Continuously Variable Transmission (TR690) (Service Information): Removal & Installation Subaru Forester SJ

REPLACEMENT

Scheme 729

Scheme 730

Scheme 731

1. Lift up the vehicle, and remove the CVTF drain plug.
2. Check the CVTF condition. < Ref. to «CONDITION CHECK»(ref-662126-S13407147872014101300000) , CVTF. >
3. Install the CVTF drain plug and gasket. NOTE: Use a new gasket. Tightening torque: 39.2 N.m (4.0 kgf-m, 28.9 ft-lb)
4. Remove the filler plug.
5. Fill in the specified fluid through the filler plug. Specified fluid: < Ref. to «HYDRAULIC CONTROL AND LUBRICATION»(ref-662126-S39046973862014101300000) , SPECIFICATION, General Description. > Capacity: Fill with the same amount of CVTF as drained.
6. Temporarily tighten the filler plug.
7. Idle the engine to raise CVTF temperature to 35 - 45°C (95 - 113°F) on Subaru Select Monitor.
8. Operate the select lever in P --> R --> N --> D and D --> N --> R --> P to circulate CVTF with the engine idling. CAUTION: Pay special attention to the following operations as the engine is at idle.
9. Place the select lever in "P" range. Then lift up the vehicle with the engine at idle to adjust the CVTF level and check for leakage. < Ref. to «ADJUSTMENT»(ref-662126-S25388033382014101300000) , CVTF. >
10. Replace with a new gasket, and attach the filler plug. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

Scheme 732

Scheme 733

1. Lift up the vehicle.
2. Remove the differential gear oil drain plug using TORX® bit T70. Drain differential gear oil.
3. Install the differential gear oil drain plug using TORX® bit T70. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
4. Pour gear oil from the charge pipe. Recommended gear oil: < Ref. to «RECOMMENDED GEAR OIL»(ref-662126-S21960492982014101300000) , SPECIFICATION, General Description. > Gear oil capacity: < Ref. to «RECOMMENDED GEAR OIL»(ref-662126-S21960492982014101300000) , SPECIFICATION, General Description. >
5. Adjust the level of differential gear oil. < Ref. to «ADJUSTMENT»(ref-662126-S27211689372014101300000) , Differential Gear Oil. >

1. Lift up the vehicle.
2. Clean the transmission exterior.
3. Remove the center exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S02884487272014101300000) , Center Exhaust Pipe. >
4. Remove the center exhaust cover.
5. Remove the propeller shaft. < Ref. to «REMOVAL»(ref-662131-S39075214892014101300000) , Propeller Shaft. >
6. Using a screwdriver or ST, remove the oil seal trying not to damage the extension case. ST 398527700 PULLER ASSY
7. Using the ST, install the oil seal. NOTE: Use a new oil seal. ST 498057300 OIL SEAL DRIFT
8. Install the propeller shaft. < Ref. to «INSTALLATION»(ref-662131-S04185762852014101300000) , Propeller Shaft. >
9. Install the center exhaust cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
10. Install the center exhaust pipe. < Ref. to «INSTALLATION»(ref-662147-S36466400162014101300000) , Center Exhaust Pipe. >
11. Adjust the CVTF level and check there is no leakage. < Ref. to «ADJUSTMENT»(ref-662126-S25388033382014101300000) , CVTF. >

Scheme 734

Scheme 735

1. Remove the front wheels.
2. Remove the center exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S02884487272014101300000) , Center Exhaust Pipe. >
3. Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil.
4. Tighten the differential gear oil drain plug. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
5. Remove the stabilizer link. < Ref. to «REMOVAL»(ref-662129-S15383380912014101300000) , Front Stabilizer. >
6. Disconnect the lower arm ball joint and housing.
7. Pull out the front drive shaft from transmission using a crowbar. NOTE: Place cloth between the tire lever or bar and the transmission in order to avoid damaging the transmission side retainer.
8. Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot. NOTE: Before pulling RH front drive shaft from transmission, turn the steering wheel to left hand full lock. Before pulling LH front drive shaft from transmission, turn the steering wheel to right hand full lock.
9. Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc.
10. Using the ST, install the differential side retainer oil seal by lightly tapping with a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Apply differential gear oil to the lip surface, so that the oil seal lip is not deformed. Apply differential gear oil to the press-fitting surface of oil seal and the differential side retainer. Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right.
11. Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
12. Replace the circlip of the drive shaft with a new part.
13. Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
14. Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
15. Insert the ball joint into housing and secure with bolt. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) CAUTION: Do not apply grease to the tapered portion of ball stud. Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
16. Install the stabilizer link. Tightening torque: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
17. Install the center exhaust pipe. < Ref. to «INSTALLATION»(ref-662147-S36466400162014101300000) , Center Exhaust Pipe. >
18. Lower the vehicle.
19. Refill differential gear oil from the charge pipe. < Ref. to «DIFFERENTIAL GEAR OIL»(ref-662126-S05850001972014101300000) . >
20. Adjust the differential gear oil level, and check for leakage. < Ref. to «ADJUSTMENT»(ref-662126-S27211689372014101300000) , Differential Gear Oil. >
21. Install the front wheels.

