RM36D0EC _52 Drivetrain _138176 K121 CVT _0579393 CONTINUOUSLY VARIABLE TRANSAXLE UNIT A

K121 CVT  CONTINUOUSLY VARIABLE TRANSAXLE UNIT  DISASSEMBLY  


CAUTION / NOTICE / HINT

NOTICE:
·

Clean the work area, tools to be used, other equipment, etc., thoroughly before performing this procedure, as there is a possibility that a CVT malfunction, which may prevent the vehicle from being driven, may occur if dust or fine foreign matter enters the CVT.

·

Do not use cotton work gloves, cloths, paper towels, etc., that may produce lint, dust or foreign matter.

·

When cleaning parts, make sure that dust or foreign matter does not enter the CVT.

·

When replacing any tapered roller bearing (inner race) or tapered roller bearing (outer race), replace both the tapered roller bearing (inner race) and tapered roller bearing (outer race) with new ones.

·

When the tapered roller bearing (inner race) is removed, the tapered roller bearing (inner race) and tapered roller bearing (outer race) need to be replaced.

·

When the tapered roller bearing (inner race) is not removed, the tapered roller bearing (inner race) and tapered roller bearing (outer race) can be reused.



HINT:

Shift shock may increase after replacing the transmission valve body assembly or forward multiple disc clutch assembly. In this case, shift shock will reduce as the vehicle in driven.


PROCEDURE

Hide 32901L 1.REMOVE OIL COOLER ELBOW SUB-ASSEMBLY

a.
C405186

Remove the 2 bolts and oil cooler elbow sub-assembly from the continuously variable transaxle assembly.


b.

Remove the 2 gaskets from the oil cooler elbow sub-assembly.


Hide 8.REMOVE REFILL PLUG

a.
C395506

Remove the refill plug and gasket from the rear transaxle case sub-assembly.


Hide 30400 9.SUPPORT CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

a.

Place the continuously variable transaxle assembly on wooden blocks.

C498846C01
3.042,1.49 3.396,1.625 3.396,1.625 3.208,1.375 false 4.25,1.625 4.49,1.625 false 3.448,1.542 3.719,1.76 0.271,0.219 10 false *a 4.51,1.51 4.781,1.729 0.271,0.219 10 false *a
*a Wooden Block - -



Hide 10.REMOVE OVERFLOW PLUG

a.
C395508

Using a 10 mm hexagon socket wrench, remove the overflow plug and gasket from the transaxle case sub-assembly.


Hide 35125E 11.REMOVE OVERFLOW (CVT) TUBE

a.
C395509

Using a 6 mm hexagon socket wrench, remove the overflow (CVT) tube from the transaxle case sub-assembly.


Hide 35111C 16.REMOVE TRANSAXLE HOUSING

a.
C395526

Remove the 21 bolts.


b.

Using a plastic-faced hammer, tap on the circumference of the transaxle housing to remove it from the transaxle case sub-assembly.


c.
C395527

Remove the 5 O-rings from the transaxle case sub-assembly.


Hide 17.REMOVE SOLENOID OIL STRAINER

a.
C457541

Remove the solenoid oil strainer from the transaxle case sub-assembly.


Hide 35174B 18.REMOVE OIL RESERVOIR LOCK PLATE

a.
C395529

Remove the 3 bolts and oil reservoir lock plate from the transaxle housing.


Hide 35394D 19.REMOVE OIL CLEANER (CVT) MAGNET

a.
C395530

Remove the 3 oil cleaner (CVT) magnets from the oil reservoir lock plate.


Hide 35882E 20.REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE

a.
C395531

Remove the bolt and differential gear lube apply tube from the transaxle housing.


Hide 35896A 21.REMOVE SECONDARY SHAFT LUBE APPLY TUBE

a.
C395532

Using a snap ring plier, remove the snap ring from the transaxle housing.


b.
C395533

Remove the secondary shaft lube apply tube from the transaxle housing.


c.
C395535

Remove the O-ring from the secondary shaft lube apply tube.


Hide 35809 22.REMOVE C-2 CLUTCH PRESSURE APPLY TUBE SUB-ASSEMBLY

a.
C395536

Remove the C-2 clutch pressure apply tube sub-assembly from the transaxle housing.


b.
C395537

Remove the O-ring from the C-2 clutch pressure apply tube sub-assembly.


