01J Continuously Variable Transmission
General Repair Information
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
Some general repair information that applies to several procedures throughout this service information is summarized here. It applies to this repair information.
CAUTION!
Before work is done with engine running, place selector lever in "P" position and press parking brake button to engage electromagnetic parking brake.
Environmental and disposal regulations for oil
Handle ATF, axle oil and other oils carefully. Dispose of drained oil properly. Always follow the legal environmental and disposal regulations.
Special Tools and Equipment
Manual release of selector lever
If the battery has been disconnected or is discharged and the vehicle must be towed or pushed, it will be necessary to push the shift mechanism emergency release to shift the selector lever from position "P" to position "N": Vehicles through 11.2005 => [ Shift Mechanism Emergency Release, Operating ] Shift Mechanism Emergency Release, Operating, vehicles from 11.2005 => [ Shift Mechanism Emergency Release ] Shift Mechanism Emergency Release.
Transmission
• Observe rules of cleanliness for working on the transmission => [ Clean Working Conditions ] Clean Working Conditions.
• Do not run engine with the end cover removed or without ATF filling and do not tow vehicle.
• After installing, the following fluid levels must be checked and topped off if necessary: ATF in the transmission => [ Automatic Transmission Fluid, Checking Level and Correcting ] Service and Repair and gear oil in front final drive => [ Front Final Drive, Checking Gear Oil Level ] Final Drive, Differential (01J Continuously Variable Transmission).
O-rings, shaft seals, seals
• O-rings, shaft seals and seals must be replaced.
• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
• Thoroughly clean housing joint surfaces before assembling.
• To install, thinly coat shaft seals along outer circumference and on sealing lip with ATF.
• Coat O-rings with ATF before inserting to prevent crushing rings during installation.
• Only use ATF for automatic transmission components. Other lubricating substances cause functional problems in the hydraulic transmission control.
• The open side of the shaft seals point toward the fluid to be sealed in.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• After installing, the following fluid levels must be checked and topped off if necessary: ATF in the transmission => [ Automatic Transmission Fluid, Checking Level and Correcting ] Service and Repair or gear oil in front final drive => [ Front Final Drive, Checking Gear Oil Level ] Final Drive, Differential (01J Continuously Variable Transmission).
Bolts and Nuts
• Loosen bolts in reverse of tightening sequence.
• Nuts and bolts which secure covers and housings should be tightened in stages according to the specified sequence and tightening method.
• Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Replace self-locking bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts and apply AMV 185 101 A1.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
Circlips, snap rings
• Do not over-stretch circlips.
• Always replace damaged or over-stretched circlips.
• Circlips must locate properly in the groove.
Mount
• Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
• Insert bearing with axle oil or ATF, depending on installation location.
• Do not interchange the outer or inner races of bearings of the same size.
• Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjusting Shims
• Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.
• Inspect for burrs and signs of damage. Install only shims that are in perfect condition.
Guided Fault Finding
Before performing any service to the transmission, try to determine the exact cause of the damage using Vehicle Diagnosis, Testing and Information System (VAS 5051B) in "Guided Fault Finding".