REMOVAL

Scheme 736

Scheme 737

1. Remove the transmission from the vehicle. < Ref. to «REMOVAL»(ref-662126-S27261880402014101300000) , Automatic Transmission Assembly. >
2. Remove the transmission cover on the transmission upper side.
3. Remove the secondary speed sensor harness connector.
4. Remove the secondary speed sensor.

INSTALLATION

Install in the reverse order of removal.

Note. Use new O-rings. Apply CVTF to the O-ring.

Tightening torque

Secondary speed sensor

5 N.m (0.5 kgf-m, 3.7 ft-lb)

Transmission cover

8 N.m (0.8 kgf-m, 5.9 ft-lb)

Scheme 738

Scheme 739

1. Set the probe of oscilloscope to TCM harness connector. Connector & terminal (B54) No. 7 (+) - No. 14 (-)
2. Start and warm up the engine.
3. Check the waveform of secondary speed sensor with engine idling. NOTE: The waveform cycle changes as the speed changes.

Scheme 740

1. Disconnect the ground cable from battery.
2. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. >
3. Clean the transmission exterior.
4. Remove the primary speed sensor harness connector.
5. Remove the primary speed sensor and the spacer.

Install in the reverse order of removal.

Note. Use new O-rings. Apply CVTF to the O-ring.

Tightening torque

Primary speed sensor

5 N.m (0.5 kgf-m, 3.7 ft-lb)

Scheme 741

Scheme 742

1. Set the probe of oscilloscope to TCM harness connector. Connector & terminal (B54) No. 6 (+) - No. 14 (-)
2. Start and warm up the engine.
3. Check the waveform of primary speed sensor with engine idling. NOTE: The waveform cycle changes as the speed changes.

Scheme 743

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Clean the transmission exterior.
4. Remove the front wheel speed sensor harness connector.
5. Remove the front wheel speed sensor.

Install in the reverse order of removal.

Note. Use new O-rings. Apply CVTF to the O-ring.

Tightening torque

5 N.m (0.5 kgf-m, 3.7 ft-lb)

Scheme 744

Scheme 745

1. Set the probe of oscilloscope to TCM harness connector. Connector & terminal (B54) No. 20 (+) - No. 14 (-)
2. Lift up the vehicle and raise the vehicle speed up to 20 km/h (12 MPH).
3. Check the waveform of front wheel speed sensor when vehicle speed is at 20 km/h (12 MPH). NOTE: The waveform cycle changes as the speed changes.

Scheme 746

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Clean the transmission exterior.
4. Remove the secondary pressure sensor harness connector.
5. Remove the secondary pressure sensor. NOTE: Use Ko-ken 3/8 12-point 27 mm (manufacturer product No. 3305M-27) deep socket.

Install in the reverse order of removal.

Note. Use new O-rings.

Tightening torque

39 N.m (4.0 kgf-m, 28.8 ft-lb)

Note. The control valve body is replaced as an assembly only, because it is a non-disassembly part.

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Clean the transmission exterior.
4. Remove the CVTF drain plug to drain CVTF.
5. Install the CVTF drain plug. NOTE: Use a new gasket. Tightening torque: 39.2 N.m (4.0 kgf-m, 28.9 ft-lb)
6. Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.
7. Remove the magnet.
8. Disconnect the control valve harness connector.
9. Remove the oil strainer.
10. Remove the control valve body. CAUTION: Do not let the manual valve drop off.
11. Remove the pressure pipe. NOTE: It may be located in transmission case side.
12. Remove the O-ring from oil strainer.
13. Remove the O-ring from pressure pipe.

Scheme 755

Scheme 756

Scheme 757

1. Clean the mating surface of oil pan and transmission case.
2. Check the control valve body for dust and other foreign matter.
3. Install the O-ring to the pressure pipe. NOTE: Use new O-rings. Apply CVTF to the O-ring.
4. Install the pressure pipe.
5. Install the control valve body to the transmission. CAUTION: Beware of the transmission harness getting caught in between. Do not impact or bend the transmission harness because it has the oil temperature sensor inside. NOTE: Engage the manual valve to the manual plate. Lead the transmission harness through from the point indicated by dashed line in the figure. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
6. Install the O-ring to oil strainer and install the oil strainer. NOTE: Use new O-rings. Apply CVTF to the O-ring. Let the transmission harness run between control valve body and oil strainer. Tightening torque: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
7. Connect the control valve harness connector.
8. Clean the magnet.
9. Attach the magnet at the specified position of the oil pan.
10. Apply liquid gasket all around the oil pan mating surface seamlessly. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
11. Install the oil pan by equally tightening the bolts. CAUTION: Beware of the transmission harness getting caught in between. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
12. Connect the battery ground terminal.
13. Fill with CVTF. < Ref. to «REPLACEMENT»(ref-662126-S41205453912014101300000) , CVTF. >
14. Adjust the CVTF level. < Ref. to «ADJUSTMENT»(ref-662126-S25388033382014101300000) , CVTF. >

Install in the reverse order of removal.

