Figure 1E

Fitting bolt

O-ring
2. Place new O-ring on the fitting bolt, and
coat with CVT fluid (Figure 2E).

Figure 2E

3. Install the fitting bolt finger tight
(Figure 3E).

Fitting
bolt

Figure 3E

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4. Torque the three Allen head bolts and fitting bolt.


Allen head bolt torque: 17.6 – 20.6 N•m (1.79 – 2.1 kg-m, 13.0 – 15.2 ft-lb)



Fitting bolt torque: 26.0 – 30.0 N•m (2.65 – 3.06 kg-m, 19.2 – 22.1 ft-lb)

5. Install the new snap ring (Figure 4E).

Snap ring
Figure 4E

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Replace the Side Cover – Pulleys and Belt (sub-assembly)

Review video # 547: “CVT Belt and Pulley Replacement” and fast forward to minute
marker 3:14. This video is located under the TECH TRAINING GARAGE VIDEOS tab
in Virtual Academy.

1. Temporarily install the dummy cover with
3 bolts, finger tight (Figure 1F).
IMPORTANT:


Do not install the thrust bearing to
the clutch assembly bore at this
time.



If cover does not seat flush see
trouble shooting The Dummy
Cover Will Not Sit Flush on
page 78.

Bolts

Dummy cover
Figure 1F

2. Temporarily install the converter housing
onto the CVT case with three bolts finger
tight (Figure 2F).
IMPORTANT: When fitting the CVT case
surfaces, DO NOT use the bolts to draw
in the case halves. Make sure the case
surfaces are flush, and have no gaps
prior to installing the bolts.

Bolts

Converter housing
Figure 2F

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3. Flip the CVT case so that the converter
housing faces down and side-cover faces
up.


Lifting fixtures J-51595 and J-51909-1
can be used for this step.



See step 5 and step 6 on page 34 for
lifting fixture information.

CAUTION:
 Do not hit the manual shaft (Figure
3F) while flipping the CVT; the manual
shaft is longer than the oil pan mating
surface. Use a plastic / wooden block
to support as needed.


Manual shaft

Figure 3F

Note the location of the terminal
connector harness. Do not pinch the
terminal connector harness between
the CVT case and work bench or
supporting blocks.

4. Rotate the primary pulley by hand to
check the pulleys rotational
characteristics.
IMPORTANT: Remember the pulley’s
rotational characteristics. This will be
used as a reference after the new side
cover-pulleys and belt sub-assembly
(sub-assembly) have been installed.

Rotate the primary
pulley by hand
Figure 4F

WARNING: Do not place fingers between
the pulley and the CVT case.

Do not place fingers
under pulley
Figure 5F

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5. Attach Lifting Fixture J-51909 (Figure 7F)
with eyelet from J-51595 (Figure 8F) to
the side cover at point shown in Figure
6F.


Lifting Fixture bolt torque (Max.):
45 N•m (4.6 kg-m, 33 ft-lb)

Attach here

CAUTION: Do not cross thread bolts
when attaching to side cover.


Eyelet bolt torque: Hand tight.
Figure 6F

6. Attach the Lifting Fixture to an
appropriate lifting device.



Figure 7F shown with Lifting Fixture
attached to side cover
(Tool #: J-51909).
Lifting Fixture #: J-51909
Figure 7F

Eyelet



Figure 8F shows a Lifting Fixture that
can be used to turn the CVT from one
side to the other. This Lifting Fixture
attaches to the top of the CVT
(Tool #: J-51595).
Lifting Fixture #: J-51595
Figure 8F

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7. Remove the nineteen (19) side cover
fixing bolts (Figure 9F).


These bolts will be replaced with new
ones and will not be reused.

Figure 9F
8. Install the two alignment Guide Pins
(J-51959 - Guide Pins) as shown in
Figure 10F and Figure 11F.
NOTE:
 The Guide Pins should be located on
opposite sides of the sub-assembly.


Guide Pins should be placed as far
apart as possible.



Guide Pins must be placed next to
dowel pins (Figure 11F).

Guide Pin

Guide Pin
Figure 10F

Guide Pin

Dowel Pin

Figure 11F

9. Raise the Lifting Fixture so that the CVT assembly weight is mostly supported by the
Lifting Fixture and just slightly raised off of the work surface (using Tool #: J-51909).

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10. Loosen the side cover with a slide hammer at the three points (tool location marks)
shown in Figure 12F.


