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CVT Automatic Transmission (Service Information): Disassembly: Disassembly

Fig 1: CVT Transaxle Externals - Exploded View
GC0084462Courtesy of CHRYSLER GROUP, LLC
1- WASHER
2 - SHIFT LEVER
3 - INHIBITOR SWITCH
4 - CVT FLUID FILTER (Certain Models)
5 - O-RING
6 - CVT FLUID COOLER
7 - SHIM
8 - OUTPUT SPEED SENSOR
9 - O-RING
10 - transmission
11 - PULLEY RATIO LINKAGE
12 - SPRING
13 - CONTROL VALVE
14 - BRACKET
15 - O-RING
16 - OIL STRAINER
17 - PLAIN WASHER
18 - MANUAL LEVER
19 - BUSHING
20 - MANUAL VALVE
21 - STEPPER MOTOR
22 - LIP SEAL
23 - SNAP RING
24 - VALVE BODY HARNESS
25 - OIL PAN GASKET
26 - OIL PAN
27 - TORQUE CONVERTER
28 - O-RING
29 - INPUT SPEED SENSOR
30 - O-RING
Fig 2: CVT Transaxle Internals - Exploded View
GC0084463Courtesy of CHRYSLER GROUP, LLC
1 - O-RING
2 - SIDE OIL SEAL
3 - ADJUSTABLE SHIM
4 - OUTER RACE
5 - REDUCTION GEAR ASSEMBLY
6 - OUTER RACE
7 - ADJUSTABLE SHIM
8 - OUTER RACE
9 - DIFFERENTIAL ASSEMBLY
10 - OUTER RACE
11 - FORWARD CLUTCH ASSEMBLY
12 - NEEDLE BEARING
13 - SEAL RING
14 - OIL PUMP COVER
15 - BAFFLE PLATE
16 - BRACKET
17 - ADJUSTABLE SHIM
18 - ADJUSTABLE SHIM
19 - CONVERTER HOUSING
20 - CONVERTER HOUSING OIL SEAL
21 - OIL PUMP CHAIN
22 - DRIVE SPROCKET
23 - THRUST WASHER
24 - BAFFLE PLATE
25 - DRIVEN SPROCKET (OIL PUMP)
26 - BAFFLE PLATE
27 - OIL PUMP
28 - LIP SEAL
29 - SNAP RING
30 - DRIVEN PLATES
31 - NEEDLE BEARING
32 - SUN GEAR
33 - NEEDLE BEARING
34 - PLANETARY CARRIER
35 - NEEDLE BEARING
36 - SNAP RING
37 - RETAINING PLATE
38 - DRIVEN PLATES
39 - DISH PLATE
40 - SNAP RING
41 - RETAINING PLATE
42 - SPRING RETAINER ASSEMBLY
43 - REVERSE PLATE PISTON
44 - DETENT SPRING
45 - transmission CASE
  1. Refer to the exploded views as necessary when performing the following steps.
    Fig 3: Torque Converter
    GC0084464Courtesy of CHRYSLER GROUP, LLC
  2. Drain the Continuously Variable Transmission (CVT) fluid from the transmission assembly.
  3. Remove the power transfer unit assembly and o-ring (4WD only).
  4. Remove the torque converter (1) from the transmission.
    Fig 4: Transmission Service Stand, Case & Mount Bolts
    GC0084465Courtesy of CHRYSLER GROUP, LLC
  5. Install Transmission Service Stand (special tool #9878, Stand, Transmission Service) (1) to the belt side of the transmission case (3) using the upper transmission mount bolts (2).
    Fig 5: Output Speed Sensor
    GC0084466Courtesy of CHRYSLER GROUP, LLC
  6. Remove the output speed sensor (1) from the converter housing. Remove and discard the o-ring from the output speed sensor.
    CAUTION:

    Set aside and reuse any adjusting shim found between the output speed sensor and the converter housing.

    Fig 6: Input Speed Sensor
    GC0084467Courtesy of CHRYSLER GROUP, LLC
  7. Remove the input speed sensor (1) from the transmission case. Remove and discard the o-ring from the input speed sensor.
    Fig 7: Shift Lever
    GC0084468Courtesy of CHRYSLER GROUP, LLC
  8. Remove the nut (1) holding the shift lever (2) to the manual shaft.
  9. Remove the shift lever from the manual shaft.
    Fig 8: Transmission Range Sensor
    GC0084469Courtesy of CHRYSLER GROUP, LLC
  10. Remove the bolts (2) holding the Transmission Range Sensor (TRS) (1) to the transmission case.
  11. Remove the (TRS) (1) from the transmission case and the manual shaft.
    Fig 9: Terminal Body
    GC0084470Courtesy of CHRYSLER GROUP, LLC
  12. Remove the snap ring (1) from the terminal body (2) and press the terminal body into the transmission case.
    CAUTION:

    Be careful not to cause damage to the terminal body.