Note. Use new O-rings. Do not impact or bend the transmission harness because it has the oil temperature sensor inside. Install the transmission ground terminal at an approximately 45° angle (A).

Tightening torque

T1: 5 N.m (0.5 kgf-m, 3.7 ft-lb)

T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb)

Scheme 758

Install in the reverse order of removal.

Scheme 759

Scheme 760

1. Disconnect the ground cable from battery.
2. Drain engine coolant. < Ref. to «REPLACEMENT»(ref-662123-S27459516722014101300000) , Engine Coolant. >
3. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. >
4. Remove the harness clip from the CVTF cooler bracket.
5. Remove the engine coolant outlet hose, engine coolant inlet hose, CVTF inlet hose and CVTF outlet hose.
6. Remove the CVTF cooler (with warmer feature) from the transmission.
7. Remove the intake manifold, EGR valve, and the insulator. < Ref. to «REMOVAL»(ref-662119-S34762705842014101300000) , Intake Manifold. > < Ref. to «REMOVAL»(ref-662157-S12178796782014101300000) , EGR Control Valve. >
8. Disconnect the engine coolant inlet hose.

1. Connect the engine coolant inlet hose. NOTE: When installing the engine coolant inlet hose, the triangle marking should face upward.
2. Install the insulator, EGR valve, and the intake manifold. < Ref. to «INSTALLATION»(ref-662119-S20346051572014101300000) , Intake Manifold. > < Ref. to «INSTALLATION»(ref-662157-S11517856332014101300000) , EGR Control Valve. >
3. Replace the CVTF inlet hose and the outlet hose.
4. Install the CVTF cooler (with warmer feature) to the transmission. Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
5. Install the engine coolant outlet hose, engine coolant inlet hose, CVTF inlet hose and CVTF outlet hose. NOTE: Use new CVTF hoses.
6. Install the harness clip to the CVTF cooler bracket.
7. Install the intercooler. < Ref. to «INSTALLATION»(ref-662121-S02050373282014101300000) , Intercooler. >
8. Connect the battery ground terminal.
9. Fill engine coolant. < Ref. to «REPLACEMENT»(ref-662123-S27459516722014101300000) , Engine Coolant. >
10. Adjust the CVTF level. < Ref. to «ADJUSTMENT»(ref-662126-S25388033382014101300000) , CVTF. >

Scheme 761

Scheme 762

1. Remove the hoses from the CVTF cooler (with warmer feature).
2. Remove the bracket from the CVTF cooler (with warmer feature).

Scheme 763

1. Attach the bracket. Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
2. Attach hoses to the CVTF cooler (with warmer feature). NOTE: Use a new CVTF cooler hose. Install so that the CVTF cooler hose is not folded over, excessively bent or twisted. Insert the CVTF cooler hose to the specified position in the proper direction.

Install in the reverse order of removal.

Note. Use new O-rings.

1. Select the thrust needle bearing. < Ref. to «ADJUSTMENT»(ref-662126-S22831904312014101300000) , Rear Drive Shaft. >
2. Install the selected thrust needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.
3. Install the rear drive shaft.
4. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
5. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

Scheme 764

1. Remove the ball bearing using ST. ST 498077600 REMOVER

Scheme 765

1. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. Apply CVTF to press-fitting surface of ball bearing. ST 399513600 INSTALLER

1. Apply CVTF to the seal ring and attach it to the seal ring groove of transfer clutch assembly. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much.
2. Install the transfer clutch assembly.
3. Select the thrust needle bearing. < Ref. to «ADJUSTMENT»(ref-662126-S22831904312014101300000) , Rear Drive Shaft. >
4. Install the selected thrust needle bearing and needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.
5. Install the rear drive shaft. < Ref. to «REAR DRIVE SHAFT»(ref-662126-S39782312252014101300000) . >
6. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
7. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

1. Remove the snap ring, and then remove the retaining plate, drive plate and driven plate.
2. Using the ST, remove the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
3. Remove the transfer clutch piston seal.
4. Remove the return spring.
5. Remove the transfer clutch piston by blowing compressed air through transfer clutch assembly hole. NOTE: Block the hole opposite to the one to be blown with compressed air by your finger.
6. Using ST, remove transfer drive gear, parking gear and ball bearing. ST 18767AA000 BEARING REMOVER NOTE: Let the ST sit on the parking gear.
7. Remove the snap ring from transfer reduction drive gear.
8. Using the ST, remove the parking gear from transfer reduction drive gear. ST1 499277100 BUSHING 1-2 INSTALLER ST2 18767AA000 BEARING REMOVER

