Reverse Brake: Installation

Check the projection (A) of the knock pins.

On reverse brake housing side

NOTE: When attached on the manual valve body side, install them on the reverse brake housing side.

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Specification:

5.5 - 6.5 mm (0.22 - 0.26 in)

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On drive pinion retainer side
NOTE: When attached on the reverse brake housing side, install them on the drive pinion retainer side.

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Specification:

8.5 - 9.5 mm (0.33 - 0.37 in)

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Install the thrust bearing as shown in the figure.
NOTE: Make sure to install in the right direction.

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Select a washer.

Using the ST, measure the height "H1" from the ST end face to the washer installation surface.

Preparation tool:

ST: GAUGE (499575600)

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Install the planetary gear and forward clutch drum as a single unit.

NOTE: Install the seal rings after adjusting the washer.

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Set the thrust bearing as shown in the figure.

NOTE: Make sure to install in the right direction.

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Using the ST, measure the height "H2" from the ST end face to the reverse brake housing mating surface.

Preparation tool:

ST: GAUGE (499575600)

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Using the following calculation, calculate an appropriate washer thickness "T".

NOTE: Adjust using 1 piece.

T = H1 - H2 - 0.35 - 0.70 mm (0.014 - 0.028 in)

T	Washer thickness mm (in)
H1	Measured value (mm (in)) of step (1)
H2	Measured value (mm (in)) of step (4)
0.35 - 0.70 mm (0.014 - 0.028 in)	Clearance specification

Install the washer.

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Install a new O-ring.
NOTE: Apply CVTF to the O-rings.

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Remove the planetary gear and forward clutch drum as a single unit.
NOTE: The thrust bearing may be removed together with the forward clutch drum.

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Install a new seal ring.
NOTE:
- Apply CVTF to the seal rings.
- Do not stretch the seal ring more than necessary.
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Mount the forward clutch drum (B) to the reverse brake housing (A), and set to the drive pinion retainer (C).
NOTE: Do not press-in forcibly because there is a possibility of offset between drive plate and driven plate.

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Install the bolt to secure the reverse brake housing.
CAUTION: Confirm close contact of the reverse brake housing to the drive pinion retainer before tightening the bolts.

Tightening torque:

37 N.m (3.8 kgf-m, 27.3 ft-lb)

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Select the primary pulley shim, when the reverse brake housing or the drive pinion retainer is replaced.

NOTE: It is not necessary when the primary pulley and secondary pulley are replaced.

Using the ST, measure the height "H1" from the ST end face to the primary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

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Measure the height "H2" from the ST end face to the secondary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

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Using the following calculation, measure the dimension "B" from the primary pulley bearing catch surface to the secondary pulley bearing catch surface.

B = H2 - H1

B	Dimension (mm (in)) from the primary pulley bearing catch surface to the secondary pulley bearing catch surface
H1	Measured value (mm (in)) of step (1)
H2	Measured value (mm (in)) of step (2)

Using the following calculation and selection criteria table, select an appropriate primary pulley shim from the dimension differences "C".

NOTE: Adjust using 1 - 2 pieces.

C = A - B

C	Dimension difference (mm (in))
A	Calculated value (mm (in)) of removal step 4 (4)
B	Calculated value (mm (in)) of step (3)

