Transmission Reassembly

Special Tools Required 

• Reverse Brake Spring Compressor 07TAE-P4V0110
• Start Clutch Installer 07TAE-P4VA131

1. Install new O-rings (A) on the CVTF feed pipes (10.9 x 56 mm) (B), then install it with the filter ends into the transmission housing (E).
   Fig 1: Identifying O-Rings And CVTF Feed Pipes

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Install the two dowel pins (C) and a new gasket (D) on the transmission housing (E).
3. Push the selector control shaft (F) toward the outside of the transmission housing, then install the intermediate housing (G).
4. Pull the selector control shaft back, then install the roller (H) in the intermediate housing by aligning the groove on the control shaft.
5. Install two new O-rings (A) on the reverse brake piston (B), then install the piston in the intermediate housing (C).
   Fig 2: Identifying O-Rings, Reverse Brake Piston And Intermediate Housing

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. Install the spring retainer/return spring assembly (D); install the return springs on the spring guides (E) on the reverse brake piston.
7. Install the reverse brake spring compressor through the drive pulley shaft to compress the return spring. Be sure the reverse brake spring compressor is set over the return springs, not over the reverse brake piston.
   Fig 3: Identifying Reverse Brake Spring Compressor

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. Compress the return springs, and make sure that the reverse brake spring compressor is set over the return springs and the spring retainer tabs do not ride on the reverse brake piston.
   Fig 4: Identifying Reverse Brake Spring Compressor Position

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Install the snap ring in the intermediate housing above the spring retainer, and remove the reverse brake spring compressor.
10. Check that the snap ring end gap (A) is 15 mm (0.59 in) or more.
    Fig 5: Identifying Snap Ring End Gap

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11. Install the disc spring (A) on the reverse brake piston in the direction shown.
    Fig 6: Identifying Disc Spring And Reverse Brake Plates

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12. Starting with the two reverse brake plates (B), alternately install the two plates and discs (C). Install the reverse brake end-plate (D), then install the snap ring (E).
13. Check that the snap ring inside diameter (A) is 143.5 mm (5.65 in) or more, and also check that the snap ring end gap (B) is 8.7 mm (0.34 in) or more.
    Fig 7: Identifying Snap Ring Inside Diameter

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14. Set up a dial indicator (A) on the reverse brake end-plate (B).
    Fig 8: Setting Up Dial Indicator On Reverse Brake End-Plate

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15. Zero the dial indicator by lifting the top disc (C) up against the reverse brake end-plate and the end-plate up against the snap ring (D).
16. Release the reverse brake end-plate (D) to lower the reverse brake end-plate, and place a steel plate (A) across width of the reverse brake end-plate.
    Fig 9: Checking Clearance Between Reverse Brake End-Plate And Top-Disc With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. Press the steel plate (A) down with 49 N (5 kgf, 11 lbf) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the reverse brake end-plate (D) and the top-disc (E). Take measurements in at least three places, and use the average as the actual clearance.

    Standard: 0.55-0.70 mm (0.022-0.028 in) 

18. If the clearance is out of standard, remove the reverse brake end-plate, and measure its thickness.
19. Select a new reverse brake end-plate from the following table and install it, then recheck that the clearance is within the standard.

    REVERSE BRAKE END-PLATE 

    REVERSE BRAKE END-PLATE SPECIFICATION
    
    

    Mark	Thickness
    2	3.8 mm (0.150 in)
    B	3.9 mm (0.154 in)
    3	4.0 mm (0.157 in)
    C	4.1 mm (0.161 in)
    4	4.2 mm (0.165 in)
    D	4.3 mm (0.169 in)
    5	4.4 mm (0.173 in)
    E	4.5 mm (0.177 in)
    6	4.6 mm (0.181 in)
    F	4.7 mm (0.185 in)
    7	4.8 mm (0.189 in)
    8	5.0 mm (0.197 in)

20. If replacing the reverse brake end-plate, make sure that the clearance is within the tolerance.
21. Install the snap ring retainer (A) over the drive pulley shaft (B).
    Fig 10: Identifying Snap Ring Retainer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
22. Wrap the drive pulley shaft splines with tape to prevent O-ring damage. Install two new O-rings (C) in the drive pulley shaft O-ring grooves, then remove the tape.
23. Install the forward clutch (D) on the drive pulley shaft, then install the snap ring (E) to secure the forward clutch.
24. Check that the snap ring outside diameter (A) is 41.4 mm (1.63 in) or less.
    Fig 11: Identifying Snap Ring Outside Diameter

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25. Install the ring gear (A) on the forward clutch (B).
    Fig 12: Identifying Ring Gear And Forward Clutch

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26. Install the input shaft/planetary carrier assembly (C) through the drive pulley shaft (D) by aligning the sun gear (E) with the forward clutch discs and aligning the planetary carrier with the reverse brake discs.
27. Install the manual valve body separator plate (A) and the two dowel pins (B) on the intermediate housing, then install the manual valve body (C) and detent spring (D).
    Fig 13: Manual Valve Body Separator Plate, Dowel Pins, Manual Valve Body And Detent Spring With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
28. Install two new O-rings (A) on the 10.9 x 18.6 mm CVTF feed pipe (B), then install it on the manual valve body (C).
    Fig 14: O-Rings, Bolts With Torque Specifications, CVTF Feed Pipe And Manual Valve Body

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
29. Install two new O-rings (D) on the 10.9 x 56 mm CVTF feed pipe (E), then install it with the filter end and an 8 mm CVTF pipe (F) in the intermediate housing.
30. Install the two dowel pins (G) and a new gasket (H) on the intermediate housing.
31. Install four new O-rings (I) on the two CVTF feed pipes (J), then install them on the manual valve body and the intermediate housing.
32. Place the end cover on the intermediate housing.
33. Install the end cover bolts (sixteen), and tighten them to the specified torque in a crisscross pattern in at least two or three steps, then turn the transmission end cover down.
34. Install the sealing ring (A) on a new secondary drive/park gear (B).
    Fig 15: Identifying Sealing Ring And Secondary Drive/Park Gear

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35. Insert the secondary drive/park gear (A) into the start clutch (B). Wiggle the secondary drive/park gear back and forth as it goes into the start clutch, and push in the secondary drive/park gear until it bottoms out.
    Fig 16: Inserting Secondary Drive/Park Gear Into Start Clutch

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36. Install the park pawl (A), the pawl spring (B), and the pawl shaft (C) on the transmission housing, then move the control lever to any position other than P.
    Fig 17: Identifying Park Pawl, Pawl Spring, And Pawl Shaft

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37. Use CVT fluid to lubricate the new O-rings (D) for the driven pulley shaft, then install the O-rings on the shaft.
38. Place the start clutch and secondary drive/park gear (E) onto the driven pulley shaft (F).
    NOTE: Make sure to hold the secondary drive/park gear engaged into the start clutch when you install the start clutch and secondary drive/park gear onto the driven pulley shaft.
39. Seat the start clutch by aligning the tip of the start clutch installer with the driven pulley shaft hole (A) and then pushing down the handle (B).
    Fig 18: Seating Start Clutch

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40. While holding the handle (A) down, push down the bottom part (B) of the start clutch installer until it contacts the seating surface of the start clutch.
    Fig 19: Pushing Down Bottom Part Of Start Clutch Installer

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41. Hold the upper hex section of the start clutch installer with a 19 mm wrench (A), then use an adjustable wrench to tighten the start clutch installer's lower nut (B) until the start clutch seats.
    NOTE: When using the start clutch installer, hold the bolt (C) and then turn the nut (B). Turning the bolt could damage the start clutch installer.