Hide 35593A 23.REMOVE CAM GUIDE SLEEVE

a.
C402343

Remove the 2 bolts and cam guide sleeve from the transaxle housing.


Hide 35556N 24.REMOVE PARKING LOCK PAWL SHAFT

a.
C395539C01
2.313,0.198 2.792,0.198 false 2.313,0.552 2.563,0.552 2.563,0.552 2.802,0.729 false 2.135,0.104 2.406,0.313 0.271,0.208 10 false *1 2.135,0.458 2.417,0.656 0.281,0.198 10 false *2
*1 Parking Lock Pawl Shaft
*2 Torsion Spring


Remove the parking lock pawl shaft and torsion spring from the transaxle housing.


Hide 35557C 25.REMOVE PARKING LOCK PAWL

a.
C395541

Remove the parking lock pawl from the transaxle housing.


Hide 35598B 26.REMOVE PARKING LOCK SLEEVE

a.
C395542

Remove the parking lock sleeve from the transaxle housing.


Hide 27.REMOVE REDUCTION DRIVEN GEAR FRONT TAPERED ROLLER BEARING (OUTER RACE)

a.
C395543N01
2.438,0.885 2.771,0.885 false 2.813,0.802 3.167,1 0.354,0.198 10 false SST

Using SST, remove the reduction driven gear front tapered roller bearing (outer race) and shim from the transaxle housing.

SST
09308-00010  

NOTICE:

Be careful not to damage the transaxle housing.


HINT:
C395544

Align the claw of SST with the indentation of the transaxle housing when removing the parts.



Hide 28.REMOVE DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)

a.
C395547N01
2.385,0.385 2.719,0.385 false 2.771,0.292 3.198,0.531 0.427,0.24 10 false SST

Using SST, remove the differential case front tapered roller bearing (outer race) and shim from the transaxle housing.

SST
09308-00010  

NOTICE:

Be careful not to damage the transaxle housing.


HINT:
C395548

Align the claw of SST with the indentation of the transaxle housing when removing the parts.



Hide 43410M 29.REMOVE FRONT DRIVE SHAFT OIL SEAL RH

a.
C395551N01
0.896,1.5 0.448,1.583 0.448,1.583 1.031,1.188 true 0.135,1.5 0.458,1.719 0.323,0.219 10 false SST

Using SST and a hammer, remove the front drive shaft oil seal RH from the transaxle housing.

SST
09950-70010  (09951-07100)
09950-60011  (09951-00600)


Hide 30.REMOVE TRANSAXLE HOUSING TYPE T OIL SEAL

a.
C395553N01
0.979,1.563 0.406,0.917 0.406,0.917 1.052,1.313 true 0.104,0.833 0.479,1.052 0.375,0.219 10 false SST

Using SST and a hammer, remove the transaxle housing type T oil seal from the transaxle housing.

SST
09950-70010  (09951-07100)
09950-60011  (09951-00510)


Hide 31.REMOVE REDUCTION DRIVEN GEAR

a.
C395708

Remove the reduction driven gear from the transaxle case sub-assembly.


Hide 41301L 32.REMOVE DIFFERENTIAL CASE SUB-ASSEMBLY

a.
C395709

Remove the differential case sub-assembly from the transaxle case sub-assembly.


Hide 35317A 33.REMOVE NO. 2 TRANSMISSION OIL PUMP SEPARATOR PLATE

a.
C395710

Detach the 4 claws to remove the No. 2 transmission oil pump separator plate from the No. 1 transmission oil pump separator plate.


Hide 35782P 34.REMOVE DRIVE SPROCKET

a.
C395711

Remove the thrust needle roller bearing from the drive sprocket.


b.
C395713C01
1.135,0.302 1.729,0.302 true 2.073,0.469 2.552,0.469 true 0.969,0.208 1.25,0.448 0.281,0.24 10 false *1 2.594,0.365 2.875,0.604 0.281,0.24 10 false *2
*1 Drive Sprocket
*2 Transmission Drive Chain


Remove the drive sprocket and transmission drive chain.


Hide 35783N 35.REMOVE DRIVEN SPROCKET

a.

Using a snap ring expander, remove the driven sprocket from the front oil pump assembly.

C395714


b.

Remove the snap ring from the front oil pump assembly.


Hide 35316A 36.REMOVE NO. 1 TRANSMISSION OIL PUMP SEPARATOR PLATE

a.
C395715

Remove the 2 bolts and No. 1 transmission oil pump separator plate from the front oil pump assembly.


