3. Remove the eleven (11) side cover bolts
shown in Figure 3J.


Retain two (2) of these bolts. They will
be temporarily installed during a later
step.

Figure 3J
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4. Remove the side cover with a slide hammer (J-25721-A) to separate the side cover and
CVT case.
 There are three slide hammer tool points shown in Figure 4J.
 The mating surfaces will be cleaned at a later step.
 This step will help with sub-assembly removal at a later step.
CAUTION:
 Do not use the speed sensor bore for slide hammer tool location.
 Do not pry the surfaces apart as internal damage may result.

Side cover

Figure 4J

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5. Align the primary pulley bearing retainer
bolt holes with the bolt hole on the case
as shown in Figure 5J.
NOTE: This helps alignment of the
bearing retainer bolt threads after reinstalling the original side cover.

Figure 5J

Assembly Guide
Pins, Pulley Bracket
(Guide Pin J-52272)
6. Install one of the “Assembly Guide Pins,
Pulley Bracket” (Guide Pin J-52272) to
one of the two pulley bearing retainer bolt
holes.


This will assist in installation of the
original side cover to the pulley
assembly.
Figure 6J

Side cover

7. Place the original side cover onto the
CVT case.


Position the primary pulley bearing
retainer to allow the guide pin to be
inserted through the bolt hole of the
side cover.

Figure 7J

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8. Install the two (2) original pulley bearing retainer bolts (Figure 8J) as follows:


Use the original bolts and O-rings at this step.
a. Install one pulley bearing retainer bolt by hand (finger tight) into open bearing
retainer bolt hole.
b. Remove the Guide Pins from the other bearing retainer bolt hole.
c. Install the other bearing retainer bolt by hand (finger tight).

9. Temporarily reattach the removed side cover onto the CVT case with two (2) original
bolts on opposite corners, hand tight.

Pulley bearing
retainer bolts

Side cover

Side cover
bolts
Figure 8J

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10. Reposition the CVT with the side cover
facing down.

Side cover
Figure 9J

11. Remove the two (2) side cover bolts
which were temporarily installed to hold
the side cover to the CVT in step 9 on the
previous page.
NOTE: Only one (1) bolt is shown in
Figure 10J and is for reference only.

Side cover
bolt
Figure 10J

12. Lift the CVT case vertically off of the subassembly and side cover.


Weight: 10.65 kg (34 lbs.)



This sub-assembly will not be reused.

IMPORTANT: The sub-assembly must
be separated from the case as shown in
Figure 11J.

Figure 11J

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13. Place the CVT case on the work bench
with the torque converter side facing
down.

Figure 12J

14. Remove the lubrication tube bolt shown
in Figure 13J and then remove the
lubrication tube from the CVT case.


Lubrication tube

Do not discard the bolt or lubrication
tube. These will be reused during
reassembly.

IMPORTANT: This step is to insure that
the lubrication tube is not bent during
sub-assembly installation.

Lubrication
tube bolt
Figure 13J

15. Place the CVT case on the work bench
with the torque converter side facing up.

Figure 14J

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Clean the CVT Surfaces

CAUTION: During the next two steps;


Avoid any debris from dropping into the torque converter housing, side cover or the
CVT case. It is extremely important to keep any debris away from CVT internals to
prevent drivability concerns.



Use brake cleaner to remove the remaining CVT fluid and any residual sealant.



Do not use sanding discs, abrasive tools, or metal blades on sealing surfaces.



To clean dowel pins a mild abrasive sandpaper can be used to remove all rust and
debris.
 This will assist at a later step when mating the CVT Case to the sub-assembly
and again when mating the CVT Case to the torque converter housing.

1. Remove any sealant that remains on the sealing surfaces of the torque converter
housing and CVT case using a plastic scraper, and then clean with a lint-free paper
towel.


Use ONLY brake cleaner to clean surfaces.

CAUTION: Debris must be kept out of the inside of the CVT and transmission range
switch connection to prevent a future drivability concern.

CVT case
sealing surface

Figure 1K

Torque converter
housing sealing
surface

Figure 2K

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CVT case
sealing surface
2. Remove any sealant that remains on the
sealing surface of the CVT case where it
seals with the sub-assembly side cover.


A plastic scraper can be used.



Use ONLY brake cleaner to clean
surfaces.



Clean with a lint-free paper towel.
Figure 3K

CAUTION: Debris must be kept out of the inside of the CVT and transmission range
switch connection to prevent possible drivability concerns.

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Clean Oil Passages in CVT Case and Oil Pump Cover
In the following steps:


Brake cleaner and compressed air will be used to clean out oil passages in the CVT
assembly.
WARNING: Wear eye/face protection when using compressed air and cleaning
fluids.
CAUTION: Regulate air pressure up to a maximum of 75 PSI.

1. Place the CVT case on the work bench
with sub-assembly side down.


Use wood blocks as necessary to
stabilize the assembly during these
steps.

CAUTION: Make sure the surface of the
work bench has been cleaned.

