Side cover

38 mm (1.5
inches) gap

CVT case

Figure 16F

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Apply pressure to
these locations

8. By hand, press down on the side cover
over each of the pulley bearings to level
and seat the side cover.
IMPORTANT: The side cover will not be
fully seated at this step.
Side Cover Alignment
Aid (# J-52275)
Figure 17F
9. Rotate the manual lever to the “N”
position.

10. Remove the Side Cover Alignment Aid
(# J-52275) shown in Figure 17F.

NOTE: Figure 18F shown with Side
Cover Alignment Aid removed.
Figure 18F

11. Continue to lower the side cover until it is flush with the CVT case.


Use a plastic hammer or rubber mallet, if the side cover is caught, and gently tap
evenly around the top of the side cover to help seat.

IMPORTANT:






Side cover must be completely seated.
Bolts cannot be used to draw case halves together.
Do NOT use metal hammers or mallets.
If it is necessary to unseat the side cover assembly, use a slide hammer and then
restart from step 1 on page 49.
Do NOT pry with a screw driver.

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12. Remove the CVT Assembly Guide Pins (# J-51959).

13. Install the sub-assembly side cover with nineteen (19) new side cover bolts to the CVT
case (Figure 19F).
CAUTION: Do not reuse original side cover bolts.


Torque the first eight (8) bolts marked as
in the sequence numbered in Figure
19F 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.

Some bolts are hidden
in Figure 19F

4

8

2
6

Torque un-numbered
bolts in clockwise pattern

3
1

5
7
Figure 19F

14. Install six (6) new O-rings from Parts Information to the six (6) new pulley bearing
retainer bolts that were removed from the new sub-assembly on page 38, step 17.

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15. Install the new pulley bearing retainer
bolts to secure the pulleys and side
cover.
a. Install four (4) bolts first, hand tight.
b. Remove two (2) guide pins from the
pulley bracket.
c. Install the last two (2) bolts with Orings, hand tight.
Figure 20F

16. Confirm the parking rod operates
correctly as follows:
a. Rotate the shift select lever counterclockwise and confirm that all detents
for each of the P-R-N-D-L are felt.

Shift select lever

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 17.
 NO: If the lever does not rotate or
if all detents are not felt:

Figure 21F

1) Remove the sub-assembly side
cover and then remove
sealant.
2) Restart from step 1 on page
49.

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17. 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 “the
same” (OK) or “worse than before the
sub-assembly was replaced” (NG)?

Figure 22F



OK: The rotational characteristic is the same or better; proceed to step 18.



NG:
1) Remove the 19 case bolts and 6 pulley bracket bolts. Refer to page 34
steps 5 and 6.
2) Remove the two (2) lubricating caps.
3) Remove the silicone from the sealing surfaces.
4) Reinstall the side cover.
5) Restart sub-assembly installation from Step 7 on Page 35.
6) Follow procedure through to page 56 step 17 and check rotational
characteristics.

18. Torque all six (6) bolts.
 Bolt torque: 28 N•m (2.8 kg-m, 20
ft-lbs).

Figure 23F
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19. Install the CVT case side axle seal
(Figure 24F).



Use Seal Installer J-52283 and Driver
Handle J-8092.
Apply a light coat of CVT fluid to the
seal lip surfaces.

J-8092
CVT
case

J-52283

Figure 24F

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

Bolts
21. Remove the converter housing which
was temporarily installed with three bolts.
Converter housing
Figure 25F

22. Unbolt the three (3) bolts holding the
dummy cover and then remove the
dummy cover.

Bolts

Dummy cover
Figure 26F

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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.

Thrust Bearing Selection
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 13:10. 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 that the CVT case and the oil dummy cover mating surfaces are clean.

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CVT case
Oil pump

Gauge block

4. Calculate the “average clutch assembly
bore depth” (D) shown in Figure 2G as
follows:
IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.
Clutch drum of clutch assembly
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

b. Confirm the Gauge Block is not sitting
on the clutch assembly or against the
input shaft.

Dummy
cover seat

Dummy
cover seat

NOTE:


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



If the clutch assembly is sitting
higher than the dummy cover
surface, see trouble shooting
The Dummy Cover Will Not
Sit Flush on page 81.

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.
(D1 + D2)
D =

---------------------------

Write the measurement for “D” here _____ mm

2

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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 cleaner (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

Measure opposite sides
Figure 8G

f. Using the formula below, calculate the average and then write down the calculated
value for H.
H =

(H1 + H2)(H1 + H2)
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 “total endplay” (A):
Total endplay: A = D – H (This will be the thrust bearing thickness).
 Fill in the measurements below for D and H from pages 60 and 61 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 Table B 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).
Table B
PART #: 314071XZ0B
1XZ0C
1XZ0D
1XZ0E
1XZ1A
1XZ1B
1XZ1C
1XZ1D

A=D-H
BEARING
CLEARANCE (A) THICKNESS
3.87 - 4.07 MM
4.07 - 4.23 mm
4.23 - 4.43 mm
4.43 - 4.58 mm
4.58 - 4.78 mm
4.78 - 4.94 mm
4.94 - 5.09 mm
5.09 - 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.
Clutch assembly
Thrust bearing
cross section

Thrust bearing
Figure 10G

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Clean the Torque Converter Housing, Dummy Cover Passages and Baffle Plates

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

2. Clean all baffle plates.

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3. Clean the oil passages of the converter housing, lubrication tube and dummy cover with
brake cleaner (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
4. Install the lubrication tube and bracket, and then the baffle plate with three bolts
(Figure 5H).
Bolt torque: 5.9 N•m (0.6 kg-m, 52 in-lb.)

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 5H

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