Hide 35310A 37.REMOVE FRONT OIL PUMP ASSEMBLY

a.
C491827

Remove the 4 bolts and front oil pump assembly from the transaxle case sub-assembly.


b.
C395719

Remove the front oil pump cover gasket from the transaxle case sub-assembly.


Hide 35330J 38.REMOVE OIL STRAINER ASSEMBLY

a.
C491828

Remove the 2 bolts and oil strainer assembly from the front oil pump assembly.


b.
C491829

Remove the O-ring from the oil strainer assembly.


Hide 35016E 39.REMOVE TRANSMISSION CASE PLATE SUB-ASSEMBLY

a.
C485356

Remove the 2 bolts and transmission case plate sub-assembly from the transaxle case sub-assembly.


Hide 35174B 40.REMOVE OIL RESERVOIR LOCK PLATE

a.
C395720

Remove the 2 bolts and oil reservoir lock plate from the transaxle case sub-assembly.


Hide 35370E 41.REMOVE STATOR (CVT) SHAFT ASSEMBLY

a.
C395721

Remove the 7 bolts and stator (CVT) shaft assembly from the transaxle case sub-assembly.


Hide 33032 42.REMOVE 1ST GEAR SUB-ASSEMBLY

a.
C395722

Remove the bolt to disconnect the No. 1 gear shift fork assembly from the No. 1 gear shift fork shaft.


b.
C395723

Remove the 1st gear sub-assembly with the No. 1 gear shift fork assembly from the No. 1 gear shift fork shaft.


Hide 33210A 43.REMOVE NO. 1 GEAR SHIFT FORK ASSEMBLY

a.

Move the No. 1 gear shift fork assembly as shown in the illustration.

C395725


b.
C395727

Remove the No. 1 gear shift fork assembly from the 1st gear sub-assembly.


Hide 44.REMOVE STAY

a.
C485357

Remove the bolt and stay from the No. 1 gear shift fork assembly.


Hide 35610A 45.REMOVE FORWARD MULTIPLE DISC CLUTCH ASSEMBLY

a.
C395729

Remove the forward multiple disc clutch assembly from the planetary gear assembly.


b.
C398094

Remove the thrust bearing race from the forward multiple disc clutch assembly.


Hide 35633H 46.REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC

a.
C395730

Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the forward clutch drum sub-assembly.

NOTICE:

Be careful not to damage the forward clutch drum sub-assembly.



b.
C395731C01
3.146,1.292 3.292,1.292 3.292,1.292 3.292,2.792 false 2.021,2.156 1.833,2.156 1.833,2.156 1.833,1.021 false 1.625,1.021 2.031,1.021 false 1.833,1.583 2.021,1.583 false 3.167,1.885 3.292,1.885 false 3.156,2.49 3.292,2.49 false 1.625,0.698 2.031,0.698 false 1.469,0.604 1.771,0.823 0.302,0.219 10 false *1 1.469,0.927 1.76,1.156 0.292,0.229 10 false *2 3.229,2.792 3.417,3.01 0.188,0.219 10 false *3
*1 Forward Clutch Flange
*2 Forward Multiple Disc Clutch Clutch Disc
*3 Forward Multiple Disc Clutch Clutch Plate


Remove the forward clutch flange, 3 forward multiple disc clutch clutch discs and 3 forward multiple disc clutch clutch plates from the forward clutch drum sub-assembly.


Hide 47.REMOVE NO. 1 CLUTCH BALANCER

a.
C395732N01
1.906,0.917 2.396,0.917 false 2.448,0.823 2.833,1.094 0.385,0.271 10 false SST

Place SST on the No. 1 clutch balancer and compress the forward clutch return spring sub-assembly with a press.

SST
09387-00020  

NOTICE:

Do not compress the forward clutch return spring sub-assembly excessively.



b.
C395733

Using a snap ring expander, remove the snap ring from the forward clutch drum sub-assembly.


c.
C395734

Remove the No. 1 clutch balancer from the forward clutch drum sub-assembly.


d.
C395735

Remove the D-ring from the No. 1 clutch balancer.


Hide 35603E 48.REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

a.
C395736

Remove the forward clutch return spring sub-assembly from the forward clutch drum sub-assembly.


Hide 49.REMOVE FORWARD CLUTCH PISTON

a.
C395737

Install the forward clutch drum sub-assembly to the stator (CVT) shaft assembly.


b.