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

1. Using the ST, install the parking gear to transfer reduction drive gear. ST 398177700 INSTALLER
2. Install the snap ring to transfer reduction drive gear.
3. Using the ST, install the transfer reduction drive gear to transfer reduction drive gear shaft. ST 499277100 BUSHING 1-2 INSTALLER
4. Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 499277100 BUSHING 1-2 INSTALLER
5. Attach the transfer clutch piston to the reduction drive gear shaft. NOTE: Apply CVTF to the transfer clutch piston lip.
6. Install the return spring.
7. Install the transfer clutch piston seal.
8. Using the ST, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
9. Install the pressure plate, driven plate, drive plate and snap ring.
10. Before measuring clearance "A", place same thickness shims on both sides to prevent the retaining plate from tilting.
11. When clearance "A" exceeds the limit for use, replace the drive plate and driven plate as a set, and select and adjust the pressure plate within the initial specified value. Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 in) Limit thickness: 1.6 mm (0.063 in) Pressure plate Part No. Thickness mm (in) 31593AA151 3.3 (0.130) 31593AA161 3.7 (0.146)
12. Check the clearance between the snap ring and retaining plate. < Ref. to «INSPECTION»(ref-662126-S39943371912014101300000) , Transfer Clutch. >

1. Install the reduction driven gear assembly.
2. Select shims. < Ref. to «ADJUSTMENT»(ref-662126-S17150692782014101300000) , Transfer Reduction Driven Gear. >
3. Install the transfer clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S40570252762014101300000) , Transfer Clutch. >
4. Install the rear drive shaft. < Ref. to «INSTALLATION»(ref-662126-S39118233202014101300000) , Rear Drive Shaft. >
5. Mount the selected shim onto ball bearing.
6. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
7. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

Scheme 779

1. Using the ST, remove the ball bearing (large) from transfer reduction driven gear. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 498077600 REMOVER
2. Using the ST, remove the ball bearing (small) from transfer reduction driven gear. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 18720AA000 REMOVER

Scheme 780

1. Install the new ball bearing (large) to reduction driven gear using the ST. ST 499277100 BUSHING 1-2 INSTALLER NOTE: Use a new ball bearing. Install to the splines inside transfer reduction driven gear shaft.
2. Install the new ball bearing (small) to reduction driven gear. NOTE: Use a new ball bearing. ST 499277100 BUSHING 1-2 INSTALLER

Note. Although CVTF filter is a maintenance-free part, replace it if a large quantity of wear debris and metal particles are found in CVTF and CVTF filter. For removal of CVTF filter, refer to "Intermediate Case". < Ref. to REMOVAL , Intermediate Case. >

Note. For installation of CVTF filter, refer to "Intermediate Case". < Ref. to INSTALLATION , Intermediate Case. >

Note. For removal of reverse brake assembly, refer to "Intermediate Case". < Ref. to REMOVAL , Intermediate Case. >

Note. For installation of reverse brake assembly, refer to "Intermediate Case". < Ref. to INSTALLATION , Intermediate Case. >

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

1. Remove the snap ring.
2. Remove the retaining plate, drive plate, driven plate and dish plate.
3. Set the ST1, ST2 and ST3 to intermediate case. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18763AA000 COMPRESSOR SHAFT ST3 18765AA000 COMPRESSOR SUPPORT
4. Compress the return spring using the set ST to remove the snap ring.
5. Using the ST, remove the snap ring and spring retainer.
6. Remove the return spring.
7. Remove the reverse brake piston by blowing compressed air intermittently from intermediate case hole.

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

1. Apply CVTF to the seal of reverse brake piston and install it to intermediate case.
2. Install the return spring.
3. Set the spring retainer and snap ring.
4. Set the ST1, ST2 and ST3 to intermediate case. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18763AA000 COMPRESSOR SHAFT ST3 18765AA000 COMPRESSOR SUPPORT
5. Compress the return spring using the ST attached, and install the snap ring.
6. Check the operation of reverse brake piston by blowing compressed air intermittently from intermediate case hole.
7. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
8. Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point.
9. Scale and record the weight "Z" of a flat board which will be put on retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 84 N (8.6 kgf, 18.9 lb).
10. Put the flat board on retaining plate.
11. Using the following formula, read the push/pull gauge, and calculate "N". N = 84 N (8.6 kgf, 18.9 lb) - Z 84 N (8.6 kgf, 18.9 lb): Load applied to clutch plate Z: Flat board weight
12. Press the center of retaining plate by applying a force of "N" or more using push/pull gauge, and then measure and record the compression amount "A". NOTE: Measure at four points with a 90° interval and calculate the average.
13. Install the dish plate, drive plate, driven plate, retaining plate and snap ring to intermediate case. NOTE: Install the dish plate in the correct direction.
14. Measure and record the clearance "B" between the retaining plate and snap ring.
15. Piston stroke calculation Calculate with A and B dimensions recorded before. If it exceeds the limit, replace with a new drive plate and adjust within the initial standard value. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring Initial standard: 2.88 - 3.18 mm (0.113 - 0.125 in) Limit thickness: 3.38 mm (0.133 in) Retaining plate Part No. Thickness mm (in) 31567AB680 5.6 (0.220) 31567AB690 5.8 (0.228) 31567AB700 6.0 (0.236) 31579AB710 6.2 (0.244)

