.m (49 in-lb) CAUTION: Do not reuse the O-ring. Apply transmission fluid when installing the O-ring.
62. Install the oil ring on the primary pulley speed sensor.
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) CAUTION: Do not reuse the O-ring. Apply transmission fluid when installing the O-ring.
64. Install the O-ring on the secondary pulley speed sensor.
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) CAUTION: Apply transmission fluid or vaseline when installing the transmission fluid filter. Do not reuse the transmission fluid filter.
66. Install the transmission fluid filter on the transaxle case. CAUTION: Do not reuse the O-ring. Apply transmission 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 transmission fluid filter.
68. Install the transmission fluid cooler on the transaxle case, and tighten the fastening bolts to the specified torque. Tightening torque: 4.3 N.m (38 in-lb) CAUTION: Do not reuse the O-ring. Apply transmission fluid when installing the O-ring.
69. Install the O-ring on the plug.
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) 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 (0.63 in)
72. Install the oil filler tube and oil level gage on the transaxle. Tightening torque: 8.5 ± 3.5 N.m (75 ± 31 in-lb)
73. Install the control cable bracket and breather hose on the transaxle. Tightening torque: 25 ± 4 N.m (18 ± 2 ft-lb)
74. Install the harness bracket on the transaxle. Tightening torque: 25 ± 4 N.m (18 ± 2 ft-lb)
75. Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle. Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)

Scheme 249

<< A >> SNAP RING REMOVAL

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

Scheme 250

<< B >> INTERNAL GEAR REMOVAL

Remove the internal gear from the forward clutch drum.

Scheme 251

<< C >> SNAP RING REMOVAL

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

Scheme 252

<< D >> SNAP RING REMOVAL

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

Scheme 253

<< E >> SEAL RING REMOVAL

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

Scheme 254

>> A << SEAL RING INSTALLATION

Install the seal rings (small and big) on the input shaft.

>> B << SNAP RING INSTALLATION

Install the input shaft on the forward clutch drum, and attach the snap ring.

>> C << SNAP RING INSTALLATION

Install the snap ring on the forward clutch drum.

>> D << INTERNAL GEAR INSTALLATION

Install the internal gear on the forward clutch drum.

>> E << SNAP RING INSTALLATION

Install the snap ring on the forward clutch drum.

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.

Scheme 255

Required special tools

1. MB990810: Side bearing puller
2. MB990947: Lower arm push arbor
3. MD999566: Crow
4. MB990984: Mount bushing lower roll insulator arbor
5. MD998917: Bearing remover
6. MD998812: Installer Cap
7. MD998813: Installer-100
8. MD998819: Installer adapter (40)

<< A >> NUT REMOVAL

Remove the nut from the reduction gear sub-assembly.

Scheme 256

<< B >> REDUCTION GEAR BEARING REMOVAL

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.

Scheme 257

Scheme 258

<< C >> REDUCTION GEAR BEARING REMOVAL

Using the special tools MB990984 and MD998917, remove the outer race of reduction gear bearing (transaxle case side) from the reduction gear sub-assembly.

Scheme 259

>> A << REDUCTION GEAR BEARING INSTALLATION

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.

Scheme 260

>> B << REDUCTION GEAR BEARING INSTALLATION

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.

Scheme 261

>> C << NUT INSTALLATION

Install the nut on the reduction gear sub-assembly to the specified torque.

Tightening torque: 250 N.m (184 ft-lb)

Scheme 262

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

1. Converter housing side: ø30.008 - 30.029 mm (1.1814 - 1.1822 in)
2. Transaxle case side: ø30.008 - 30.029 mm (1.1814 - 1.1822 in)

ASSEMBLY

Scheme 263

Required special tools

1. MD998812: Installer Cap
2. MD998813: Installer-100
3. MD998819: Installer adapter (40)

>> A << REDUCTION PINION GEAR/IDLER GEAR INSTALLATION

CENTER BOSS PORTION REFERENCE

Scheme 264

Using the special tools MD998812, MD998813 and MD998819, attach the idler gear to the reduction pinion gear.

Scheme 265

Scheme 266

Required special tools

1. MB990810: Side bearing puller
2. MD998812: Installer Cap
3. MD998813: Installer-100
4. MD998823: Installer adapter (48)

<< 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.

Scheme 267

<< B >> DIFFERENTIAL SIDE BEARING REMOVAL

Using the special tools MB990810, remove the inner race of differential side bearing (converter housing side) from the differential sub-assembly.

Scheme 268

>> A << DIFFERENTIAL SIDE BEARING INSTALLATION

Using the special tools MD998812, MD998813 and MB998823, install the inner race of reduction gear bearing (converter housing side) on the reduction gear sub-assembly.

Scheme 269

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.

Scheme 270

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

1. Converter housing side: ø 40.026 - 40.051 mm (1.5758 - 1.5768 in)
2. Transaxle case side: ø40.026 - 40.051 mm (1.5758 - 1.5768 in)

Scheme 271

>> A << DIFFERENTIAL CASE/FINAL GEAR INSTALLATION

FINAL GEAR EDGE TO FLANGE DISTANCE

Scheme 272

Install the final gear on the differential case, and tighten the fastening bolts to the specified torque.

Tightening torque: 130 N.m (96 ft-lb)

Scheme 273

See also:
• SERVICE SPECIFICATIONS
• IDENTIFICATION OF NEEDLE BEARINGS