Apply compressed air (approximately 250 kPa (2.5 kgf/cm2, 36 psi)) to the fluid hole of the stator (CVT) shaft assembly to separate the forward clutch piston from the forward clutch drum sub-assembly.

C395738

NOTICE:

Be careful as fluid may spray when applying compressed air.



c.
C395739

Remove the forward clutch piston from the forward clutch drum sub-assembly.


d.
C395740C01
1.021,0.302 1.302,0.49 0.281,0.188 10 false *1 2.625,1.844 2.896,2.042 0.271,0.198 10 false *2
*1 O-Ring
*2 D-Ring


Remove the O-ring and D-ring from the forward clutch piston.


e.
C395737

Remove the forward clutch drum sub-assembly from the stator (CVT) shaft assembly.


Hide 50.REMOVE CLUTCH DRUM OIL SEAL RING

a.
C395741

Remove the 2 clutch drum oil seal rings from the stator (CVT) shaft assembly.

NOTICE:

Do not expand the clutch drum oil seal rings excessively.



Hide 35720M 51.REMOVE PLANETARY GEAR ASSEMBLY

a.
C395742

Remove the planetary gear assembly from the front planetary ring gear sub-assembly.


b.
C395745

Remove the thrust needle roller bearing from the planetary gear assembly.


Hide 35075D 52.REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY

a.
C395747

Remove the thrust needle roller bearing from the front planetary ring gear sub-assembly.


b.
C395749

Remove the front planetary ring gear sub-assembly from the transaxle case sub-assembly.


Hide 35726A 53.REMOVE PLANETARY RING GEAR THRUST WASHER

a.
C395750

Remove the planetary ring gear thrust washer from the transaxle case sub-assembly.


Hide 35681B 54.REMOVE NO. 1 BRAKE DISC

a.
C395751

Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.

NOTICE:

Be careful not to damage the transaxle case sub-assembly.



b.
C491815C01
3.083,1.354 3.25,1.354 3.25,1.354 3.25,2.917 false 3.083,1.854 3.25,1.854 false 3.083,2.354 3.25,2.354 false 2,1.167 2,2.167 2,2.167 2.177,2.167 false 2.177,1.167 1.833,1.167 false 2.177,1.625 2,1.625 false 1.875,0.771 2.208,0.771 false 1.688,0.688 1.865,0.896 0.177,0.208 10 true *1 1.646,1.063 1.813,1.281 0.167,0.219 10 true *2 3.156,2.958 3.344,3.198 0.188,0.24 10 false *3
*1 Brake Flange
*2 No. 1 Brake Disc
*3 No. 1 Brake Plate


Remove the brake flange, 3 No. 1 brake discs and 3 No. 1 brake plates from the transaxle case sub-assembly.


Hide 55.REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

a.
C395754N01
1.792,0.927 2.927,0.625 2.927,0.625 2.042,1.281 true 2.979,0.521 3.365,0.74 0.385,0.219 10 false SST

Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.

SST
09350-32014  (09351-32040)
09950-70010  (09951-07200)

NOTICE:

Do not compress the 1st and reverse brake return spring sub-assembly excessively.



b.
C395755

Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.

NOTICE:

Be careful not to damage the transaxle case sub-assembly.



c.
C395756

Remove the 1st and reverse brake return spring sub-assembly from the transaxle case sub-assembly.


Hide 35623L 56.REMOVE REVERSE BRAKE PISTON

a.

Apply compressed air (approximately 250 kPa (2.5 kgf/cm2, 36 psi)) to the fluid hole to disconnect the reverse brake piston from the transaxle case sub-assembly.

C395757

NOTICE:

Be careful as fluid may spray when applying compressed air.



b.
C395758

Remove the reverse brake piston from the transaxle case sub-assembly.


c.
C395759

Remove the 2 O-rings from the reverse brake piston.


Hide 57.REMOVE REDUCTION DRIVEN GEAR REAR TAPERED ROLLER BEARING (OUTER RACE)

a.
C395760N01
0.656,1.479 1.167,1.479 false 0.354,1.385 0.813,1.583 0.458,0.198 10 false SST

Using SST, remove the reduction driven gear rear tapered roller bearing (outer race) from the transaxle case sub-assembly.

SST
09308-00010  

HINT:
C395761

Align the claw of SST with the indentation of the transaxle case sub-assembly when removing the parts.