1. Install the straight pin to reduction driven gear assembly.
2. Fit the straight pin portion to the recess portion of transmission case and install the reduction driven gear and install the snap ring.
3. Select the snap ring. < Ref. to «ADJUSTMENT»(ref-662126-S35718225352014101300000) , Reduction Driven Gear. >
4. Replace with the selected snap ring. NOTE: If the clearance measured in step 3 ) is within standard, the snap ring replacement is not necessary.
5. Install the forward clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S18660459362014101300000) , Forward Clutch Assembly. >
6. Install the intermediate case. < Ref. to «INSTALLATION»(ref-662126-S12624772052014101300000) , Intermediate Case. >
7. Install the transfer reduction driven gear assembly. < Ref. to «INSTALLATION»(ref-662126-S16999793992014101300000) , Transfer Reduction Driven Gear. >
8. Install the transfer clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S40570252762014101300000) , Transfer Clutch. >
9. Install the rear drive shaft. < Ref. to «INSTALLATION»(ref-662126-S39118233202014101300000) , Rear Drive Shaft. >
10. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
11. Install the transmission to vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

Scheme 792

Scheme 793

Scheme 794

1. Remove the bearing retainer using ST1, ST2 and ST3. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 18767AA000 BEARING REMOVER
2. Remove the snap ring.
3. Remove the ball bearing using ST1, ST2 and ST3. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 498077600 REMOVER

Scheme 795

Scheme 796

1. Using the ST, install the ball bearing to bearing retainer. ST 398177700 INSTALLER NOTE: Use a new ball bearing. Make sure to install the ball bearing in the right direction. Apply CVTF to the press-fitting area.
2. Using the ST, install the reduction driven gear. ST 499277200 INSTALLER

Note. Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts.

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

1. Remove the transmission assembly from the vehicle. < Ref. to «REMOVAL»(ref-662126-S27261880402014101300000) , Automatic Transmission Assembly. >
2. Remove the air breather hose. < Ref. to «REMOVAL»(ref-662126-S12646688312014101300000) , Air Breather Hose. >
3. Remove the oil pan and control valve body. < Ref. to «REMOVAL»(ref-662126-S00294576922014101300000) , Control Valve Body. >
4. Remove the transmission harness. < Ref. to «REMOVAL»(ref-662126-S11934778832014101300000) , Transmission Harness. >
5. Remove the extension case. < Ref. to «REMOVAL»(ref-662126-S08781516902014101300000) , Extension Case. >
6. Remove the rear drive shaft. < Ref. to «REMOVAL»(ref-662126-S01629269292014101300000) , Rear Drive Shaft. >
7. Remove the transfer clutch assembly. < Ref. to «REMOVAL»(ref-662126-S34367105242014101300000) , Transfer Clutch. >
8. Remove the transfer reduction driven gear assembly. < Ref. to «REMOVAL»(ref-662126-S24756743472014101300000) , Transfer Reduction Driven Gear. >
9. Remove the intermediate case. < Ref. to «REMOVAL»(ref-662126-S27308104852014101300000) , Intermediate Case. >
10. Remove the forward clutch assembly. < Ref. to «REMOVAL»(ref-662126-S35674913842014101300000) , Forward Clutch Assembly. >
11. Remove the transmission case. < Ref. to «REMOVAL»(ref-662126-S20385877352014101300000) , Transmission Case. >
12. Set the ST to the secondary pulley, and expand the V groove of pulley until the variator chain gets completely loose. ST 18769AA000 EXPANDER PULLEY
13. Remove the chain guide from lubrication pipe and support rod.
14. Remove the lubrication pipe and support rod.
15. Detach the four claws to remove the two chain guides.
16. Remove the secondary pulley mounting bolt.
17. Remove the secondary pulley from drive pinion retainer and intersect the V groove of secondary pulley and V groove of primary pulley. Remove the variator chain from secondary pulley and remove the secondary pulley. CAUTION: Cover the V grooves of secondary pulley and primary pulley with cloth to protect the both pulleys and variator chain from scratching.
18. Remove the variator chain from primary pulley.
19. Remove the primary pulley mounting bolt.
20. Remove the primary pulley.
21. Remove the two seal rings from drive pinion retainer.
22. Remove the two seal rings from primary pulley.

