NTB15-102a

8. Subtract 20 mm from each measurement.
EXAMPLE: 70.8 mm and 70.0 mm are the measured values. Subtracting 20 mm from
each value equals 50.8 mm and 50.0 mm, respectively.
NOTE:


20 mm is the thickness of the gauge block.



All measurements are made in millimeters.

9. Add the two measurements, and then divide by two.


Write down the calculated value as “Mc”.
EXAMPLE: 50.8 mm plus 50.0 mm equals 100.8 mm. 100.8 mm divided by
2 equals 50.4 mm Mc.

10. Perform step 2-9 on the converter housing’s outer race bore (see Figure 21).


Write down the calculated value as “Mh”.

Measuring
converter
housing side

Figure 21

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NTB15-102a

11. Open ASIST, and then go to
ASIST>Specialty Tools>NTB15-102 Shim
Calculator to access the calculation tool.
12. With the calculation tool displayed, input the
measurement values in the correct boxes
from page 13, step 9 and 10 (see Figure
22).
NOTE: All measurements must be inputted
in millimeters.

Step 12 and 13

Step 14

Figure 22

13. Input the height measurement of the
reduction gear assembly (see Figure 22).


The measurement value is located
on a label attached to the reduction
gear’s packaging (see Figure 23).

14. Click on Calculate (see Figure 22).


A shim part number will appear (see
example in Figure 24).
Figure 23

15. Obtain or order this shim from your parts
department.




If two (2) part numbers display, install
one (1) shim of each part number.
All shims will be installed on the
CVT case side later on during the
assembly procedure.
Always restock the shim kit. This will
assure these shims are immediately
available for other future repairs.

XXXXX

16. If the window in Figure 25 appears:
a. Verify all measurements, calculations,
and inputted values are correct, and
then try the calculation again.
b. If the same message appears again,
get a screen shot or photo of the
message showing all measurements.
Call the Powertrain Call Center (PCC)
for the next step, and then attach the
screen shot of the calculation to the
PCC form.
17. If Figure 24 appeared, finish step 15, and
then go to the next page.

14/48

Figure 24

XXX

XX
XX

Figure 25

NTB15-102a

Remove Control Valve Assembly (Valve Body)

1. Remove the 19 oil pan bolts, and then
remove the CVT oil pan and gasket
(see Figure 26).





Save the oil pan bolts. They will be
reused.
Save the magnets. They will be
reused.
The oil pan will be replaced with a
new one.
The oil pan gasket will be replaced
with a new one.
Figure 26

Manual plate

2. Remove the nut and lock washer
to remove the manual plate (see
Figure 27).


Lock washer

These parts will be reused.
Lock nut

Figure 27

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NTB15-102a

Short bolts
3. Remove the three (3) oil strainer
mounting bolts, and then remove the
oil strainer with O-ring (see Figure 28).


The oil strainer and O-ring will be
replaced.

Long bolt
Figure 28

4. Remove the two (2) oil strainer bracket
bolts, and then remove the oil strainer
bracket (see Figure 29).

Brackets
and bolts
Figure 29

5. Remove the two (2) fluid temp sensor
bolts, and then disconnect the wiring
harness connector (see Figure 29 and
30).

Wiring harness
connector
Figure 30
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NTB15-102a

44 mm bolt

6. Remove the nine (9) valve body
mounting bolts, and then carefully
remove the valve body (see Figure 31).
NOTE: Eight bolts are 54 mm long, and
one bolt is 44 mm long.

Figure 31

7. Carefully remove the lip seal (see
Figure 31a).

Lip seal

Figure 31a

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NTB15-102a

Remove Oil Pump Assembly
1. Remove the two (2) nuts, and then
remove the first baffle plate (see
Figure 32).
CAUTION: To avoid rounding off these
nuts, it is best to use a 3/8 drive 6-pt
10 mm socket.

First baffle
plate nuts

Figure 32

2. While spreading out the snap ring,
remove as an assembly the driven and
drive sprockets and oil pump chain
(chain). See Figure 33 and 35.

3. Remove the thrust washer (see
Figure 34).


The thrust washer will be reused.

