CVT Reassembly

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

Place the torque converter housing
flat during installation.

J-50818



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.
Figure 1I

J-52284
2. Is this vehicle an all-wheel drive (AWD)?
YES: Proceed to step 3.
NO: Install the torque converter housing
side axle seal (Figure 2I).

J-8092



Use Seal Installer J-52284 and Driver
Handle J-8092.



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

Converter
housing
Figure 2I

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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

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 81 – 82.




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.

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

NTB17-039

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

Baffle plate B
and bolts

7. Torque the bolts from step 5 and 6 in the
following order:
2

a. Baffle plate B bolts: 5.9 N•m (0.6 kgm, 52.2 in-lb.)
1

b. “L” bracket bolts: 25.5 N-m (2.6 kg-m,
19 ft- lb). Torque 11 and then 22 .

“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

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
up (Figure 8I).

Figure 8I

Raised
edge

Figure 9I

Snap ring
ends

a. Expand the snap ring with a suitable

tool, and then push down on the
driven sprocket until it bottoms out
(Figure 10I).

Driven
sprocket

b. Release the snap ring and then pull

up on the driven sprocket until the
snap ring locks into its groove.
NOTE: A click sound is heard when
the snap ring locks in place.
Figure 10I

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First baffle
plate nuts

10. Install baffle plate A with two nuts
(Figure 11I).
 Nut torque: 5.9 N•m (0.6 kg-m, 52.2
in-lb.)

Figure 11I

11. Install a new O-ring on the input shaft
(Figure 12I).


O-ring

Apply CVT fluid to the O-ring and Oring groove before installing.

Figure 12I
12. Install the differential assembly and the reduction gear assembly into the CVT case
(Figure 13I).


Thoroughly clean each assembly before installing.



Oil the bearings and gear teeth with CVT fluid before installing.
Reduction gear
assembly

Differential
assembly

Figure 13I
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13. Confirm the pin (Figure 14I) is located in
the CVT case prior to installation of the
converter housing.

Pin

NOTE: Apply petroleum jelly or
equivalent to keep it in place if
necessary.

Figure 14I

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14. Apply one continuous 2.0 mm (0.8 inches) diameter bead (Figure 15I) of pink colored
Loctite 5460 Sealant (see the Parts Information section of this bulletin).


Before sealant application, make sure the mating surfaces are clean from oil, dirt,
old sealant, etc. (Figure 15I).
IMPORTANT: Have the converter housing ready for installation prior to applying the
sealant.

NOTE:
 Start applying sealant where shown, making sure that the starting point and the
ending point are about the middle between the bolt holes.
 Overlap both ends of the bead by 3-5 mm (0.12-0.20 inches).
 Make sure to apply sealant around the center bolt hole.

Also apply sealant
around this bolt hole

Figure 15I

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15. Install the torque converter housing onto the CVT case (see Figure 16I for torque
sequence):


Install new bolts (24).
a. Torque the first six (6) bolts with symbol
b. Torque the remaining bolts with symbol


in numbered sequence (see below).
in numbered sequence (see below).

All bolts are 30 mm (1.2 inches) in length.
 Bolt torque: 45.0 N•m (4.6 kg-m, 33.2 ft-lb.)
IMPORTANT: Make sure to torque the bolts in the sequence shown
(Figure 16I).

23
22
21
7

20

19

24

8

9

18
17
10

16
11
15
14
13

12

Figure 16I

16. Clean off the excess sealant.
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Control Valve (Valve Body) Strainer and Pan Installation

IMPORTANT:


Installation steps in this bulletin may contain different style parts than what were
originally installed in the CVT. Pay careful attention, REASSEMBLY MAY NOT BE
IDENTICAL TO DISASSEMBLY.



Confirm that the QR label, control valve and CD part numbers all match before
installing the control valve (refer to NTB12-103).



For additional information, see video # 547: “CVT Belt and Pulley Replacement” and
fast forward to minute marker 19:52. This video is located under the TECH
TRAINING GARAGE VIDEOS tab in Virtual Academy.

CAUTION: Handle the valve body carefully.

NOTE: If an oil strainer bracket was
removed, discard it. An oil strainer
bracket (Figure 1J) will not be used with
the new oil strainer.