    Fig 10: Fluid Cooler
    GC0084471Courtesy of CHRYSLER GROUP, LLC
  13. Remove CVT fluid cooler (1) from transmission case. Remove and discard the CVT fluid cooler o-ring.
    Fig 11: Fluid Filter
    GC0084472Courtesy of CHRYSLER GROUP, LLC
  14. Remove the bolts holding the CVT fluid filter to the transmission case.
  15. Remove the CVT fluid filter (1) from the transmission case (certain models).
    Fig 12: Converter Housing Mounting Bolts
    GC0084473Courtesy of CHRYSLER GROUP, LLC
  16. Remove the converter housing mounting bolts.
    Fig 13: Converter Housing
    GC0084474Courtesy of CHRYSLER GROUP, LLC
  17. Remove the converter housing (1) by tapping with plastic hammer.
    CAUTION:

    There is a possibility that the drive sprocket adjusting shim may be dislodged and fall out.

    Fig 14: Removing Outer Race Reduction Gear
    GC0099041Courtesy of CHRYSLER GROUP, LLC
  18. Remove outer race of reduction gear bearing (1) from the converter housing using Puller (special tool #7794-A, Remover, Seal) and Puller (special tool #C-637, Slide Hammer, Universal).
    Fig 15: Removing Differential Side Oil Seal
    GC0084475Courtesy of CHRYSLER GROUP, LLC
  19. Remove differential side oil seal (1) from converter housing using a screwdriver. (2WD)
    Fig 16: Removing Converter Housing Oil Seal
    GC0084476Courtesy of CHRYSLER GROUP, LLC
  20. Remove converter housing oil seal (1) from converter housing using a screwdriver.
    Fig 17: Removing Outer Race Of Differential Side Bearing
    GC0084477Courtesy of CHRYSLER GROUP, LLC
  21. Remove outer race (1) of differential side bearing from converter housing using a suitable punch.
    CAUTION:

    When removing the outer race, tap the outer race on both sides evenly. When removing the outer race, do not damage the converter housing.

    Fig 18: Input Shaft O-Ring
    GC0084478Courtesy of CHRYSLER GROUP, LLC
  22. Remove and discard the O-ring (1) from the input shaft.
    Fig 19: Adjusting Shim At Drive Sprocket
    GC0084479Courtesy of CHRYSLER GROUP, LLC
  23. Remove the adjusting shim (1) from the drive sprocket, if necessary.
    Fig 20: Baffle Plate
    GC0084480Courtesy of CHRYSLER GROUP, LLC
  24. Remove the nuts holding the baffle plate (1) to the transmission.
  25. Remove the baffle plate.
    Fig 21: Identifying Snap Ring, Oil Pump Chain & Driven Sprocket
    GC0084481Courtesy of CHRYSLER GROUP, LLC
  26. Expand the snap ring (1) and remove the driven sprocket (3), the oil pump chain (2), and the drive sprocket.
    Fig 22: Thrust Washer At Oil Pump Cover
    GC0084482Courtesy of CHRYSLER GROUP, LLC
  27. Remove the thrust washer (1) from the oil pump cover.
    Fig 23: Snap Ring At Oil Pump
    GC0084483Courtesy of CHRYSLER GROUP, LLC
  28. Remove the snap ring (1) from the oil pump.
    Fig 24: Reduction Gear Assembly
    GC0084484Courtesy of CHRYSLER GROUP, LLC
  29. Remove the reduction gear assembly (1) from the transmission case.
    Fig 25: Differential Assembly
    GC0084485Courtesy of CHRYSLER GROUP, LLC
  30. Remove the differential assembly (1) from the transmission case.
    Fig 26: Bracket
    GC0084486Courtesy of CHRYSLER GROUP, LLC
  31. Remove the bolts holding the bracket (1) to the oil pump cover and the transmission.
  32. Remove the bracket (1).
    Fig 27: Baffle Plate
    GC0084487Courtesy of CHRYSLER GROUP, LLC
  33. Remove the bolts holding the baffle plate (1) to the transmission.
  34. Remove the baffle plate.
    Fig 28: Reaction Shaft Support
    GC0084488Courtesy of CHRYSLER GROUP, LLC
  35. Remove the bolts holding the reaction shaft support (1) to the transmission.
  36. Remove the reaction shaft support from the transmission case.
    Fig 29: Seal Rings
    GC0084489Courtesy of CHRYSLER GROUP, LLC
  37. Remove and discard the seal rings (1) from the reaction shaft support.
    Fig 30: Oil Pan
    GC0084490Courtesy of CHRYSLER GROUP, LLC
  38. Remove the bolts holding the oil pan (1) to the transmission case.
  39. Remove the oil pan from the transmission case.
    Fig 31: Oil Pan Gasket
    GC0084491Courtesy of CHRYSLER GROUP, LLC
  40. Remove the oil pan gasket (1) from the transmission case.
    Fig 32: Oil Strainer
    GC0084492Courtesy of CHRYSLER GROUP, LLC
  41. Remove the bolts holding the oil strainer (1) to the valve body.
  42. Remove the oil strainer.
  43. Remove and discard the oil strainer o-ring.
    Fig 33: Oil Pump Retaining Bolts
    GC0084493Courtesy of CHRYSLER GROUP, LLC
  44. Remove the bolt (2) holding the oil pump to the transmission case from the rear of the transmission.
  45. Remove the bolts (1) holding the oil pump to the transmission case from inside the transmission.
  46. Remove the oil pump from the transmission case.
    Fig 34: Oil Pump Mounting Bolt O-Ring
    GC0084494Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    One of the oil pump retaining bolts is installed from the outside of the transmission case into the rear part of the oil pump.

