Primary Pulley and Secondary Pulley
Primary Pulley and Secondary PulleyREMOVAL
NOTE:
Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts.
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 transmission case.
17) Remove the reduction drive gear.
18) Set the ST to secondary pulley, expand the V groove of pulley, and then completely loosen the variator chain.
ST 18769AA010 EXPANDER PULLEY
19) Remove the chain guide.
(1) Remove the chain guide from lubrication pipe.
(2) Detach the four claws to remove the chain guide.
(3) Remove the lubrication pipe.
(4) Remove the support rod mounting bolts.
(5) Raise the support rod to remove the chain guide.
(6) Move the chain guide to the secondary pulley side.
(7) Detach the four claws to remove the chain guide.
(8) Remove the support rod.
CAUTION:
Protect the both pulleys and variator chain from scratching.
20) Remove the primary pulley mounting bolt.
21) Remove the primary pulley from the reverse brake housing and intersect the V groove of secondary pulley and the V groove of primary pulley. Remove the variator chain from primary pulley, and remove the primary pulley.
CAUTION:
Cover the V grooves of secondary pulley and primary pulley with cloth to protect the both pulleys and variator chain from scratching.
22) Remove the ST (EXPANDER PULLEY) from the secondary pulley.
23) Remove the variator chain from secondary pulley.
24) Remove the secondary pulley mounting bolts, and remove the secondary pulley.
25) Remove the seal ring from drive pinion retainer.
26) Remove the seal ring from the input shaft.
INSTALLATION
1) Select shims for pulley alignment.
2) Install the seal ring to the input shaft.
NOTE:
^ Use a new seal ring.
^ When installing the seal ring, do not expand the seal ring too much.
^ Apply CVTF to the seal rings.
3) Install the seal ring to drive pinion retainer.
NOTE:
^ Use a new seal ring.
^ Apply CVTF to the seal rings.
4) Install the selected shims to the primary pulley bearing catch surface.
5) Install the secondary pulley to the drive pinion retainer.
6) Install and tighten the secondary pulley securing bolts.
(1) Tighten the three bolts until the seating surfaces contact the bearing retainer.
NOTE:
^ Be careful not to tilt the bearing retainer of the secondary pulley.
^ Apply CVTF to the bolt.
(2) Tighten the bolts in the order of (A) to (B) to (C) to (B).
Tightening torque:
67.5 Nm (6.9 kgf-m, 49.8 ft-lb)
7) Place the variator chain on the V groove of the secondary pulley, and set the ST.
ST 18769AA010 EXPANDER PULLEY
8) Expand the V groove of the secondary pulley.
9) Install the primary pulley to the reverse brake housing together with the variator chain.
CAUTION:
Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching.
(1) 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.
(2) Install the primary pulley to the reverse brake housing so that the bolt hole of primary bearing retainer and the bolt hole of reverse brake housing are aligned.
10) Install the primary pulley bolt.
Tightening torque:
21 Nm (2.1 kgf-m, 24.3 ft-lb)
11) Install the chain guide.
(1) Place the support rod inside of the variator chain.
CAUTION:
Protect the both pulleys and variator chain from scratching.
(2) Install the chain guide to the variator chain.
(3) Move the chain guide to the support rod side.
(4) While holding the support rod, press the chain guide so that the support rod runs through between the protrusions of chain guide and install the chain guide to the support rod.
(5) Install the support rod.
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
(6) Install the lubrication pipe.
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
(7) Install the chain guide so that the lubrication pipe runs through between the protrusions of each chain guide. Then remove the ST (PULLEY EXPANDER).
12) Install the reduction drive gear.
13) Select the reduction drive gear shim.
14) Install the transmission case.
15) Install the transmission control device.
16) Install the oil strainer and oil pan.
17) Install the reduction driven gear assembly.
18) Install the transfer driven gear assembly.
19) Install the transfer clutch assembly.
20) Install the parking pawl.
21) Install the extension case.
22) Install the inhibitor switch.
23) Install the secondary speed sensor.
24) Install the primary speed sensor.
25) Install the turbine speed sensor.
26) Install the transmission harness.
27) Install the control valve body.
28) Install the air breather hose.
29) Install the transmission assembly to the vehicle.
INSPECTION
^ Check the surface of primary and secondary pulley cones for damage or wear.
^ Check the primary and secondary pulley for damage.
^ Check the bearing for seizure or wear.
^ Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.
ADJUSTMENT
PROCEDURE IN REPLACEMENT OF PRIMARY AND SECONDARY PULLEY, OR IN REPLACEMENT OF PRIMARY PULLEY, SECONDARY PULLEY AND VARIATOR CHAIN
1) Measure the depth "Lp" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average.
ST 499575400 GAUGE
2) Measure the depth "Ls" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average.
ST 499575400 GAUGE
3) Calculate the following formula.
Calculation formula:
T (mm) = B - A + Lp - Ls - 28.602
[T (in) = B - A + Lp - Ls - 1.126]
T: Pulley alignment
A: Specified primary pulley dimension
B: Specified secondary pulley dimension
Lp: Depth from the ST upper face to the primary pulley bearing catch surface
Ls: Depth from the ST upper face to the secondary pulley bearing catch surface
28.602 mm (1.126 in): Constant
4) Select one to two shims so that the total thickness meets the value obtained from step 3).
PROCEDURE WHEN REPLACING ONLY DRIVE PINION RETAINER OR REVERSE BRAKE HOUSING
1) Clean the mating surface of current drive pinion retainer and converter case.
2) Measure and record the shim thickness that is attached on the current reverse brake housing.
3) Using the current drive pinion retainer, measure the depth "Lp1" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average.
ST 499575400 GAUGE
4) Using the current drive pinion retainer or current reverse brake housing, measure the depth "Ls1" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average.
ST 499575400 GAUGE
5) Calculate the "LD1" using the following formula and record it.
Calculation formula:
LD1 mm (in) = Ls1 - Lp1
LD1: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface
Lp1: Depth from the ST upper face to the primary pulley bearing catch surface
Ls1: Depth from the ST upper face to the secondary pulley bearing catch surface
6) Using the new drive pinion retainer or new reverse brake housing, measure the depth "Lp2" from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average.
ST 499575400 GAUGE
7) Using the new drive pinion retainer or new reverse brake housing, measure the depth "Ls2" from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average.
ST 499575400 GAUGE
8) Calculate the "LD2" using the following formula and record it.
Calculation formula:
LD2 mm (in) = Ls2 - Lp2
LD2: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface
Lp2: Depth from the ST upper face to the primary pulley bearing catch surface
Ls2: Depth from the ST upper face to the secondary pulley bearing catch surface
9) Calculate the recorded values of "LD1" and "LD2" to obtain the positive number to select the shims. Calculation formula: T1 mm (in) = LD1 - LD2 or T2 mm (in) = LD2 - LD1
T1, T2: Difference between new drive pinion retainer or new reverse brake housing and current drive pinion retainer or current reverse brake housing
LD1: Calculated value of current drive pinion retainer or current reverse brake housing
LD2: Calculated value of new drive pinion retainer or new reverse brake housing
