Wiring Harness: Service and Repair
Transmission HarnessREMOVAL
INHIBITOR HARNESS
1) Remove the transmission from the vehicle.
2) Remove the transmission case cover.
3) Remove the harness connector from the ground terminal, turbine speed sensor, primary speed sensor, secondary speed sensor and secondary pressure sensor.
4) Remove the harness connector from inhibitor switch.
5) Remove the inhibitor harness connector from the transmission harness stay.
6) Remove the harness clip from the transmission, and remove the inhibitor harness.
TRANSMISSION HARNESS
1) Disconnect the ground cable from battery.
2) Remove the air intake boot assembly.
3) Disconnect the following connectors.
^ Transmission harness connectors
^ Inhibitor harness connector
^ Transmission radio ground terminal
4) Remove the pitching stopper.
5) Remove the air breather hose from the pitching stopper bracket, and then remove the pitching stopper bracket and transmission radio ground cord.
6) Remove the transmission case cover.
7) Remove the transmission harness stay and ground terminal.
8) Remove the transmission harness connector from the harness stay.
9) Clean the transmission exterior.
10) Set the ST on the vehicle.
ST 18761AA010 SHEET SPECIAL TOOL
11) Remove the valve cover and gasket.
12) Remove the transmission harness connector from the control valve body.
13) Remove the transmission harness from the valve cover.
14) Remove the O-ring from the transmission harness.
INSTALLATION
INHIBITOR HARNESS
Install in the reverse order of removal.
NOTE:
Install the transmission ground terminal in the direction within the range of approx. 30° (A).
Tightening torque:
T1: 7 Nm (0.7 kgf-m, 3.7 ft-lb)
T2: 14 Nm (1.4 kgf-m, 10.3 ft-lb)
Transmission Case
REMOVAL
1) Remove the transmission assembly from the vehicle.
2) Remove the air breather hose.
3) Remove the control valve body.
4) Remove the transmission harness.
5) Remove the turbine speed sensor.
6) Remove the secondary speed sensor.
7) Remove the primary speed sensor.
8) Remove the inhibitor switch.
9) Remove the extension case.
10) Remove the transfer clutch assembly.
11) Remove the transfer driven gear assembly.
12) Remove the parking pawl.
13) Remove the reduction driven gear assembly.
14) Remove the oil pan and oil strainer.
15) Remove the transmission control device.
16) Remove the oil baffle securing bolt.
17) Remove the oil cooler pipe.
18) Remove the transmission case.
NOTE:
The total number of transmission case mounting bolts is 15.
19) Remove the oil baffle.
20) Remove the O-ring.
21) Remove the seal ring from the transmission case.
INSTALLATION
1) Clean the mating surface of transmission case and converter case.
2) Select the reduction gear shim.
3) Remove the transmission case, and install the selected reduction gear shim to the reduction drive gear.
4) Install the O-rings to the reverse clutch housing and drive pinion retainer.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
5) Install the seal ring to the transmission case.
NOTE:
^ Use a new seal ring.
^ Apply CVTF to the seal rings.
6) Cover the secondary pulley with the oil baffle, and temporarily install it with bolts.
7) Apply liquid gasket seamlessly to the mating surface of transmission case.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
8) Install the transmission case.
NOTE:
The total number of transmission case mounting bolts is 15.
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
9) Install the oil cooler pipe.
NOTE:
Use new O-rings.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
10) Install the oil baffle securing bolt.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
11) Install the transmission control device.
12) Install the oil pan and oil strainer.
13) Install the reduction driven gear assembly.
14) Install the parking pawl.
15) Install the transfer driven gear assembly.
16) Install the transfer clutch assembly.
17) Install the extension case.
18) Install the inhibitor switch.
19) Install the secondary speed sensor.
20) Install the primary speed sensor.
21) Install the turbine speed sensor.
22) Install the transmission harness.
23) Install the control valve body.
24) Install the air breather hose.
25) Install the transmission assembly to the vehicle.
DISASSEMBLY
1) Remove the oil stopper plate.