  47. Remove and discard the o-ring (1) from the oil pump mounting bolt. (Only on bolt installed from the outside of the transmission case).
    Fig 35: Lip Seal At Transaxle Case
    GC0084495Courtesy of CHRYSLER GROUP, LLC
  48. Remove and discard the lip seal (1) from the transmission case.
    Fig 36: Detent Spring
    GC0084496Courtesy of CHRYSLER GROUP, LLC
  49. Remove the bolt holding the detent spring (1) to the transmission case.
  50. Remove the detente spring from the transmission case.
    Fig 37: Forward Clutch Assembly
    GC0084497Courtesy of CHRYSLER GROUP, LLC
  51. Remove the forward clutch assembly (1) from the transmission case.
    Fig 38: Needle Bearing On Forward Clutch
    GC0084498Courtesy of CHRYSLER GROUP, LLC
  52. Remove needle bearing (1) from forward clutch drum side of the sun gear.
    Fig 39: Sun Gear At Planetary Carrier
    GC0084499Courtesy of CHRYSLER GROUP, LLC
  53. Remove the sun gear (1) from the planetary carrier.
    Fig 40: Needle Bearing At Sun Gear
    GC0084500Courtesy of CHRYSLER GROUP, LLC
  54. Remove the needle bearing (1) from the sun gear.
    Fig 41: Planetary Carrier Assembly
    GC0084501Courtesy of CHRYSLER GROUP, LLC
  55. Remove the planetary carrier assembly (1) from the transmission case.
    Fig 42: Needle Bearing At Planetary Carrier
    GC0084502Courtesy of CHRYSLER GROUP, LLC
  56. Remove the needle bearing (1) from the planetary carrier.
    Fig 43: Bracket At Valve Body Assembly
    GC0084503Courtesy of CHRYSLER GROUP, LLC
  57. Remove the bolts holding the bracket (1) to the valve body assembly.
  58. Remove the bracket from the valve body assembly.
    Fig 44: Manual Lever
    GC0084504Courtesy of CHRYSLER GROUP, LLC
  59. Remove the nut holding the manual lever (1) to the manual shaft.
  60. Remove the manual lever.
    Fig 45: Bolts For Valve Body Assembly
    GC0084505Courtesy of CHRYSLER GROUP, LLC
  61. Use this illustration when removing valve body attaching bolts.
    Fig 46: Pulley Ratio Linkage
    GC0084506Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Tilt the valve body assembly away from the transaxle case on the manual shaft side to ease removal. Pay attention to completely remove the terminal body from the transaxle case.

  62. Remove the valve body assembly from the transmission case as follows:
    1. Insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of the valve body assembly to fix the pulley ratio linkage (1).
    2. Remove the bolts holding the valve body assembly to the transmission case.
    3. Remove the valve body assembly from the transmission case.
    Fig 47: Bushing At Control Valve
    GC0084507Courtesy of CHRYSLER GROUP, LLC
  63. Remove and set aside the bushing (1) from the valve body.
    Fig 48: Removing/Installing Manual Shaft
    GC0084508Courtesy of CHRYSLER GROUP, LLC
  64. Remove the pin at the manual shaft using a punch (2).
  65. Remove the manual shaft from case.
    Fig 49: Lip Seal At Transaxle Case
    GC0084509Courtesy of CHRYSLER GROUP, LLC
  66. Remove and discard the lip seal (1) from the transmission case.
    Fig 50: Removing Outer Race Of Differential Side Bearing
    GC0084510Courtesy of CHRYSLER GROUP, LLC
  67. Remove outer race (1) of differential side bearing from converter main housing using Puller (special tool #9664, Remover, Bearing Cup) and Puller (special tool #C-637, Slide Hammer, Universal).
    Fig 51: Selective Shim At Transaxle Case
    GC0084511Courtesy of CHRYSLER GROUP, LLC
  68. Remove the selective shim (1) from the transmission case.
    Fig 52: Removing Outer Race Reduction Gear
    GC0099041Courtesy of CHRYSLER GROUP, LLC
  69. Remove outer race of reduction gear bearing (1) from transmission case using Puller (special tool #C-637, Slide Hammer, Universal) and Puller (special tool #7794-A, Remover, Seal).
    Fig 53: Selective Shim At Transaxle Case
    GC0084512Courtesy of CHRYSLER GROUP, LLC
  70. Remove the selective shim (1) from the transmission case.
    Fig 54: Side Oil Seal At Transaxle Case
    GC0084513Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    When removing the side oil seal, do not damage the transaxle case.