Oil strainer
bracket

Figure 1J

1. Install a new lip seal (Figure 2J).


Do NOT reuse the old lip seal.



Apply a small amount of petroleum
jelly or equivalent to the lip seal to
keep it in place on the CVT.

Lip seal

Figure 2J

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25 mm bolts

2. Install the Control Valve with eleven (11)
mounting bolts (Figure 3J).
IMPORTANT: Leave four (4)
holes blank at this step.

bolt

CAUTION: Make sure the wiring harness
does not get pinched (see Figures 4J and
5J for correct routing).


54 mm (2.125 inches) long bolt
7 pieces



44 mm (1.73 inches) long bolt
2 pieces



25 mm long (1 inch) long bolt
2 pieces

44 mm bolts

;
;
Figure 3J
;

CAUTION: The two 25 mm bolts are
installed WITHOUT the strainer
bracket.
 Bolt torque: 7.9 N•m (0.81 kg-m,
70 in-lb.)

Correctly routed

Incorrectly routed

Figure 4J

Figure 5J

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3. Replace the metal bracket of the fluid temperature sensor as follows:

NOTE: The new bracket will be oriented the same way the old bracket was.
a. Cut the old plastic zip tie with an appropriate tool to remove the fluid temperature

sensor’s metal bracket from the terminal harness assembly (Figure 6J and Figure
7J).

CAUTION: Cut the plastic zip tie over the metal bracket to avoid damage to the fluid
temperature sensor.

b. Discard the removed metal bracket and plastic zip tie.

c. Use the new plastic zip tie from the Parts Information to attach the fluid temperature

sensor of the terminal connector harness to the fluid temperature sensor’s new
metal bracket.

IMPORTANT:
 Locate the plastic zip tie at the center notch of three notches on the fluid
temperature sensor (Figure 7J).


Tighten the plastic zip tie so that it is oriented as shown in Figure 6J.

d. Cut off the plastic zip tie excess.

Fluid temperature
sensor

Fluid temperature
sensor

Plastic zip tie
located at corner
Figure 6J

Plastic zip tie
in center notch
Fluid temperature
Temperatur
sensor’s
e sensor
metal
b k t
bracket

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Figure 7J

NTB17-039

4. Connect the electrical harness connector
(Figure 8J).
Harness
connector
Figure 8J

5. Install the CVT fluid temperature sensor
bracket to the valve body with one (1)
bolt (Figure 9J).
NOTE: Leave one (1) bolt hole blank as it
will be used to secure the oil strainer at a
later step.


54 mm (2.125 inches) long bolt.

1 bolt

 Bolt torque: 7.9 N•m (0.81 kg-m,
70 in-lb.)
Figure 9J

6. Install the new oil strainer with its new
O-ring seal with two (2) bolts
(Figure 10J).
NOTE: Replacement strainer maybe a
different shape than the original.


54 mm (2.125 inches) long bolt
2 pieces.

54 mm
bolts

;

 Bolt torque: 7.9 N•m (0.81 kg-m,
70 in-lb.)
Figure 10J

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7. Install the manual plate, lock washer, and
nut (Figure 11J).

Manual plate

NOTE: Make sure the manual plate fits
into the slot of the manual valve before
applying torque to the nut.

Lock washer



Reuse the existing manual plate, lock
washer, and nut.

Slot and manual
plate end

Nut

 Nut torque: 22.1 N•m (2.3 kg-m,
16 ft-lb.)
Manual valve
8. Clean the original oil pan and magnets
with a suitable cleaner. Visible debris
should not be present at re-assembly.

Figure 11J

9. Reassemble the original magnets to the
pan.
NOTE: Return the magnets to their
original locations.
10. Install a new oil pan gasket to the pan.

11. Install the oil pan bolts (see Figure 12J).


Reuse the existing pan bolts.
 Oil pan bolts torque: 7.9 N•m (0.81
kg-m, 70 in-lb.)

Figure 12J

12. Install a new drain washer to the drain plug on the oil pan.

13. Install the primary speed sensor to the CVT assembly.
IMPORTANT: Install a new O-ring to the speed sensor before installation. DO NOT
reuse the old O-ring.


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

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