c. Pull the oil filter cover away from the
CVT case to remove.

Figure 2E
2. Pull the oil filter with grommet away from the CVT case to remove.


Discard the removed filter with grommet (non-reusable).

NOTE: Grommet may separate from the filter and remain on the CVT case.
Grommet

Oil filter
Figure 3E
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3. Remove the O-ring from the oil filter
cover.


Discard the removed O-ring (nonreusable).

Figure 4E

4. Thoroughly wipe and clean the inside of
the oil filter cover.


Brake cleaner may be used during
this step to thoroughly remove any
residual material.

Figure 5E

5. Thoroughly wipe and clean the filter bore
(highlighted in green) of the CVT case.

Filter bore
Figure 6E

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NTB17-034e

Remove the Oil Pan and Torque Converter Housing
1. Reposition the CVT assembly on the
work bench with the torque converter
housing side facing up.


Use plastic or wood blocks to stabilize
the CVT assembly on the work bench
if needed.

NOTE: CVT fluid will drain from the CVT
case when the oil pan is removed.
2. Remove the oil pan and oil pan gasket
which were installed to the CVT
temporarily. Bolts will be reused.



Discard the removed oil pan gasket.

Figure 1F
Keep the original oil pan for installation during reassembly.

3. Remove the nineteen (19) bolts shown in Figure 2F from the torque converter housing.


Do not discard these bolts. They will be temporarily re-used later in this procedure.

NOTE: Some bolts are not visible in Figure 2F. Yellow circles give the general area of
bolt locations.
4. Remove the torque converter housing from the CVT case.



Use a Slide Hammer (J-25721-A) at the three locations shown in Figure 2F if
needed.
The input shaft thrust bearing washer may be attached to the torque converter housing,
remove it and put it aside; it will be reused.

Tool location is behind
torque converter
housing
Torque converter
housing

Figure 2F
28/129

Tool location is behind
torque converter
housing
NTB17-034e

Remove the Oil Seals from the Torque Converter Housing

1. Remove the torque converter oil seal from the torque converter housing with a suitable
tool.


Take care not to damage the seal-to-case surface when removing seal.



Discard the torque converter oil seal (non-reusable).

2. Remove the differential side oil seal from the torque converter housing with a suitable
tool.


Discard the differential side oil seal (non-reusable).

Torque converter
housing

Differential side
oil seal
Torque converter
oil seal

Figure 1G

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NTB17-034e

Remove the CVT Internal Components
Reduction
gear assembly

Lip seal

1. Remove the final drive assembly and the
reduction gear assembly at the same
time by lifting both straight up.

O-ring
Final drive
assembly

Figure 1H

Lip seal

2. Remove the lip seal from the CVT case.


Discard the removed lip seal (nonreusable).

Figure 2H

O-ring
3. Remove the O-ring from the CVT case.


Discard the removed O-ring (nonreusable).

Figure 3H
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4. Remove the O-ring from the input shaft.


Discard the removed O-ring (non-reusable).

5. Remove the thrust bearing from the drive sprocket and set aside to reuse during reassembly.
NOTE: The thrust washer for the thrust bearing may either be on the drive sprocket or
may have remained with the torque converter housing when it was removed.


The thrust washer will be reused later in this procedure.

If present, the thrust
washer would cover
the bearing.
Input shaft O-ring

Thrust
bearing

Drive
sprocket

Figure 4H

6. Spread the snap ring shown in Figure 5H and then remove both sprockets and the
chain.

Sprockets
and chain

Snap ring
Figure 5H
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NTB17-034e

Parking rod

Detent plate

7. Remove the parking rod from the detent
plate.


Rotate the parking rod vertically to
align the tab on the parking rod
(Figure 7H) with the slot on the detent
plate and then separate from the
detent plate.

Figure 6H

Align tab
with slot

Detent plate

Figure 7H

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Reverse
brake tube

8. Remove the two (2) bolts shown in Figure
8H and then remove the reverse brake
tube from the CVT.


2 Bolts

Do not discard. These will be reused
during assembly.

Figure 8H

Sleeve
9. Remove the sleeve from the reverse brake
tube.


Discard the removed sleeve (nonreusable).

Figure 9H

10. Remove the six (6) bolts shown in Figure
10H and then remove the chain cover.


Do not discard. These will be reused
during assembly.

Chain cover
Figure 10H

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11. Remove the input shaft assembly and the
oil pump cover (dummy cover) from the
CVT as a unit.


Hold input shaft assembly by the end,
as shown in Figure 11H, and pull
straight up to remove.
CAUTION: If the input shaft is not
held at the end the dummy cover,
shaft and bearing will separate.
Input shaft assembly
and the oil pump
cover (dummy cover)

Figure 11H

12. Confirm the “type” of bearing used on the end of the input shaft, and then proceed to the
indicated step.
 For type “A” Roller Bearing proceed to step 13 on page 35.
 For type “B” Ball Bearing skip to step 15 on page 36.
 For type “C” Sealed Ball Bearing skip to step 15 on page 36.

Bearing type A
Figure 12H

34/129

Bearing type B and C.
 Type C shown

NTB17-034e

13. Remove the outer race of the roller
bearing from the counter bearing bore of
the CVT case by hand.
CAUTION: Do not use excessive force to
remove the bearing race. A magnet can
be used to lift this bearing if needed.
NOTE: The outer race of the roller
bearing might remain on the shaft when
removing the input shaft and dummy
cover.

