Fitting bolt

Figure 24B

b. Remove the three oil pump Allenhead bolts, and remove the oil pump
(Figure 25B).
NOTE:
o Do NOT discard the Allen-head
bolts. Bolts will be re-used.
o New oil pump will be installed
at later steps.
Figure 25B

18. Remove CVT fluid filter as follows:

a. Remove the four (4) bolts and then
remove the CVT fluid filter cover
(Figure 26B).
NOTE: Bolts will be reused.
CVT fluid filter cover
Figure 26B

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Fluid filter

b. Remove the CVT fluid filter with
grommet seal and O-ring seal
(Figure 27B).


Discard the oil filter and seal. They
will be replaced.
O-ring seal
Figure 27B

Grommet



Grommet is fitted to the bottom
end of the filter and is included
with replacement filter
(Figure 28B).

Figure 28B

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Clean the CVT case surfaces

1. Thoroughly clean the mating surfaces of the CVT case and Torque Converter Housing.


A plastic scraper can be used.

CAUTION:
 DO NOT use sanding discs, similar abrasive tools, or metal blades.


Use brake spray or equivalent solvent and lint-free towels only.



Make sure brake spray or solvents used are compatible with local regulations.



Avoid debris entering into the inside of the CVT.



Make sure rust and debris have been cleaned off of dowel pins and receiving
holes (Figure 1C).

2. Clean the dowel pins and dowel pin receiving holes of any rust or debris with emery
cloth (Figure 1C).
NOTE: Use small wire brush or similar tool at the inside surface of dowel pin holes. DO
NOT SCRAPE CVT CASE mating surfaces.

Clean dowel pin
receiving holes
Clean
dowel pin

Figure 1C

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Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT Filter Area

In the following steps:


Brake cleaner and compressed air will be used to clean out oil passages in the CVT
assembly.



Make sure the brake cleaner or solvents are compatible with local regulations.
WARNING: Wear eye / face protection when using compressed air and cleaning
fluids.
CAUTION:
 Regulate air pressure up to a maximum of 75 PSI.


Do not use water-based (aqueous) cleaners.

1. Clean the area where the CVT fluid filter
fits (Figure 2C).


Clean within
this area

Make sure the old filter grommet seal
is removed.

2. Clean the fluid passages to and from the
filter (Figure 2C).

Fluid
passages
Figure 2C

3. Clean filter cover (Figure 3C).

Figure 3C
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4. Spray brake clean in all oil passages of the CVT case where shown in Figure 4C and
Figure 5C.
5. Remove lip seal if not already removed.
6. Apply compressed air in the same passages.
NOTE:
 Do not stand in front of the passages while using compressed air.
 Do not spray brake clean directly into clutch pack.

Lip seal

Figure 4C

Apply cleaner, and then
75 PSI maximum air
pressure in these
passages.
Air pressure comes
out these passages.

Figure 5C

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New Oil Pump Installation

1. Install the new oil pump using three (3)
original Allen-head bolts (Figure 1D).
NOTE:


Finger tighten the Allen-head bolts at
this time.

IMPORTANT: A Parts Kits Reference Table
is provided on page 102.




Use the check off column on the left
to ensure the correct new part is
installed at each step.

Figure 1D

Attach this to the repair order.
Fitting bolt

O-ring
2. Place new O-ring on the fitting bolt, and
coat with CVT fluid (Figure 2D).

Figure 2D

3. Install the fitting bolt finger tight
(Figure 3D).

Fitting
bolt

Figure 3D

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4. Torque the three (3) Allen head bolts and fitting bolt.
 Allen head bolt torque: 17.6 – 20.6 N•m (1.79 – 2.1 kg-m, 13.0 – 15.2 ft-lb)
 Fitting bolt torque: 26.0 – 30.0 N•m (2.65 – 3.06 kg-m, 19.2 – 22.1 ft-lb)

5. Install the original snap ring (Figure 4D).

Snap ring
Figure 4D
6. Install the CVT fluid filter and components (Figure 5D).


Install a new filter with grommet (one part).



Install a new O-ring.



Confirm that all components and areas where components fit are thoroughly clean.



Apply CVT fluid to the grommet seal and O-ring before installing.



Install the filter cover.
 Bolt torque 4.2 N•m (0.43 kg-m, 37.2 in-lb.)

Fluid filter

O-ring seal

CVT fluid filter cover

Figure 5D

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Replace the Side Cover – Pulleys and Chain (sub-assembly)

1. Temporarily install the dummy cover with
3 bolts, finger tight (Figure 1E).
IMPORTANT:


Do not install any thrust bearing to
the clutch assembly bore at this
time.



If cover does not seat flush see
trouble shooting The Dummy
Cover Will Not Sit Flush on
page 98.

Bolts

Dummy cover
Figure 1E

2. Temporarily install the converter housing
onto the CVT case with three bolts finger
tight (Figure 2E).
IMPORTANT:


When fitting the CVT case
surfaces, DO NOT use the bolts to
draw in the case halves.



Make sure the case surfaces are
flush, and have no gaps prior to
installing the bolts.

Bolts

Converter housing
Figure 2E

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3. Flip the CVT case so that the converter
housing faces down and side-cover faces
up.


Lifting fixture J-51595 can be used for
this step. This tool is not shown in
Required Tools / Materials.