Rotate between the 3 locations on the side cover until the CVT case separates from
the sub-assembly; this can take more than one rotation to loosen sealant.
CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from
the CVT case.
NOTE: Apply rust penetrant to the two dowel pins as needed.

Tool location
marks

Dowel
pin

Dowel
pin

Figure 12F

11. Raise the Lifting Fixture to remove the
“side cover with pulleys and belt subassembly” (sub-assembly) from the CVT
case (Figure 13F).
CAUTION: Make sure the primary speed
sensor is removed from the subassembly.


Speed sensor will be reused.



DO NOT discard speed sensor.



This sub-assembly will not be
reused.

Sub-assembly

CVT case

Figure 13F
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12. Thoroughly clean the mating surfaces of the CVT case (Figure 14F) that the subassembly was just separated from (a plastic scraper can be used).


Confirm that dowel pins have remained in the CVT case. If not, remove them from
the sub-assembly and relocate back to the CVT case.

CAUTION:
 DO NOT use sanding discs, similar abrasive tools, or metal blades.
 Use brake spray or equivalent solvent and lint-free towels only.
 Make sure brake spray or solvents used are compatible with local regulations
 Avoid debris entering into the inside of the CVT.
 Make sure rust and debris have been cleaned off of dowel pins and receiving
holes.

13. Replace the O-ring on the CVT case side with a new one; discard original O-ring
(Figure 15F).


Coat the O-ring with CVT fluid before installing.

Mating surfaces

O-ring
Figure 14F

Figure 15F

14. Remove the thrust bearing from the
planetary carrier plate (Figure 16F).


Thrust bearing will be re-used.
DO NOT discard.
CAUTION: If not found on the
planetary carrier plate, the thrust
bearing may still be attached to the
primary pulley.
Thrust bearing
Figure 16F

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15. Rotate the shift select lever counter
clockwise to the “L” range position
(Figure 17F), so that the park pawl is at
its lowest position (Figure 18F).
Shift select lever

Figure 17F

Park pawl

Figure 18F

Lifting Fixture

16. Attach the Lifting Fixture to the new subassembly.
CAUTION: Do not cross thread side
cover holes when installing the Lifting
Fixture. Always start bolts by hand.
Sub-assembly
Figure 19F

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17. Apply one continuous 2.0 mm diameter bead of sealant along the center of the CVT
case side mating surface (Figure 20F).
Sealant:
 Loctite 5460 (See the Parts Information section of this bulletin)
 Color: Pink
IMPORTANT:
 Confirm that the mating surfaces are clean before applying sealant.
 Make sure that the starting point and the ending point of the sealant is
between two bolt holes. Overlap both ends of the bead by 3 – 5 mm.
CAUTION: Be careful not to contact or contaminate the sealant. If the sealant has
been disturbed or contaminated in any way before case assembly, remove the
sealant completely and re-start from step 17.

Figure 20F

IMPORTANT: If the Guide Pins were removed to clean the case surfaces, reinstall them
now.

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18. Install the original thrust bearing on the primary pulley of the new sub-assembly part
(Figure 21F).
IMPORTANT: The thrust bearing surface must lay flush with the primary pulley. Any
additional height will affect the total end play that is measured later in this procedure.
CAUTION: The thrust bearing has two sides. Reference Figure 21F for bearing
orientation.


Apply a small amount of petroleum jelly or equivalent to the original thrust bearing to
hold it in place on the primary pulley.
Primary pulley

Thrust bearing

Thrust bearing; must sit
flush with primary pulley
surface.
Figure 21F

19. Coat the primary pulley bearing, secondary pulley gear teeth and the secondary bearing
with CVT fluid prior to installation (Figure 22F).
CAUTION: Do NOT drip any CVT fluid onto the sealant.
The following Figures are for reference only and may or may not have the sealant in place,
or have the old sealant removed. Clean the surfaces and apply sealant when and where
instructed.

Coat these
surfaces with
CVT fluid

Figure 22F
20. Route the Guide Pins into the appropriate CVT holes one at a time (the Guide Pins are
different lengths).
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IMPORTANT:
Before continuing, it is recommended that you review and understand the instructions on
pages 41 to 47.
The sub-assembly will lower into the CVT case without applying extra vertical force.
IF THE SUB-ASSEMBLY DOES NOT LOWER COMPLETELY,
INTERFERENCE IS PRESENT.

! PHYSICAL

Key Technique: Raise to remove weight on interference, adjust as necessary, and
then lower again.