  71. Remove side oil seal (1) from transmission case using a screwdriver.
    Fig 55: Retaining Plate Of The Reverse Brake
    GC0084514Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Check if there is damage, deformation, or burning on the surface of any of the drive or driven plates. Check for permanent fatigue of the dish plate, driven plates, retaining plate, snap ring, and the drive plates. Replace all reverse brake components if any of these conditions exist.

  72. Remove the reverse brake snap ring using a screwdriver. Then remove the reverse brake retaining plate, the drive plates, the driven plates, and the dish plate from the transmission case.
    Fig 56: Removing/Installing Retaining Plate & Spring Retainer Assembly
    GC0084515Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Set the spring compressor right on top of the return spring of the spring retainer assembly. Do not remove the return springs from the spring retainer assembly.

  73. Compress the reverse brake return spring using Compressor (special tool #5058A, Compressor, Spring) (1) and Compressor (special tool #9875, Compressor). Remove the snap ring (2) from the transmission case.
  74. Remove the retaining plate and the spring retainer assembly.
    Fig 57: Fluid Passage
    GC0084516Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    There is a possibility that the reverse brake piston might be stuck if excessive pressure is required to remove.

  75. Try removing the reverse brake piston from the transmission case by hand if unable to remove by hand, apply compressed air to the fluid passage (1). and remove the reverse brake piston from the transmission case.
    Fig 58: Bolts At Drive Belt Assembly
    GC0084517Courtesy of CHRYSLER GROUP, LLC
  76. Remove the case bolts (1) at the drive belt assembly (2).
    NOTE:

    Pin at pulley sensor stays with drive belt assembly case.

  77. Separate drive belt assembly case from main housing.
    Fig 59: Sheave Retaining Bolts
    GC0084518Courtesy of CHRYSLER GROUP, LLC
  78. Remove the bolts (2) that hold both sheaves to the case (1).
    Fig 60: Installing Puller Onto Secondary Sheave
    GC0084519Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not allow the Puller to come in contact with the belt at any time

  79. Install the Puller (special tool #9874, Compressor, Pulley) (1) and Insert (special tool #8513A, Insert, Crankshaft) (2) onto the secondary sheave (3).
    Fig 61: Compressing Sheave Using Compressor Tool
    GC0084520Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not over tighten the compressor tool. Tighten to no more than 7 N.m (50 in. lbs.)

    NOTE:

    The belt is directional, look for an arrow indicating the direction of the belt for installation.

  80. Compress sheave (2) to the stop.
    Fig 62: Lifting/Moving Secondary Sheave
    GC0084521Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not allow the primary sheave to contact the drive surface of the secondary sheave.

    NOTE:

    You may need to lightly tap case while holding secondary sheave.

  81. Lift and move the secondary sheave (1) closer to the primary sheave.
    Fig 63: Pin At Sheave Height Sensor
    GC0084522Courtesy of CHRYSLER GROUP, LLC
  82. Remove the pin (1) from the sheave height sensor (3).
    Fig 64: Sheave Height Sensor
    GC0084523Courtesy of CHRYSLER GROUP, LLC
  83. Lift the primary sheave (3) enough to remove the sheave height sensor (1).
    Fig 65: Drive Belt
    GC0084524Courtesy of CHRYSLER GROUP, LLC
  84. Remove the drive belt (1) from both secondary (3) and primary sheaves (2).
  85. Remove the secondary sheave.
    Fig 66: Shim Under Sheave
    GC0084525Courtesy of CHRYSLER GROUP, LLC
  86. Remove the shim (3) under the secondary sheave (1).
    Fig 67: Secondary Sheave
    GC0084526Courtesy of CHRYSLER GROUP, LLC
  87. Remove the primary sheave.
  88. Remove bolts at the park pawl.
  89. Remove the park pawl.
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