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

NTB16-110b

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

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