PRIMARY PULLEY SHIM SELECTION CRITERIA FOR CALCULATED VALUES

Dimension difference (mm (in))	Thickness of primary pulley shim
0.551 - 0.600 (0.022 - 0.024)	Select the shim 0.6 mm (0.024 in) thicker than the primary pulley shim before replacement.
0.451 - 0.550 (0.018 - 0.022)	Select the shim 0.5 mm (0.020 in) thicker than the primary pulley shim before replacement.
0.351 - 0.450 (0.014 - 0.018)	Select the shim 0.4 mm (0.016 in) thicker than the primary pulley shim before replacement.
0.251 - 0.350 (0.010 - 0.014)	Select the shim 0.3 mm (0.012 in) thicker than the primary pulley shim before replacement.
0.151 - 0.250 (0.006 - 0.010)	Select the shim 0.2 mm (0.008 in) thicker than the primary pulley shim before replacement.
0.051 - 0.150 (0.002 - 0.006)	Select the shim 0.1 mm (0.004 in) thicker than the primary pulley shim before replacement.
0.050 - -0.050 (0.002 - -0.002)	Select a new shim of the same thickness as the primary pulley shim before replacement.
-0.051 - -0.150 (-0.002 - -0.006)	Select the shim 0.1 mm (0.004 in) thinner than the primary pulley shim before replacement.
-0.151 - -0.250 (-0.006 - -0.010)	Select the shim 0.2 mm (0.008 in) thinner than the primary pulley shim before replacement.
-0.251 - -0.350 (-0.010 - -0.014)	Select the shim 0.3 mm (0.012 in) thinner than the primary pulley shim before replacement.
-0.351 - -0.450 (-0.014 - -0.018)	Select the shim 0.4 mm (0.016 in) thinner than the primary pulley shim before replacement.
-0.451 - -0.550 (-0.018 - -0.022)	Select the shim 0.5 mm (0.020 in) thinner than the primary pulley shim before replacement.
-0.551 - -0.600 (-0.022 - -0.024)	Select the shim 0.6 mm (0.024 in) thinner than the primary pulley shim before replacement.

PRIMARY PULLEY SHIM SELECTION CRITERIA FOR CALCULATED VALUES (MEASUREMENT BASE EXAMPLES)

Dimension difference (mm (in))	Thickness of primary pulley shim
0.56 - 0.60 (0.022 - 0.024)	Select the shim 0.6 mm (0.024 in) thicker than the primary pulley shim before replacement.
0.46 - 0.55 (0.018 - 0.022)	Select the shim 0.5 mm (0.020 in) thicker than the primary pulley shim before replacement.
0.36 - 0.45 (0.014 - 0.018)	Select the shim 0.4 mm (0.016 in) thicker than the primary pulley shim before replacement.
0.26 - 0.35 (0.010 - 0.014)	Select the shim 0.3 mm (0.012 in) thicker than the primary pulley shim before replacement.
0.16 - 0.25 (0.006 - 0.010)	Select the shim 0.2 mm (0.008 in) thicker than the primary pulley shim before replacement.
0.06 - 0.15 (0.002 - 0.006)	Select the shim 0.1 mm (0.004 in) thicker than the primary pulley shim before replacement.
0.05 - -0.05 (0.002 - -0.002)	Select a new shim of the same thickness as the primary pulley shim before replacement.
-0.06 - -0.15 (-0.002 - -0.006)	Select the shim 0.1 mm (0.004 in) thinner than the primary pulley shim before replacement.
-0.16 - -0.25 (-0.006 - -0.010)	Select the shim 0.2 mm (0.008 in) thinner than the primary pulley shim before replacement.
-0.26 - -0.35 (-0.010 - -0.014)	Select the shim 0.3 mm (0.012 in) thinner than the primary pulley shim before replacement.
-0.36 - -0.45 (-0.014 - -0.018)	Select the shim 0.4 mm (0.016 in) thinner than the primary pulley shim before replacement.
-0.46 - -0.55 (-0.018 - -0.022)	Select the shim 0.5 mm (0.020 in) thinner than the primary pulley shim before replacement.
-0.56 - -0.60 (-0.022 - -0.024)	Select the shim 0.6 mm (0.024 in) thinner than the primary pulley shim before replacement.

Install the oil guide.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

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Install the manual valve body and separator plate.
NOTE: Apply CVTF to the threaded portion of the bolts and seat surface.

Tightening torque:

9 N.m (0.9 kgf-m, 6.6 ft-lb)

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Install the primary pulley, secondary pulley and variator chain. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>PRIMARY PULLEY AND SECONDARY PULLEY>INSTALLATION .