Drive sprocket
Chain
Driven sprocket
Figure 33

Snap ring:
Spread out
to release
sprocket

Thrust washer
Figure 34

Figure 35

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NTB15-102a

“L” bracket and bolts

4. Remove the two (2) bolts, and then
remove the “L” bracket (see Figure 36).

Figure 36

5. Remove the three (3) bolts, and then
remove the second baffle plate (see
Figure 37).
Second
baffle plate
and bolts

Figure 37

6. Remove the two (2) bolts, and then
remove the third baffle plate (see
Figure 38).

Third baffle
plate and
bolts

Figure 38

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NTB15-102a

7. Remove the five (5) bolts, and then
remove the oil pump cover (see
Figure 39).
CAUTION: Be careful when removing
and handling the oil pump cover. The
lathe cut seals, installed on the bottom
side, will be reused.

Oil pump
cover and
bolts

Figure 39

8. Remove the oil pump fitting bolt located
above the left rear corner of the oil pan
(see Figure 40).
Oil pump
fitting bolt

Figure 40

Allen head bolts
9. Remove the three (3) Allen™ head bolts,
and then remove the oil pump (see
Figure 41).
NOTES:



The Allen™ head bolts will be reused.
The oil pump and snap ring will be
replaced.

Oil pump

Figure 41

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NTB15-102a

Remove CVT Fluid Filter

1. Remove the four (4) bolts, and then
remove the CVT fluid filter cover (see
Figure 42).
Oil filter
cover and
bolts

Figure 42

2. Remove the CVT fluid filter with grommet
seal and O-ring seal (see Figure 43).


The filter and seal will be replaced
with new ones.



Figure 43 does not show the
grommet seal. It is fitted to the
bottom end of the filter.

Discard
filter and
seal

Figure 43

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NTB15-102a

Clean Oil Passages in CVT Case, Oil Pump Cover, and CVT Filter Area
NOTE: In this section, brake spray or a suitable cleaning solvent and compressed air
will be used to clean out oil passages in the CVT assembly. Make sure the brake spray
or solvents used are compatible with local regulations.
WARNING: Wear eye protection when using compressed air.
CAUTION: Regulate air pressure up to a maximum of 75 PSI.
1. Spray in all oil passages in the CVT case where shown in Figure 44.
2. Next, apply compressed air pressure in the same oil passages.
NOTE: Do not stand in front of the passages shown in Figure 45 during compressed
air use.

Figure 44
Apply cleaner, and then
75 PSI maximum air
pressure in these
passages
Air pressure comes
out these passages

Figure 45

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NTB15-102a

Clean within
this area

3. Clean the area where the CVT fluid filter
fits (see Figure 46).


Make sure the old filter grommet seal
is removed.

Figure 46

4. Remove the three (3) bolts, and then
remove the baffle plate from the converter
housing (see Figure 47).

Baffle plate
and bolts

Figure 47

5. Remove the bolt, and then remove the
lubrication tube and its bracket (see
Figure 48).

Lubrication
tube,
tube
bracket,
and
and
bracket
bolt

Figure 48

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NTB15-102a

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

6. Clean out/spray in the oil passages in the
converter housing and lubrication tube
(see Figure 49 and 50).
NOTE: Do not stand in front of the
passages shown in Figure 49 and 50
during compressed air use.
Air pressure
comes out these
passages

Figure 49

Figure 50

7. Install the lubrication tube and bracket
(see Figure 51).


Bolt torque: 5.9 N•m (0.6 kg-m,
52 in-lb)

Lubrication
tube and
bracket

Figure 51

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NTB15-102a

8. Install the baffle plate with three (3) bolts
(see Figure 52).


Baffle plate
and bolts

Bolts torque: 5.9 N•m (0.6 kg-m,
52 in-lb)

Figure 52
9. Clean out/spray in the oil pump cover oil passages where shown in Figure 53 and 54.
NOTE: Do not stand in front of the passage shown in Figure 53 during compressed air
use.
Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages

Figure 53

Figure 54


Make sure all exposed internal areas of the CVT (including the oil pan and magnets)
have been thoroughly cleaned.



Keep all parts covered with a lint-free covering when repairs have stopped.
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NTB15-102a

Reassemble CVT Assembly
Replace Both Differential Side Oil Seals and Torque Converter Seal

1. Remove the following seals using suitable
tools:




CVT case (drive shaft) differential side
oil seal
Converter housing (drive shaft)
differential side oil seal
Torque converter seal
 See Figure 55, 56, and 57.
CAUTION: Be careful not to damage
the seal bore surfaces.

Figure 55

Figure 56

Figure 57

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NTB15-102a

2. Install a new converter seal with Seal
Installer J-50818 (see Figure 58).




The converter housing seal will be
0.5 mm below the bore’s surface