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New Snap Ring Selection and Installation to the New Sub-assembly

Top of the
shipping box
1. Remove the top of the shipping box of
the new sub-assembly.
NOTE: Outer cardboard of the shipping
box can be disassembled for easy
removal of the sub-assembly by
removing the shipping tape.

Figure 1N

2. Remove the upper board with foam
spacer assembly.


Packing material may be different
then what is shown in Figure 2N.

Upper board

Figure 2N

3. Locate the data sheet in the shipping box
and place it in a safe place.


This data sheet is required for snap
ring selection in the following steps.

Figure 3N

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4. Locate the plastic bag which contains the
snap rings (Figure 4N).


There are six individual snap rings in
the plastic bag.



Take the plastic bag out of the
shipping box, and put aside on the
work bench.

NOTE: See Reference # 5 in the KIT
PARTS REFERENCE TABLE.
Figure 4N

5. Take the new sub-assembly out of the
shipping box and place it on the work
bench.
CAUTION:


Hold the sub-assembly by the side
cover ONLY when removing it
from the shipping box.



DO NOT handle the belt or pulleys
of the sub-assembly when
removing from the shipping box.



DO NOT BREAK the foam cushion
in the shipping box. This will be
used as a stabilizer for the subassembly during the repair.

New sub-assembly
Figure 5N

NOTE: See Reference # 4 in the KIT
PARTS REFERENCE TABLE.

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6. Take the lower board with foam cushion (lower board) out of the shipping box (Shown in
Figure 7N).
IMPORTANT: Step 7 is for kits that have a
separate spacer (Figure 6N). In later kits
this spacer will be part of the Lower
board and step 7 will not be used.
7. Take the spacer (Figure 6N) out of the
shipping box and place on the work
bench where the sub-assembly will be
installed, and then place the lower board
on top of the spacer as shown in Figure
7N.
NOTE: The spacer will be the last item
that is removed from the shipping box
and is approximately 1 inch thick.

Spacer

Figure 6N



Position the lower board so that it hangs over the spacer.



Align the lower board so that the left and right cut outs are even with the spacer.

NOTE: The positioning of the lower board with foam cushion will allow the CVT case
enough clearance from the work bench to allow it to seat flush with the sub-assembly.
Cut out even
with spacer

Lower board with
foam cushion

Lower board
over-hang

Cut out even
with spacer

Cut out even
with spacer
Figure 7N

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8. Remove the sub-assembly from the
plastic bag.

9. Place the new sub-assembly onto the
lower board.


The sub-assembly must be level and
oriented as shown in Figure 8N for
proper seating of the CVT case later
in this procedure.

Lower board
and spacer

Figure 8N

New sub-assembly

10. Remove the snap ring from the
secondary pulley front bearing of the new
sub-assembly.


Discard the removed snap ring.

Snap ring
Figure 9N

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11. Calculate “E” for snap ring selection as follows:

NOTE: For the value of “B1”, refer to the data sheet that was put aside when the subassembly shipping box was opened.


Calculated case depth from step 8c on page 56

→

D ___________



Subtract constant value

→

─
41.30
------------------------------------



Subtotal

→



Add value for “B1” from data sheet

→ + B1 ___________
------------------------------------



Total calculated depth

→

=

___________

= E ___________

E = This will be used to select a snap ring from Table A on page 62.

EXAMPLE:
If D = 41.39 mm
Constant
= 41.30 mm (subtracted)
And B1 = 1.56 mm (added)
____________________
E = 1.65 mm

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12. Select the appropriate Part Number from Table A shown below, based on the calculated
result of “E” in step 11.
EXAMPLE: If E = 1.65, and is between or equal to 1.64 to 1.67, choose new snap ring
Part Number “31506 3JX9C”.
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
Reference only.
1.65
This does not
1.69
equal “E”
1.73
1.77
1.79

Table A
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
1.65
1.69
1.73
1.77
1.79

13. Open the plastic bag (with snap rings) that was removed from the shipping box in step
4, and then choose the correct Part Number selected from Table A.
NOTE: There are six individually packed snap rings in the plastic bag. See Reference #
5 in the KIT PARTS REFERENCE TABLE.
14. Measure the new snap ring and confirm its thickness is equal to the Snap Ring
Reference in Table A.
15. Install the selected snap ring to the secondary pulley front bearing of the new subassembly.
NOTE: Discard unused snap rings.

Selected snap ring
Figure 10N

Figure 11N
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Install Sub-assembly to CVT Case

CVT case sealing
surface

1. Make sure the CVT case sealing surface
of the side cover is thoroughly cleaned.

2. Make sure the dowel pins are cleaned
and any rust has been removed.

Figure 1P
Torque converter
housing
3. Flip the CVT case over on the work
bench with the torque converter housing
side facing up.
CAUTION: Make sure the work bench
surface is thoroughly cleaned before
flipping the CVT case.