Use the “visual gap size” below (Figures 23F and 24F), between the sub-assembly and the
CVT case, to determine the cause of interference.

44 mm - Page 42
38 mm - Page 43

CASE GAP = ?

19 mm - Page 44
6 mm Page 45

Figure 23F

Case gap

Figure 24F
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21. Carefully lower the Lifting Fixture to install the sub-assembly into the CVT case as
follows:


While visually looking down into the bore (Figure 26F) to confirm that the output gear
is clearing the CVT case bearing bore,
a. Level the sub-assembly by placing hands on top to guide it into the CVT case.
b. Lower the sub-assembly until a gap of 38 mm (1.5 inches) is present to the CVT

case (Figure 29F on page 43) and then proceed to step 22.
 If the sub-assembly will not lower any farther than 44 mm (1.75 inches) the
output gear has not cleared the bearing bore (Figure 25F).

Sub-assembly will not lower past 44 mm (1.75 inches)?


Interference is present between the output gear and bearing bore.

Sub-assembly

44 mm (1.75
inches) gap

CVT case

Output gear

Bearing bore
Output gear

Figure 25F

Bearing bore

Figure 26F

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CVT case

NTB16-110a

CAUTION: In the following steps be careful not to contact or contaminate the sealant. If the
sealant has been disturbed or contaminated in any way before case assembly, remove the
sealant completely and re-start from step 17 on page 39.
22. Align the parking rod with the parking pawl as follows:
IMPORTANT: Perform step 22 while the sub-assembly has a 38 mm gap (1.5 inches)
to the CVT case (Figure 29F).
c. Rotate the shift select lever clockwise on the side of the CVT to adjust the park rod

to the highest position.
d. Use a magnet, or similar tool, to align the park rod in the CVT case (

28F) with the opening in the parking pawl (

in Figure
in Figure 27F) in the side cover.

NOTE: If the parking rod is not located correctly it will keep the case from lowering.

The following Figures are for reference only.
Side cover

Parking pawl
Parking rod
Pocket
magnet
Figure 27F

CVT case
Figure 28F

Sub-assembly

38 mm (1.5
inches) gap

CVT case
Figure 29F

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23. Continue to slowly lower the sub-assembly into the CVT case.


If the primary and the secondary pulley bearings do not align properly with their
bores (Figure 30F) or are at an angle, a gap of 19 mm (0.75 inches) may be
present.
 As needed, level the sub-assembly as it is lowered into the CVT case to help the
primary and the secondary pulley bearings align in their bores.
 MINOR LEVELING ADJUSTMENTS with limited weight on the sub-assembly will
help the installation. Vertical force is not needed.
 Once the sub-assembly is LEVEL the primary and the secondary pulley bearings
will smoothly align while lowering.

Sub-assembly will not lower past 19 mm (0.75 inches)?


If this occurs Do NOT force sub-assembly into case.
a. Raise the sub-assembly slightly.
b. Level the sub-assembly (visually check the gap between case and sub-assembly
side cover and confirm that it is even all around).
c. Gently lower the sub-assembly.
d. Gently shake the sub-assembly horizontally, lower, raise and repeat as needed
to help align.
e. Lower to clear dowel pins to 6 mm (0.25 inches).

Sub-assembly

Primary
pulley bearing

19 mm (0.75
inches) gap

Secondary
pulley bearing
Bearing bore
CVT Case

Bearing bore
Figure 30F

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IMPORTANT: In the following steps the case halves must sit flush against each other
without a gap before installing the bolts. The bolts CANNOT be used to draw the cases
together. DO NOT APPLY VERTICAL FORCE.
24. Once the dowel pins are cleared, ease the sub-assembly down onto the CVT case until
the case halves are flush.


Confirm the dowel pins are clean and aligned and are not catching on the subassembly case cover.
WARNING: Be careful not to get fingers caught between the CVT case and subassembly when seating.

Sub-assembly will not lower past 6 mm (0.25 inches)?
If the sub-assembly will not lower past 6 mm (0.25 inches), the primary pulley splines are
not aligned.


If this occurs Do NOT force sub-assembly into case.
a. Raise the sub-assembly slightly so the weight is not completely on the primary
pulley splines.
b. Slightly rotate the primary pulley through the bottom of the CVT and then lower
the sub-assembly.
c. Repeat as needed.

Sub-assembly

Primary pulley
6 mm (0.25
inches) gap
Belt
element
CVT
case

Primary pulley
splines