Figure 1L

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2. Spray brake cleaner into each oil passage, indicated in green, of the CVT case where
shown in Figure 2L and Figure 3L, until the fluid runs clear for 5 seconds.
IMPORTANT: Do not apply brake cleaner or compressed air to passages shown in red.
3. Apply compressed air in the same passages to remove remaining cleaner and debris.
NOTE: Do not stand in front of the passages while using compressed air.

Figure 2L

Figure 3L

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4. Spray brake cleaner into the reverse
brake tube.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.

Reverse brake
tube

Figure 4L

5. Clean the counter bearing bore area (Figure 5L).
Counter
bearing bore

Figure 5L

6. Spray brake cleaner into the high clutch
fluid passage on the torque converter
housing.

High clutch fluid
passage

CAUTION: Brake cleaner will exit the
passage shown as “fluid discharge” in
Figure 6L while cleaning passage.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.

Fluid discharge
Figure 6L

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7. Spray brake cleaner into the reduction
gear bearing fluid passage on the torque
converter housing.

Reduction
gear bearing
fluid passage

CAUTION: Do not face the passage
indicated in red of Figure 7L while
cleaning.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.

Fluid discharge
Figure 7L

Input shaft

Oil pump cover

8. Clean the passages of the oil pump cover
as follows:
a. Remove the input shaft from the oil
pump cover.
CAUTION: Do not drop the counter
bearing outer race (roller bearing type
only).

Figure 8L

Thrust bearing
b. Note the orientation and then remove
the thrust bearing.


Do NOT discard. This will be
reused at a later step.

Figure 9L

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c. Remove the washer.


Washer

Do NOT discard. This will be
reused at a later step.

d. Spray brake cleaner into the oil pump
cover oil passages indicated in green
shown in Figure 11L.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Figure 10L

CAUTION: Do not face the passage indicated in red in Figures 11L and 12L while
cleaning.
Oil pump cover

Oil pump cover

Figure 11L

Figure 12L

Washer
e. Install the original washer.
NOTE:


Orientation is NOT critical for
the washer.



Apply petroleum jelly to the
washer to hold it in place
during assembly.
Figure 13L
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f. Install the original thrust bearing.


Orientation IS critical. See Figure 15L for thrust bearing cross section.

CAUTION:


The thrust bearing has two sides. Refer to Figures below.



Apply petroleum jelly or equivalent to hold in place.

Oil pump cover

Thrust bearing

Figure 14L

Figure 15L

g. Insert the input shaft to the oil pump cover (Figure 16L).
CAUTION:


The input shaft has a sealing ring.



Be careful not to damage the sealing ring while assembling the input shaft to
the oil pump cover.



Apply petroleum jelly to the sealing ring on the input shaft before installation.
 Sealing ring is hidden behind input gear in Figure 16L.
Oil pump cover
Thrust bearing

Sealing ring location
Figure 16L

Figure 17L

 Make sure all exposed internal areas of the CVT (including the oil pan and magnets)
have been thoroughly cleaned.
 Cover all parts with a lint-free covering, when not being worked on, to prevent
contamination which could cause drivability concerns.
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Measuring the CVT Sub-assembly Case Depth

Torque converter
housing

1. Temporarily install the torque converter
housing to the CVT case with two (2)
bolts at opposite corners, hand tight
(Figure 1M).


Use original bolts to secure.

Figure 1M

2. Reposition the CVT on the work bench
with the torque converter housing side
facing down (Figure 2M).
3. Clean and then zero the Digital Depth
Gauge (J-50272).

4. Set the Digital Gauge to millimeters.

Figure 2M

5. Clean the Gauge Block (J-50271).
NOTE: Only if a Gauge Block (J-50271)
is not available, measurement “X” (Figure
5M, page 54) will need to be determined
for the measuring bar being used. This
can be done either with a set of calipers
or with Digital Depth Gauge (J-50272).

Gauge Block
(J-50271)

6. Confirm the sealing surfaces of the CVT
case is clean.
7. Place Gauge Block (J-50271) across
sub-assembly sealing surface as shown
in Figure 3M.

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Figure 3M

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8. Measure the average distance (Y) shown in Figure 5M as follows:


Refer to the Figures 4M and 5M and then proceed to page 55.



Measure only from areas that do not have any signs of contact.
IMPORTANT: Please refer to Figure 4M for acceptable areas (highlighted in green)
to measure “Y”.
Measuring area

Do not measure in this
area
Figure 4M

Y = The distance between the upper surface of the Gauge Block and the surface where
snap ring seats.

Figure 5M

Proceed to the next page.

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Secondary pulley bearing snap ring surface
Do not measure
into this groove.

Measure to this slightly
raised machined surface

Figure 6M

a. Measure between the top of the Gauge Block (J-50271), to where the snap ring on
the secondary pulley bearing seats (Figure 6M).


This will be measured in three locations to calculate an average for “Y”.

Y1_________, Y2________, Y3_________
b. Calculate the average for “Y” with the formula below and then record it below.

Y=

(millimeter)

Y = _________
c. Calculate case depth “D” as follows:
IMPORTANT: Essential tool Gauge Block (J-50271) is 20 mm thick.


Average depth calculated in step 8b →



Subtract Gauge Block thickness

→

Y__________
─ X__________
-------------------------------------------------