2) Remove all plugs from the transmission case.
3) Remove the oil seal using a screwdriver wrapped with cloth etc.
4) Using the ST, remove the ball bearing of the secondary pulley.
(1) Remove the claw of ST1, and attach the claw of ST2.
ST1 398527700 PULLER ASSY
ST2 18760AA000 CLAW
(2) Using the ST, remove the ball bearing of the secondary pulley.
ST1 398527700 PULLER ASSY
ST2 18760AA000 CLAW
5) Remove the oil guide.
6) Remove the ball bearing from reduction driven gear using ST.
ST 398527700 PULLER ASSY
7) Remove the CVTF filter cover and gasket.
8) Remove the CVTF filter.
ASSEMBLY
1) Face the O-ring side of the CVTF filter to the transmission case side, and install the CVTF filter.
NOTE:
Apply CVTF to the O-ring of CVTF filter.
2) Install the CVTF filter cover and gasket.
NOTE:
Use a new gasket.
Tightening torque:
17 Nm (1.7 kgf-m, 12.5 ft-lb)
3) Using the ST, install the oil seal.
NOTE:
^ Use a new oil seal.
^ Apply CVTF to the oil seal lip and press-fitting surface.
ST 18657AA000 INSTALLER
4) Using ST1 and ST2, install the ball bearing on the reduction driven gear side.
NOTE:
Use a new ball bearing.
ST1 398177700 INSTALLER
ST2 28499TC010 PRESS SNAP RING
5) Using ST1, ST2 and ST3, install the ball bearing on the secondary pulley side.
NOTE:
Use a new ball bearing.
ST1 499277100 BUSHING 1-2 INSTALLER
ST2 398177700 INSTALLER
ST3 28499TC010 PRESS SNAP RING
6) Install all plugs.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
^ For the plug (A), fill the CVTF, and then tighten the plug (A) using a new O-ring.
Tightening torque:
T1: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
T2: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T3: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
7) Install the oil stopper plate.
NOTE:
Use a new bolt.
Tightening torque:
9 Nm (0.9 kgf-m, 6.6 ft-lb)
INSPECTION
^ Check the transmission case for damage.
^ Check for leakage of CVTF from the connection between converter case and transmission case.
^ Check the bearing for smooth operation.
^ Check the bearing for seizure or wear.
ADJUSTMENT
NOTE:
When replacing the transmission case with a new part, perform the following check and adjustment for the selection.
^ Select the transfer driven gear shim.
^ Select the transfer drive gear shim.
^ Select the reduction drive gear shim.
CVTF Filter
REMOVAL
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 "Transmission Case".
INSTALLATION
NOTE:
For installation of CVTF filter, refer to "Transmission Case".
INSPECTION
^ Check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter.
^ Check for broken part or damaged O-ring.
TRANSMISSION HARNESS
1) Clean the mating surface of valve cover and transmission side.
2) Check the control valve body for dust and other foreign matter.
3) Install the O-ring to the transmission harness.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
4) Install the transmission harness to the valve cover.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
5) Install the gasket to the transmission.
NOTE:
Use a new gasket.
6) Apply liquid gasket to the oval hole of gasket.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
7) Connect the transmission harness connector to the control valve body, and install the valve cover.
CAUTION:
Be careful not to catch the sheet of the ST.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
8) Remove the ST (SHEET SPECIAL TOOL).
9) Install the transmission harness connector to the harness stay.
10) Install the transmission harness stay and transmission ground terminal.
NOTE:
Install the transmission ground terminal in the direction within the range of approx. 30° (A).
Tightening torque:
T1: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
T2: 14 Nm (1.4 kgf-m, 10.3 ft-lb)
11) Install the transmission case cover.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
12) Install the pitching stopper bracket and transmission radio ground cord.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
13) Install the air breather hose to the pitching stopper bracket.
14) Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
15) Connect the following harness connectors.
^ Transmission harness connectors
^ Inhibitor harness connector
^ Transmission radio ground terminal
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
16) Install the air intake boot assembly.
17) Adjust the CVTF level.