Scheme 805

Scheme 806

Scheme 807

Scheme 808

Scheme 809

1. Select shims for pulley alignment. < Ref. to «ADJUSTMENT»(ref-662126-S13700326662014101300000) , Primary Pulley and Secondary Pulley. >
2. Install the two seal rings to drive pinion retainer. NOTE: Use a new seal ring. Apply CVTF to the seal rings. When installing the seal ring, do not expand the seal ring too much.
3. Install the selected shims to the primary pulley bearing catch surface.
4. Install the two seal rings to primary pulley. NOTE: Use a new seal ring. Apply CVTF to the seal rings.
5. Install the primary pulley and adjust the position of bolt holes of primary bearing retainer and converter case to tighten the primary pulley bolt. NOTE: Use a new seal washer. Tightening torque: 21 N.m (2.1 kgf-m, 15.5 ft-lb)
6. Set the ST to secondary pulley and expand the V groove of pulley. ST 18769AA000 EXPANDER PULLEY
7. Place the variator chain on the primary pulley groove and attach the secondary pulley and variator chain together to the drive pinion retainer. CAUTION: Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching. Place the variator chain on primary pulley. Intersect the V groove of primary pulley and the V groove of secondary pulley and install the secondary pulley while placing the variator chain on secondary pulley. While aligning the bolt hole of secondary bearing retainer and the bolt hole of driving pinion retainer, install the secondary pulley to drive pinion retainer.
8. Install the secondary pulley bolt. NOTE: Apply CVTF to the bolt. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)
9. Install the chain guide. NOTE: Install it with two claws facing outward and with two claws facing inward.
10. Engage the cutout portions of support rod and drive pinion retainer and install the support rod.
11. Engage the cutout portions of lubrication pipe and drive pinion retainer and install the lubrication pipe.
12. Install the chain guide so that the lubrication pipe and support rod run through between the protrusions of each chain guide. Then remove the ST (EXPANDER PULLEY).
13. Install the O-ring to the lubrication pipe. NOTE: Use new O-rings.
14. Install the lubrication pipe.
15. Install the transmission case. < Ref. to «INSTALLATION»(ref-662126-S24446785972014101300000) , Transmission Case. >
16. Install the forward clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S18660459362014101300000) , Forward Clutch Assembly. >
17. Install the intermediate case. < Ref. to «INSTALLATION»(ref-662126-S12624772052014101300000) , Intermediate Case. >
18. Install the transfer reduction driven gear assembly. < Ref. to «INSTALLATION»(ref-662126-S16999793992014101300000) , Transfer Reduction Driven Gear. >
19. Install the transfer clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S40570252762014101300000) , Transfer Clutch. >
20. Install the rear drive shaft. < Ref. to «INSTALLATION»(ref-662126-S39118233202014101300000) , Rear Drive Shaft. >
21. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
22. Install the transmission harness. < Ref. to «INSTALLATION»(ref-662126-S10559458132014101300000) , Transmission Harness. >
23. Install the control valve body and oil pan. < Ref. to «INSTALLATION»(ref-662126-S31062024692014101300000) , Control Valve Body. >
24. Install the air breather hose. < Ref. to «INSTALLATION»(ref-662126-S20998501832014101300000) , Air Breather Hose. >
25. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

For removal of variator chain, refer to "Primary Pulley and Secondary Pulley". < Ref. to REMOVAL , Primary Pulley and Secondary Pulley. >

For installation of variator chain, refer to "Primary Pulley and Secondary Pulley". < Ref. to INSTALLATION , Primary Pulley and Secondary Pulley. >

Note. Refer to "Drive Pinion Shaft" for removal procedures. < Ref. to REMOVAL , Drive Pinion Shaft Assembly. >

Note. Refer to "Drive Pinion Shaft" for installation procedures. < Ref. to INSTALLATION , Drive Pinion Shaft Assembly. >

1. Clean the mating surface of converter case cover and converter case.
2. Select the shim for front reduction drive gear. < Ref. to «ADJUSTMENT»(ref-662126-S06999071332014101300000) , Front Reduction Drive Gear. >
3. Apply CVTF to the shims and install on the bearing catch surface of the front reduction driven gear.
4. Install the seal ring to converter case cover. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much.
5. Install the front reduction drive gear and front reduction driven gear together.
6. Install the converter case cover. < Ref. to «INSTALLATION»(ref-662126-S35732903242014101300000) , Converter Case Cover. >
7. Install the drive pinion shaft assembly. < Ref. to «INSTALLATION»(ref-662126-S42265191962014101300000) , Drive Pinion Shaft Assembly. >
8. Install the primary pulley, secondary pulley and variator chain. < Ref. to «INSTALLATION»(ref-662126-S01045588112014101300000) , Primary Pulley and Secondary Pulley. >
9. Install the transmission case. < Ref. to «INSTALLATION»(ref-662126-S24446785972014101300000) , Transmission Case. >
10. Install the forward clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S18660459362014101300000) , Forward Clutch Assembly. >
11. Install the intermediate case. < Ref. to «INSTALLATION»(ref-662126-S12624772052014101300000) , Intermediate Case. >
12. Install the transfer reduction driven gear assembly. < Ref. to «INSTALLATION»(ref-662126-S16999793992014101300000) , Transfer Reduction Driven Gear. >
13. Install the transfer clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S40570252762014101300000) , Transfer Clutch. >
14. Install the rear drive shaft. < Ref. to «INSTALLATION»(ref-662126-S39118233202014101300000) , Rear Drive Shaft. >
15. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
16. Install the primary speed sensor. < Ref. to «INSTALLATION»(ref-662126-S18588737822014101300000) , Primary Speed Sensor. >
17. Install the transmission harness. < Ref. to «INSTALLATION»(ref-662126-S10559458132014101300000) , Transmission Harness. >
18. Install the control valve body and oil pan. < Ref. to «INSTALLATION»(ref-662126-S31062024692014101300000) , Control Valve Body. >
19. Install the air breather hose. < Ref. to «INSTALLATION»(ref-662126-S20998501832014101300000) , Air Breather Hose. >
20. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

