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 them with the filter ends into the transmission housing (C).
   Fig 1: Identifying O-Rings On CVTF Feed Pipes

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Install the two dowel pins (D) and a new gasket (E) on the transmission housing.
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 On Reverse Brake Piston

   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) of the reverse brake piston.
7. Install the reverse brake spring compressor through the drive pulley shaft to compress the spring retainer/return spring assembly (A). Be sure the reverse brake spring compressor is set over the spring retainer, not over the reverse brake piston.
   Fig 3: Installing Reverse Brake Spring Compressor

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

   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. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the intermediate housing, and that the ring end gap (A) is 15 mm (0.59 in) or more.
    Fig 5: Identifying Snap Ring End Gap

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Install the disc spring (A) on the spring retainer (B) in the direction shown.
    Fig 6: Identifying Disc Spring On Spring Retainer

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
12. Starting with the two reverse brake plates (C), alternately install the two reverse brake plates and the reverse brake discs (D). Install the reverse brake end-plate (E), then install the snap tiny (F)
13. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the intermediate housing, and 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 End Gap

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
14. Set up a dial indicator (A) on the reverse brake end-plate (B).
    Fig 8: Setting Dial Indicator On Reverse Brake End-Plate

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
15. Zero the dial indicator by lifting the top disc (C) up against the reverse brake end-plate and the reverse brake end-plate up against the snap ring (D).
16. Release the reverse brake end-plate (A) to lower the reverse brake end-plate, and place a steel plate (B) across width of the reverse brake end-plate.

    Standard: 0.55-0.70 mm (0.0217-0.0276 in) 

    Fig 9: Pressing Steel Plate Down Using Force Gauge

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

    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 the reverse brake end-plate is replaced, install the snap ring, and check that the snap ring inside diameter and end gap are within the tolerance.
21. Install the snap ring retainer (A) over the drive pulley shaft (B).
    Fig 10: Installing Snap Ring Retainer And Drive Pulley Shaft

    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. After installing the snap ring, check that the snap ring is seated in the snap ring groove of the drive pulley shaft, and that the snap ring outside diameter (A) is 41.4 mm (1.63 in) or less.
    Fig 11: Identifying Snap Ring Outside Diameter

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
25. Install the ring gear (A) on the forward clutch (B).
    Fig 12: Identifying Ring Gear On Forward Clutch

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 (F) and aligning the planetary carrier with the reverse brake discs (G).
27. Install the manual valve body separator plate (A) and the two dowel pins (B) on the intermediate housing (C), then install the manual valve body (D) and detent spring (E).
    Fig 13: Manual Valve Body Separator Plate And Dowel Pins On Intermediate Housing 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 On CVTF Feed Pipe With Torque Specifications

    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 (K) 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).
    NOTE: The secondary drive/park gear must be replaced when disassembling the transmission.