Hide 58.REMOVE DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)

a.
C395763N01
2.042,1.208 2.5,1.208 false 2.552,1.104 3.01,1.375 0.458,0.271 10 false SST

Using SST, remove the differential case rear tapered roller bearing (outer race) from the transaxle case sub-assembly.

SST
09308-00010  

HINT:
C395764

Align the claw of SST with the indentation of the transaxle case sub-assembly when removing the parts.



Hide 43420H 59.REMOVE FRONT DRIVE SHAFT OIL SEAL LH

a.
C395766N01
1.073,1.531 0.365,1.104 0.365,1.104 1.156,1.25 true 0.063,1.01 0.5,1.25 0.438,0.24 10 false SST

Using SST and a hammer, remove the front drive shaft oil seal LH from the transaxle case sub-assembly.

SST
09950-60011  (09951-00650)
09950-70010  (09951-07100)


Hide 60.REMOVE REDUCTION DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE)

a.
C396245C01
2.792,2.25 2.958,2.104 2.958,2.104 2.708,2.198 false 1.615,1.906 2.333,1.344 2.333,1.344 1.823,1.26 false 0.24,0.823 0.49,1.083 0.25,0.26 10 false *a 2.406,0.677 2.677,0.927 0.271,0.25 10 false *b 2.99,2 3.333,2.198 0.344,0.198 10 false SST 2.385,1.24 2.729,1.438 0.344,0.198 10 false SST
*a Hold
*b Turn


Using SST, remove the reduction driven gear rear tapered roller bearing (inner race) from the reduction driven gear.

SST
09950-00020  
09950-00030  
09950-40011  (09957-04010)
09950-60011  (09951-00250)

NOTICE:

Because SST is attached to the roller portion, there is a possibility that the roller portion could break and SST could come off before the reduction driven gear rear tapered roller bearing (inner race) comes off.



b.
C396246C01
1.604,1.906 2.365,1.438 2.365,1.438 1.823,1.271 false 2.771,2.26 2.948,2.083 2.948,2.083 2.688,2.219 false 0.229,0.823 0.458,1.063 0.229,0.24 10 false *a 2.396,0.677 2.667,0.927 0.271,0.25 10 false *b 2.417,1.333 2.813,1.531 0.396,0.198 10 false SST 2.99,1.979 3.385,2.177 0.396,0.198 10 false SST
*a Hold
*b Turn


If the roller portion breaks and SST comes off, reattach SST to the inner race in the position shown in the illustration, and continue removing the parts.

SST
09950-00020  
09950-00030  
09950-40011  (09957-04010)
09950-60011  (09951-00250)


Hide 61.REMOVE REDUCTION DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE)

a.
C396248C01
0.771,1.521 0.531,1.875 0.531,1.875 1.438,1.573 true 0.271,0.615 0.531,0.844 0.26,0.229 10 false *a 2.938,0.479 3.219,0.719 0.281,0.24 10 false *b 0.219,1.802 0.594,2.01 0.375,0.208 10 false SST
*a Hold
*b Turn


Using SST, remove the reduction driven gear front tapered roller bearing (inner race) from the reduction driven gear.

SST
09950-40011  (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
09950-60011  (09951-00210)


Hide 62.REMOVE DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (INNER RACE)

a.
C396250C01
0.615,1.583 0.406,1.844 0.406,1.844 1.229,1.646 true 0.198,0.667 0.51,0.896 0.313,0.229 10 false *a 2.833,0.573 3.073,0.813 0.24,0.24 10 false *b 0.094,1.771 0.552,1.969 0.458,0.198 10 false SST
*a Hold
*b Turn


Using SST, remove the differential case rear tapered roller bearing (inner race) from the differential case sub-assembly.

SST
09950-40011  (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
09950-60011  (09951-00460)


Hide 63.REMOVE DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (INNER RACE)

a.
C396252C01
0.635,1.583 0.438,1.875 0.438,1.875 1.219,1.625 true 0.229,0.615 0.479,0.833 0.25,0.219 10 false *a 2.833,0.563 3.083,0.823 0.25,0.26 10 false *b 0.135,1.802 0.594,2 0.458,0.198 10 false SST
*a Hold
*b Turn


Using SST, remove the differential case front tapered roller bearing (inner race) from the differential case sub-assembly.

SST
09950-40011  (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
09950-60011  (09951-00460)


Hide 64.REMOVE STRAIGHT PIN

a.
C398091

Remove the 2 straight pins from the transaxle case sub-assembly.