Scheme 810

Scheme 811

Scheme 812

1. Remove the seal ring and O-ring.
2. Using the ST, remove the ball bearing from front reduction drive gear. ST 899864100 REMOVER
3. Using the ST, remove the ball bearing from front reduction drive gear. ST 498077000 REMOVER

Scheme 813

Scheme 814

Scheme 815

1. Using the ST, install the ball bearing to front reduction drive gear. NOTE: Use a new ball bearing. ST 18651AA000 INSTALLER
2. Using ST1 and ST2, install the ball bearing to front reduction drive gear. NOTE: Use a new ball bearing. ST1 499757002 PRESS SNAP RING ST2 398177700 INSTALLER
3. Install the seal ring. NOTE: Use a new seal ring. When installing the seal ring, do not expand the seal ring too much. Install the O-ring when installing the torque converter assembly.

Note. For removal of front reduction driven gear, refer to the " FRONT REDUCTION DRIVE GEAR ". < Ref. to REMOVAL , Front Reduction Drive Gear. >

Note. For installation of front reduction driven gear, refer to the " FRONT REDUCTION DRIVE GEAR ". < Ref. to INSTALLATION , Front Reduction Drive Gear. >

Scheme 816

Scheme 817

Scheme 818

Scheme 819

1. Remove the front reduction driven shaft from the front reduction driven gear.
2. Remove the snap ring.
3. Remove the retaining plate, drive plate, driven plate and dish plate.
4. Remove the seal ring from front reduction driven shaft.
5. Remove the ball bearing, while tapping the entire circumference around the ball bearing outer race a little at a time through the front reduction driven shaft hole using the round bar with diameter of 7 mm (0.28 in).

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. NOTE: Make sure of the direction of dish plate.
2. Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point.
3. Scale and record the weight "Z" of a flat board which will be put on retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 130 N (13.3 kgf, 29.2 lb).
4. Put the flat board on retaining plate.
5. Using the following formula, calculate load "N", a force of pressing with push/pull gauge. N = 130N (13.3 kgf, 29.2 kg) - Z 130 N (13.3 kgf, 29.2 lb): Load applied to clutch plate Z: Flat board weight
6. Press the center of retaining plate by applying a force of "N" using push/pull gauge, and then measure and record the compression amount "A". NOTE: Measure at four points with a 90° interval and calculate the average.
7. Install the dish plate, driven plate, drive plate, retaining plate and snap ring. NOTE: Make sure of the direction of dish plate.
8. Measure and record the clearance "B" between the retaining plate and snap ring. NOTE: Before measuring, press down the whole circumference of retaining plate using your finger.
9. Piston stroke calculation Calculate with A and B dimensions recorded before. If out of standard, replace with a new drive plate and adjust it within standard. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring Specification: 2.4 - 2.8 mm (0.094 - 0.11 in) Retaining plate Part No. Thickness mm (in) 31667AB430 3.1 (0.122) 31667AB440 3.3 (0.130) 31667AB450 3.5 (0.138)
10. Press-fit the ball bearing into front driven shaft. NOTE: Use a new ball bearing.
11. Install the seal ring to the front driven shaft. NOTE: Install a new seal ring. Apply CVTF to the seal rings.
12. Install the front reduction driven shaft to the front reduction driven gear.
13. Install the front reduction driven gear assembly to converter case cover.
14. Apply compressed air intermittently to check the piston operation. NOTE: Hold the arrowed area with a finger.