CVT case

Outer race
Figure 13H

14. Inspect type “A” bearing (Roller bearing)
as follows:


Inspect the bearing outer race and
input shaft for flaking and/or pitting.



Install the bearing outer race onto the
input shaft assembly with the “bearing
number” facing the gear, and then
rotate the bearing while applying an
axial load by hand to check for any
abnormality.
CAUTION: DO NOT drop the outer
race of the bearing.
 Were any abnormalities found or
felt in the bearing (sound, flat
spots, flaking)?

Input shaft
Figure 14H

o NO: Put bearing and shaft aside and then skip to step 16 on page 36.
o YES:
a) Document the abnormalities found with video and then contact the PCC
for authorization to replace the CVT. See page 129 for PCC contact
information.
b) Loosely re-assemble the CVT in the reverse order of disassembly with the
original parts.
c) Refer to the ESM, section TM – Transaxle & Transmission for CVT
replacement.

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15. Inspect type “B” and type “C” bearings
(ball bearing) as follows:


Apply an axial load and rotate the
bearing by hand to check for any
abnormality (sound, flat spot, flaking).
 Were any abnormalities observed
in the bearing when applying an
axial load (sound, flat spots,
flaking)?
o NO: Proceed to step 16.
o YES:

Figure 15H

a) Document the abnormalities found with video and then contact the PCC
for authorization to replace the CVT. See page 129 for PCC contact
information.
b) Loosely re-assemble the CVT in the reverse order of disassembly with the
original parts.
c) Refer to the ESM, section TM – Transaxle & Transmission for CVT
replacement.

16. If the bearing is judged to be OK, remove
the shim (Figure 16H) from the bottom of
the counter bearing bore.


A magnet can be used to remove the
shim if needed.



This shim will be reused later in this
procedure.

Counter bearing
bore

Shim
Figure 16H

17. Remove the differential side oil seal from
the CVT case by driving it away from the
case with a suitable tool.



Discard the differential side oil seal
(non-reusable).

CVT case

Take care not to damage the seal to
case surface when removing seal.
Differential side oil seal
Figure 17H
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NTB17-034e

18. Rotate the manual shaft (Figure 18H)
until it stops in the park position (see
Figure 19H).

3 mm punch

Park position
Roll pin

IMPORTANT: Confirm that the detent
plate is in the PARK position before
proceeding. Do not remove the roll pin
in any other position. This will allow
pin removal and avoid damage to the
case.
19. Remove the roll pin completely from the
manual shaft with a 3 mm punch.


Manual shaft

Discard the roll pin (non-reusable).

CAUTION: Do not enlarge the hole by
using an inappropriately sized punch.
IMPORTANT: Do not leave the roll pin in
the CVT case.

Figure 18H

Detent spring

Park position

20. Remove the detent spring bolt shown in
Figure 19H and then remove the detent
spring from the CVT case.


Do not discard the bolt. It will be
reused during reassembly.

Figure 19H

Retaining pin

21. Remove the manual shaft retaining pin
(straight pin) from the CVT case by
grasping and pulling vertically by hand.


Do not discard the pin. It will be
reused during reassembly.

Manual shaft

Figure 20H

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22. Remove the two (2) bolts shown in Figure
21H for the transmission range switch.


Do not discard the bolts. They will be
reused during reassembly.

CAUTION:


DO NOT remove the manual shaft
lock nut at this step.



DO NOT try to remove the
transmission range switch from the
manual shaft.
Transmission range
switch

Figure 21H
CVT case

5.3 inches
23. Slide the manual shaft approximately 5.3
inches (135 mm) out of the CVT case to
allow removal of the oil pump in step 24.
CAUTION: Do not remove the manual
shaft completely from the CVT case. If
the retaining pin slot contacts the seal
damage may occur.

Manual shaft

Figure 22H

24. Remove the three (3) Allen bolts show in
Figure 23H and then remove the oil pump
from the CVT case.


This oil pump will not be reused.



Do not discard Allen bolts. They will
be reused during reassembly.

Oil pump

3 Allen bolts
Figure 23H

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NTB17-034e

Snap ring
25. Remove the snap ring from the original
oil pump.
CAUTION: DO NOT discard the removed
snap ring. This snap ring will be re-used.

Figure 24H

Oil pump
gasket
26. Remove the oil pump gasket from the
CVT case.


Discard the oil pump gasket (nonreusable).

Figure 25H

27. Temporarily install the transmission range switch with the two (2) original bolts removed
in step 22 on page 38, finger tight.


The transmission range switch will be permanently installed later in this procedure.

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NTB17-034e

Remove the Sub-assembly
IMPORTANT: The following steps (1-8) are ONLY to separate the sealant of the side
cover.
The sub-assembly with belt and pulley CANNOT be removed from the CVT while in this
orientation and will be removed from the case at a later step.

1. Reposition the CVT on the work bench
with the torque converter housing side
down.
NOTE: A wood block may be used to
stabilize the CVT during
disassembly/reassembly.

Figure 1J

2. Remove the two (2) pulley bearing
retainer bolts shown in Figure 2J.


Do not discard bolts. They will be
temporarily installed during a later
step.

Figure 2J

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