4. Remove the two (2) temporary bolts and
then remove the torque converter
housing from the CVT case.


Discard these bolts.

Figure 2P

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5. Install the CVT case onto the new subassembly as follows:

CVT case

NOTE: Sealant will be applied between
these components at a later step.
a. Slowly lower the CVT case onto the
sub-assembly.
IMPORTANT:


Only use the weight of the
CVT case when installing it to
the sub-assembly.



Do NOT use any other
external force to seat the CVT
case to the sub-assembly.

New
sub-assembly

Figure 3P
Primary pulley
sub-assembly

b. Align the “primary pulley front
bearing bore” of the CVT case to the
primary pulley front bearing of the
sub-assembly.

CVT case

NOTE: Figure 4P is shown looking
down into the CVT case while it is
being lowered.

Primary pulley
front bearing bore
Figure 4P

CVT case

c. Align one of two dowel pin holes
found on the CVT case to the subassembly.

Dowel pin
New sub-assembly
Figure 5P

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d. Align the second dowel pin of the subassembly with the hole on the
opposite side of the CVT case and
seat CVT case.
Dowel pin
Figure 6P
e. If the CVT case will not seat on the
sub-assembly:
1) Access the counter driven gear
through the top of the CVT case,
and
2) Rotate the counter driven gear on
the primary pulley back and forth.
NOTE: This will allow the splines
of the secondary pulley and the
planetary carrier plate to align.
See Figure 8P.

Counter
driven gear

Figure 7P
Counter
driven gear

Secondary
pulley splines

Figure 8P
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f. Confirm that the mating surface of the CVT case is seated to the sub-assembly
completely.


If the CVT case does not sit completely flush with the sub-assembly, DO NOT
apply any vertical force to seat it.
1) If this occurs, first lift the CVT case up slightly and then lower.
2) Repeat until the CVT case and sub-assembly sit flush with each other.

CVT case

No gap

New sub-assembly
Figure 9P

g. Rotate the counter driven gear back and forth by hand to confirm that rotation is
smooth.

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6. Temporarily install two (2) original bolts hand tight to hold the sub-assembly to the CVT
case.

CVT case

New sub-assembly

Bolts

Figure 10P

Figure 11P

7. Lift the sub-assembly / CVT case away
from the cradle and set aside; discard the
cradle.


Leave the sub-assembly side cover
facing down as shown in Figure 12P.



Weight: 29 kg (64 lbs.)

Sub-assembly
side cover

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Figure 12P

NTB17-034e

Install the Oil Pump and the Manual Shaft

CVT case
1. Install the oil pump gasket to the CVT
case.


Use a new gasket (non-reusable).



Apply CVT Fluid before installation.

NOTE: See Reference # 14 in the KIT
PARTS REFERENCE TABLE.
Oil pump
gasket
2. Remove the hand tight transmission
range switch bolts and then slide the
manual shaft out only far enough to
install the oil pump.
CAUTION: Do not remove the manual
shaft completely from the CVT case. If
the retaining pin slot contacts the seal
damage may occur.

Figure 1Q
CVT case

Manual shaft

Oil pump

3. Install a new oil pump to the CVT case.


Reuse the three original Allen bolts for
the oil pump.



35 mm (1.4 inches) long bolt.
 Bolt torque:
20.3 N•m (2.1 kg-m, 15 ft-lbs.)

Figure 2Q

NOTE: See Reference # 13 in the KIT
PARTS REFERENCE TABLE.

4. Install the snap ring that came out of the
original oil pump to the new oil pump.
Snap ring
Figure 3Q

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Manual shaft

5. Slide the manual shaft back to the
original position.

Oil pump
Figure 4Q

Retaining
pin
6. Install the original retaining pin as shown
in Figure 5Q.


Align the manual shaft groove (Figure
6Q) to allow the retaining pin (Figure
5Q) to go through completely.

Manual
shaft

Figure 5Q

Groove for the retaining pin (straight pin)

Slide
direction

Hole for the roll pin
Figure 6Q

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IMPORTANT:
In the following step:
 Do not drive the roll pin flush with the detent plate.
 If the roll pin is driven flush, it will be overextended on the opposite side and the
manual shaft/detent plate assembly will not rotate.
 The roll pin MUST be the same length on both sides of the detent plate after it is
installed through the detent plate and manual shaft.

7. Install the new roll pin through the detent
plate and manual shaft.


The roll pin must be inserted through
the detent plate so that both ends are
the same length.