1. Remove the transmission assembly from the vehicle. < Ref. to «REMOVAL»(ref-662126-S27261880402014101300000) , Automatic Transmission Assembly. >
2. Remove the air breather hose. < Ref. to «REMOVAL»(ref-662126-S12646688312014101300000) , Air Breather Hose. >
3. Remove the oil pan and control valve body. < Ref. to «REMOVAL»(ref-662126-S00294576922014101300000) , Control Valve Body. >
4. Remove the transmission harness. < Ref. to «REMOVAL»(ref-662126-S11934778832014101300000) , Transmission Harness. >
5. Remove the secondary pressure sensor. < Ref. to «REMOVAL»(ref-662126-S38169765672014101300000) , Secondary Pressure Sensor. >
6. Remove the primary speed sensor. < Ref. to «REMOVAL»(ref-662126-S11346884712014101300000) , Primary Speed Sensor. >
7. Remove the extension case. < Ref. to «REMOVAL»(ref-662126-S08781516902014101300000) , Extension Case. >
8. Remove the rear drive shaft. < Ref. to «REMOVAL»(ref-662126-S01629269292014101300000) , Rear Drive Shaft. >
9. Remove the transfer clutch assembly. < Ref. to «REMOVAL»(ref-662126-S34367105242014101300000) , Transfer Clutch. >
10. Remove the transfer reduction driven gear assembly. < Ref. to «REMOVAL»(ref-662126-S24756743472014101300000) , Transfer Reduction Driven Gear. >
11. Remove the intermediate case. < Ref. to «REMOVAL»(ref-662126-S27308104852014101300000) , Intermediate Case. >
12. Remove the forward clutch assembly. < Ref. to «REMOVAL»(ref-662126-S35674913842014101300000) , Forward Clutch Assembly. >
13. Remove the transmission case. < Ref. to «REMOVAL»(ref-662126-S20385877352014101300000) , Transmission Case. >
14. Remove the primary pulley, secondary pulley and variator chain. < Ref. to «REMOVAL»(ref-662126-S40929524132014101300000) , Primary Pulley and Secondary Pulley. >
15. Remove the drive pinion shaft assembly. < Ref. to «REMOVAL»(ref-662126-S03541838132014101300000) , Drive Pinion Shaft Assembly. >
16. Remove the front differential assembly. < Ref. to «REMOVAL»(ref-662126-S32066829202014101300000) , Front Differential Assembly. >
17. Remove the converter case cover. < Ref. to «REMOVAL»(ref-662126-S21270510982014101300000) , Converter Case Cover. >
18. Remove the front reduction drive gear and front reduction driven gear. < Ref. to «REMOVAL»(ref-662126-S17250921812014101300000) , Front Reduction Drive Gear. >

1. Install the front reduction drive gear and front reduction driven gear. < Ref. to «INSTALLATION»(ref-662126-S02698867112014101300000) , Front Reduction Drive Gear. >
2. Install the converter case cover. < Ref. to «INSTALLATION»(ref-662126-S35732903242014101300000) , Converter Case Cover. >
3. Install the front differential assembly. < Ref. to «INSTALLATION»(ref-662126-S26188537962014101300000) , Front Differential Assembly. >
4. Install the drive pinion shaft assembly. < Ref. to «INSTALLATION»(ref-662126-S42265191962014101300000) , Drive Pinion Shaft Assembly. >
5. Install the primary pulley, secondary pulley and steel chain. < Ref. to «INSTALLATION»(ref-662126-S01045588112014101300000) , Primary Pulley and Secondary Pulley. >
6. Install the transmission case. < Ref. to «REMOVAL»(ref-662126-S20385877352014101300000) , Transmission Case. >
7. Install the forward clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S18660459362014101300000) , Forward Clutch Assembly. >
8. Install the intermediate case. < Ref. to «INSTALLATION»(ref-662126-S12624772052014101300000) , Intermediate Case. >
9. Install the transfer reduction driven gear. < Ref. to «INSTALLATION»(ref-662126-S16999793992014101300000) , Transfer Reduction Driven Gear. >
10. Install the transfer clutch assembly. < Ref. to «INSTALLATION»(ref-662126-S40570252762014101300000) , Transfer Clutch. >
11. Install the rear drive shaft. < Ref. to «INSTALLATION»(ref-662126-S39118233202014101300000) , Rear Drive Shaft. >
12. Install the extension case. < Ref. to «INSTALLATION»(ref-662126-S25042953042014101300000) , Extension Case. >
13. Install the primary speed sensor. < Ref. to «INSTALLATION»(ref-662126-S18588737822014101300000) , Primary Speed Sensor. >
14. Install the secondary pressure sensor. < Ref. to «INSTALLATION»(ref-662126-S01781096662014101300000) , Secondary Pressure Sensor. >
15. Install the transmission harness. < Ref. to «INSTALLATION»(ref-662126-S10559458132014101300000) , Transmission Harness. >
16. Install the control valve body and oil pan. < Ref. to «INSTALLATION»(ref-662126-S31062024692014101300000) , Control Valve Body. >
17. Install the air breather hose. < Ref. to «INSTALLATION»(ref-662126-S20998501832014101300000) , Air Breather Hose. >
18. Install the transmission assembly to the vehicle. < Ref. to «INSTALLATION»(ref-662126-S03255485532014101300000) , Automatic Transmission Assembly. >

Scheme 825

Scheme 826

1. Remove the CVTF cooler pipe COMPL.
2. Remove the pitching stopper bracket and transmission radio ground cord, if mounted.
3. Remove the oil drain plug and overflow drain plug. < Ref. to «REPLACEMENT»(ref-662126-S28547052982014101300000) , Differential Gear Oil. >
4. Remove all plugs.