Touch side of primary
pulley to align splines
Planetary
carrier splines

Do not place fingers
below primary pulley

Figure 31F
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Rotate the shift select lever

25. Confirm the parking rod operation as
follows:
a. Rotate the shift select lever counter

clockwise and confirm that all detents
for each of the P-R-N-D-L are felt.
b. Rotate the lever clockwise to return

the rod back to the P position.
c. Are all of the detents felt?

 YES: Proceed to step 26.
 NO: If the lever does not rotate or
if all detents are not felt:

Figure 32F

1) Raise the sub-assembly and remove all sealant.
2) Restart from step 17 on page 39.

26. Remove the guide pins.

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27. Install the new side cover bolts for sub-assembly to the CVT case (Figure 33F).


Torque the first eight (8) bolts marked as
in the sequence numbered in Figure
33F below, and then torque the rest of the bolts in a clockwise manner.
 Bolt torque: 45 N•m (4.6 kg-m, 33 ft-lb) 19 pieces.

8

4
2
6

Torque un-numbered
bolts in clockwise pattern

3
1
5
7
Figure 33F
28. Confirm the rotational smoothness of the primary pulley as follows:
a. With clean hand, access the primary pulley from the bottom of the CVT to rotate.
b. Rotate the primary pulley by hand and confirm that the characteristic is the same as
previously checked at step 4 (page 33), prior to removing the original sub-assembly.
c. Is the rotational characteristic worse than before the sub-assembly was replaced?


NO: The rotational characteristic is the same or better; proceed to step 29.



YES:
1) Remove the sub-assembly from the CVT case.
2) Wipe and clean the sealant completely from both the CVT case rim and
side cover rim.
 Refer to step 7 – 12 and 14 – 16 of “Replace Side Cover – Pulleys
and Belt”.
3) Restart sub-assembly installation from Step 17 of “Replace Side Cover
– Pulleys and Belt” on Page 39.
4) Return to step 28 and recheck rotational characteristic.

29. Remove the Lifting Fixture.

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J-52281

30. Install the CVT case side axle seal
(Figure 34F).


Use Seal Installer J-52281 and Driver
Handle J-8092.



Apply a light coat of CVT fluid to the
seal lip surfaces.

J-8092

CVT
case

Figure 34F

31. Place the CVT on the work bench with
the side cover facing down on the bench.

32. Remove the converter housing which
was temporarily installed with three bolts.

Bolts

Converter housing
Figure 35F

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Clutch Total Endplay Adjustment – Thrust Bearing Selection

IMPORTANT: The clutch total endplay (Figure 1G) must always be adjusted between the
clutch drum and the dummy cover when a new sub-assembly is installed and is adjusted
with thrust bearing thickness.
There are eight (8) thicknesses of thrust bearing available for total endplay adjustment.


For additional information, see video # 547: “CVT Belt and Pulley Replacement”
and fast forward to minute marker 13:22. This video is located under the TECH
TRAINING GARAGE VIDEOS tab in Virtual Academy.

Dummy
cover

CVT case

Total
endplay

Clutch
drum

Thrust
bearing

Figure 1G

1. Clean and then zero the Digital Depth Gauge (part #: J-50272).
 Set Digital Depth Gauge to millimeters.

2. Clean Gauge Block J-50271.

3. Confirm the mating surfaces of the CVT case are clean.
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4. Calculate the average (D) clutch
assembly bore depth (Figure 2G) as
follows:
IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.

Figure 2G

Clutch assembly
bore
a. Position the Gauge Block over the
clutch assembly bore on the surface
where the dummy cover seats
(Figure 3G).
IMPORTANT: This surface is lower
than the CVT case to torque converter
housing surface.
Gauge Block
Figure 3G

NOTE: The clutch assembly should
sit 2-3 mm lower than the dummy
cover seat (Figure 4G).

Dummy
cover seat

Dummy
cover seat

b. Confirm the Gauge Block is not sitting
on the clutch assembly or against the
input shaft.
NOTE: If the clutch assembly is sitting
higher than the dummy cover surface,
see trouble shooting The Dummy
Cover Will Not Sit Flush on page 78.

Clutch assembly
Figure 4G

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c. Position the Depth Gauge on the

Depth Gauge

Gauge Block (Figure 5G).

Datum level

NOTE: Make sure the Depth Gauge’s
datum level is flush with the top of the
Gauge Block.
d. Carefully slide the gauge down until it

bottoms out on the bottom of the
clutch assembly bore. Write this
measurement as D1 (use millimeters).

Clutch assembly
bore

NOTE: Do not measure from the
clutch assembly bore shown in red
(Figure 6G).

Gauge Block
Figure 5G

Do not measure
from this raised step
(highlighted in red).

Measure here; D2

Measure here; D1
Figure 6G

e. Measure this same distance on the opposite side (180 degrees) of the clutch

assembly bore and write it as D2.

f.

Using the formula below, calculate the average and write down the calculated value
as D.
D =

(D1 + D2)
-------------2

Write the measurement for “D” here _____ mm

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5. Measure the average (H) dummy cover
height (Figure 8G) as follows:

Clean surfaces

Clean here

a. Clean the dummy cover surfaces that

contact the CVT case and thrust
bearing (Figure 7G).
CAUTION: Use brake spray (or
equivalent) and lint-free towel only.
Make sure the brake spray or
solvents used are compatible with
local regulations.
Clean here
b. Place the dummy cover upside down
on a work bench, and place the
Gauge Block onto the thrust bearing
surface (Figure 8G).

