Part 2

51. Install the forward clutch pack snap ring.





52. Install the forward clutch roller cage bearing.





53. NOTE: This is a selective fit washer for the input shaft set up.

Install the forward clutch upper bearing washer.





54. Install the forward clutch upper roller bearing.





55. Lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals and split ring seal.





56. Install the input shaft and a new planet carrier thrust washer.





57. Install the differential assembly in the case.





58. Install the bearing race onto the differential assembly.





59. Compress the special tool and hand-tighten the bolt.





60. Install the special tools onto the case.





61. Position the case onto the special tools and install the bolts.
^ Tighten to 8 Nm (71 inch lbs.).





62. Loosen the top bolt of the special tool. Using a feeler gauge, measure the opening.





63. Measure the thickness of the bearing shim that came out when the race was removed. The thickness of the bearing shim should match the measured opening of the special tool. If the measurements do not match, use a new selective bearing race shim.

Differential Bearing Race Selective Shim:

64. Install the selective bearing race shim into the housing.





65. Position the new bearing race in place.





66. Install the special tools on this side of the case.





67. Install the remaining special tools from the other side of the case. Using the special tools, install the bearing race.





68. Install a new converter housing gasket.





69. NOTE: This is not a final torque. For this step only you can reuse the old bolts that were removed.

Position the converter housing in place. Install only 8 bolts, evenly around the case, to carry out the input shaft end play. It may be necessary to remove the converter housing to install the correct shim. Tighten the bolts in a crisscross sequence.
^ Tighten the bolts to 8 Nm (71 inch lbs.).





70. Install the special tool to measure the input shaft end play.
^ Tighten the wing nut.





71. Install the remaining special tool.
^ Push down on the special tool and zero out the dial indicator.
^ Lift up on the special tool and record the measurement 0.22-0.53 mm (0.008-0.021 inch). If the measurement is not within specification, install a new input shaft bearing spacer.





72. NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.

Position the converter housing in place. Install new converter housing bolts and tighten in 3 stages. These bolts are torque-to-yield bolts.

Starting at No. 1, tighten the bolts in a counterclockwise rotation.
^ Stage 1: Tighten bolts to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten bolts to 8 Nm (71 inch lbs.).
^ Stage 3: Tighten an additional 90 degrees.





73. Install the side shaft gear assembly.
^ Tighten to 35 Nm (26 ft. lbs.).





74. Position the output shaft seal in place.





75. Using the special tool, install the output shaft seal.





76. Position the output shaft seal in place.





77. Using the special tool, install the output shaft seal.





78. CAUTION: Vehicles having transmissions with transmission build dates prior to December 6, 2005 have longer feed tubes for the primary and secondary feed tubes. The shorter feed tube goes in the main pressure case hole.

Vehicles having transmissions with transmission build dates after December 6, 2005 use the same size, shorter feed tube in the primary, secondary and main pressure feed tube locations.

Be sure to note what size the feed tubes are when removed and install them in the same case hole location they were removed from.

Short and long feed tubes cannot be interchanged because CVT cases built after December 6, 2005 that use the shorter feed tube in all 3 locations have shallower case holes in the primary and secondary feed tube locations. Putting the longer feed tubes in these cases will result in cross leakage when the mechatronic assembly is installed. Putting shorter feed tubes in a location that used the longer hole may also result in a cross leak when the mechatronic assembly is installed from the tube being pushed farther down and not sealing.

For transaxles built before December 6, 2005, lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals on the feed tubes.

1 Install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube.
2 Install new O-ring seals on the primary pressure feed tube, secondary pressure feed tube and main (pump) pressure feed tube.





79. For transaxles built before December 6, 2005 lubricate all of the O-ring seals with clean CVT transmission fluid.
1 Clutch supply feed tube
2 Primary feed tube (longer tube)
3 Secondary feed tube (longer tube)
4 Main pressure feed tube (shorter tube)
5 Torque converter clutch feed tube





80. For transaxles built after December 6, 2005, lubricate all of the bonded seals on the feed tubes with clean CVT transmission fluid.
1 Clutch supply feed tube
2 Primary feed tube (short tube)
3 Secondary feed tube (short tube)
4 Main pressure feed tube (short tube)
5 Torque converter clutch feed tube





81. NOTE: Note the location of the 5 feed tubes.

Install all of the feed tubes into the case.
1 Align the inner tube and install the clutch (manual valve) supply feed tube.
2 Install the primary pressure feed tube.
3 Install the secondary pressure feed tube.
4 Install the main (pump) pressure feed tube.
5 Install a new torque converter clutch pressure feed tube.





82. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

NOTE: The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

Position the mechatronic unit onto the case.





83. Tighten the mechatronic bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 40 degrees (1/8 turn).





84. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Lubricate the O-ring seal with clean CVT transmission fluid and install the electrical connector into the case.





85. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Rotate the outer shell connector in place and install the bolt.
^ Tighten to 6 Nm (53 inch lbs.).





86. CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt.
This is used for keeping a specific distance from the differential gears.

Install the OSS sensor spacer, sensor and bolt.
^ Tighten to 8 Nm (71 inch lbs.).





87. Connect the electrical connectors.





88. CAUTION: Make sure that the fluid filter pickup tube seal was removed from the bore when the filter was removed. Failure to remove the seal prior to installing the new filter will result in transaxle failure.

CAUTION: Make sure that the transmission fluid filter is fully seated into the bore. If the filter is not correctly installed, internal transaxle damage will occur.

Lubricate the O-ring seal that is on the new filter with clean CVT transmission fluid and install the fluid filter.





89. Make sure that the filter is seated over one of the mechatronic bolts.





90. Install a new transaxle fluid pan gasket.





91. Make sure that the magnet in the pan is in the correct location prior to installing the transmission fluid pan.





92. Install the transmission fluid pan. Tighten the bolts in the sequence indicated.
^ Tighten to 12 Nm (9 ft. lbs.).





93. CAUTION: Do not set the torque converter in the pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.

Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.





94. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.





95. Using 4 new retainers, install the transaxle insulator.





96. Install a new transmission fluid tube indicator grommet.





97. Install the transmission fluid level indicator and tube.
^ Tighten to 10 Nm (89 inch lbs.).





98. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
99. Position the transaxle mount in place and install the upper retaining bolts.
^ Tighten to 55 Nm (41 ft. lbs.).