Figure 7G

c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover (Figure 8G).
NOTE: Make sure the Depth Gauge’s datum level is flush with the top of the Gauge
Block.
d. Carefully slide the Depth Gauge down until it contacts the dummy cover surface that
mates with the CVT case. Write this measurement as H1 (use millimeters).
e. Measure this same distance on the opposite side of the dummy cover and it write as
H2 (Figure 8G).
Gauge Block

Figure 8G

f. Using the formula below, calculate the average and then write down the calculated
value as H.
(H1 + H2)(H1 + H2)
H=
H = --------------Write the measurement for “H” here _____ mm
2
2
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6. Choose the thrust bearing to adjust Clutch Total Endplay (A) as follows:
a. Calculate A (Total Endplay):
Total Endplay A = D – H (This will be the thrust bearing thickness).
 Fill in the measurements below for “D” and “H” from pages 51 and 52 to calculate
for “A”.
D measurement ______ mm
– H measurement ______ mm
= A - - - - - - - - - - - - - - - - ______ mm

Please print this page and
attach it to the repair order.

b. Choose the appropriate bearing from the table below, based on A (eight different

thicknesses of thrust bearings are available).
Example: If A = 4.3 mm, it falls between the lower and upper clearances for bearing
thickness 3.93 mm.
 Refer to PARTS INFORMATION for Thrust Bearing part numbers by thickness.
c. Measure and confirm that the selected thrust bearing is the correct thickness before

installing (Figure 9G).
d. Circle the thrust bearing part number that was selected in Table A .

Table A
PART #: 314071XZOB
1XZ0C
1XZ0D
1XZ0E
1XZ1A
1XZ1B
1XZ1C
1XZ1D

A=D-H
BEARING
CLEARANCE (A) THICKNESS
3.87 - 4.07 MM
4.08 - 4.23 mm
4.24 - 4.43 mm
4.44 - 4.58 mm
4.59 - 4.78 mm
4.79 - 4.94 mm
4.95 - 5.09 mm
5.10 - 5.29 mm

3.57
3.75
3.93
4.1
4.28
4.46
4.61
4.79
Figure 9G

7. Install the thrust bearing to the clutch assembly bore (Figure 10G).
CAUTION: The thrust bearing has two sides. See image below for appropriate
orientation.

Thrust bearing
cross section

Thrust bearing
Figure 10G
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Clean the Converter Housing Passages

IMPORTANT: Remove as much of the CVT and cleaning fluids as possible, and clean the
related parts in the following steps.

1. Remove the baffle plate and lubrication
tube as follows:
Baffle plate
and bolts

a. Remove the three bolts, and then
remove the baffle plate from the
converter housing (Figure 1H).

Figure 1H

Lubrication
tube,
tube
bracket,
and
and
bracket
bolt
b. Remove the bolt and then remove the
lubrication tube and its bracket
(Figure 2H).

Figure 2H

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2. Clean the oil passages of the converter housing, lubrication tube and dummy cover with
brake spray (or equivalent) where shown in Figures 3H and 4H below.
NOTE: Do not stand in front of the passages shown while using compressed air.
Air pressure
comes out these
passages

Apply cleaner,
and then 75 PSI
air pressure to
these passages

Apply cleaner, and
then 75 PSI air
pressure to this
passage
Figure 3H

Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages
Figure 4H
3. Install the lubrication tube and bracket, and then the baffle plate with three bolts
(Figure 5H).
Bolt torque: 5.9 N•m (0.6kg-m, 52 in-lb.)

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 5H
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CVT Reassembly

1. Install a new torque converter seal with
Seal Installer J-50818 (Figure 1I).


Place the torque converter housing
flat during installation.



Apply a light coat of CVT fluid to the
seal lip surfaces.



The torque converter housing seal will
be 0.5 mm (0.020 inches) below the
bore’s surface when the seal installer
bottoms out.

J-50818

Figure 1I

J-52282
2. Install the torque converter housing side
axle seal (Figure 2I).


Use Seal Installer J-52282 and Driver
Handle J-8092.



Apply a light coat of CVT fluid to the
seal lip surfaces.

J-8092

Converter
housing
Figure 2I

Dummy
cover lathe
cut seals
3. Apply petroleum jelly or equivalent to the
dummy cover’s lathe cut seals (Figure
3I) before installing the dummy cover to
the CVT case.

Figure 3I

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NTB16-110a

Input shaft
Input shaft
lathe cut
seals
4. Confirm that the input shaft’s lathe cut
seals are in the correct locations.

Figure 4I

5. Install the dummy cover first, then baffle
plate C, and then the related bolts finger
tight (Figure 5I).
IMPORTANT: Visually check that the
dummy cover is fully seated on the CVT
case. If it is not, refer to Trouble
Shooting pages 78 – 79.




Do not force the dummy cover into
place.
Make sure the dummy cover is fully
seated before installing the bolts.
Do not torque these bolts at this time.

6. Install baffle plate B and “L” bracket with
the related bolts finger tight (Figure 6I).

Dummy
cover, baffle
plate C, and
bolts
Figure 5I

Baffle plate B
and bolts

7. Torque the bolts from step 5 and 6 in the
following order:
a. Baffle plate B bolts: 5.9 N•m (0.6 kgm, 52.2 in-lb.)
b. “L” bracket bolts: 25.5 N-m (2.6 kg-m,
19 ft- lb). Torque 1 and then 22 .

2
1

“L” bracket
and bolts

c. Dummy cover and baffle plate C bolts
torque: 19.0 N•m (1.9 kg-m, 14 ft-lb.)
Figure 6I

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Thrust washer

8. Install the thrust washer onto the dummy
cover (Figure 7I).


Use petroleum jelly or equivalent to
hold the thrust washer in place.



Make sure the tabs fit into the holes.
Tabs
Figure 7I

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Drive sprocket
Chain
Driven sprocket
9. Install the drive sprocket, driven sprocket,
and chain as an assembly (Figure 8I).


Make sure the raised edge (wider
edge) on the drive sprocket is facing