Manual shaft

CAUTION:
 Do not hit the manual shaft (Figure
3E) while flipping the CVT; the
manual shaft protrudes past the CVT
case. Use a plastic / wooden block to
support as needed.


Figure 3E

Note the location of the terminal
connector harness. Do not pinch the
terminal connector harness between
the CVT case and work bench or
supporting blocks.

4. Rotate the primary pulley by hand to
check the pulleys rotational
characteristics.

Rotate the primary
pulley by hand

IMPORTANT:




Remember the pulley’s rotational
characteristics. This will be used
as a reference after the new side
cover-pulleys and belt subassembly (sub-assembly) have
been installed.

Figure 4E

This will be used as a reference
later in the procedure to determine
if the sub-assembly installation is
successful or not.

WARNING: Do not place fingers between
the pulley and the CVT case.
Do not place fingers
under pulley
Figure 5E

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NOTE: When working with sub-assembly install, uninstall, and bracket attachment, it is
critical that CVT and sub-assembly are level. If not level, the pulleys and bearings can sit
slightly at an angle and will hinder installation.

5. Remove the nineteen (19) side cover
bolts (Figure 6E).


Loosen the bolts with hand tools only.



These bolts will be replaced with new
ones and will not be reused.

Figure 6E

6. Remove the six (6) pulley bracket bolts.


Bolts will be reinstalled to the original
pulley and belt sub-assembly.

Figure 7E

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7. Attach universal Lifting Fixture J-52082 with spacers J-52082-2 to the side cover as
shown in Figure 8E.
NOTE: Install and tighten by hand only.
a. Loosen all of the wing-nut bolts on the Lifting Fixture.
b. Confirm that three (3) spacers (# J-52082-2) are present between the longer legs
and triangle bracket as shown in Figure 8E.
c. Install the Lifting Fixture to the CVT case at the six (6) bolt holes shown in Figure 7E
on page 35.
d. Tighten the two (2) joint to triangle brackets.
e. Tighten the wing-nut bolts on the Lifting Fixture finger tight.
CAUTION: Do not cross thread the bolts when attaching to the CVT side
cover.

(3) Spacers
(# J-52082-2)

Triangle
bracket

Lifting Fixture J-52082
Longer legs

Triangle
bracket joint

Figure 8E

8. Install the two CVT Assembly Guide Pins (J-51959 - Guide Pins) as shown in Figure 9E
and Figure 10E.


The Guide Pins must be located next to the dowel pins.
Guide Pin

Guide Pin

Guide Pin

Dowel Pin
Pins
Dowel Pin
Figure 9E

Figure 10E
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9. Raise the Lifting Fixture so that the CVT assembly weight is mostly supported by the
Lifting Fixture and just slightly raised off of the work surface (using Tool #: J-52082).
10. Loosen the side cover with a slide hammer at the three points shown in Figure 11E.


Rotate between the 3 locations on the side cover until the CVT case separates from
the sub-assembly; this can take more than one rotation to loosen sealant.
CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from
the CVT case.
NOTE: Apply rust penetrant to the two dowel pins as needed.

The following Figure is for reference only and does not show the lifting device attached.
Tool location
marks

Dowel
pin

Dowel
pin

Figure 11E

11. Raise the lifting fixture to remove the
“side cover with pulleys and chain subassembly” (sub-assembly) from the CVT
case (Figure 12E) and set aside.
CAUTION: Make sure the primary speed
sensor is removed from the subassembly.


Speed sensor will be reused.



DO NOT discard speed sensor.



This sub-assembly will not be
reused.

12. Remove the lifting Fixture from the subassembly and replace all six (6) original
bolts.

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Sub-assembly

Figure 12E

CVT case

NTB17-039e

13. Thoroughly clean the mating surfaces of the CVT case (Figure 13E) that the subassembly was just separated from (a plastic scraper can be used).


Clean off dowel pins.



Confirm that dowel pins have remained in the CVT case. If not, remove them from
the sub-assembly and relocate back to the CVT case.



Reinstall guide pins if they were removed during case cleaning.

CAUTION:
 DO NOT use sanding discs, similar abrasive tools, or metal blades.
 Use brake cleaner or equivalent solvent and lint-free towels only.
 Make sure brake spray or solvents used are compatible with local regulations
 Avoid debris entering into the inside of the CVT.
 Make sure rust and debris have been cleaned off of dowel pins and receiving
holes.
14. Remove the O-ring from the CVT case (Figure 14E).


This O-ring will not be reused.

Mating surfaces

O-ring

Figure 13E

Figure 14E

15. Remove the thrust bearing from the
planetary carrier plate (Figure 15E).


Thrust bearing will be re-used.
DO NOT discard.
CAUTION: If not found on the
planetary carrier plate, the thrust
bearing may still be attached to the
primary pulley.

Thrust bearing
Figure 15E

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Shift select lever
16. Rotate the shift select lever counter
clockwise to the “L” range position
(Figure 16E), so that the parking rod is at
its lowest position (Figure 17E).

Figure 16E

Parking rod

Figure 17E

17. Remove the six (6) bolts from the new
sub-assembly and then remove their Orings.


These bolts will be reused.



These O-rings will not be reused.

Lifting Fixture

18. Attach Lifting Fixture to the new subassembly, and then raise sub-assembly
out of shipping box.
CAUTION: Do not cross thread side
cover holes when installing the Lifting
Fixture. Always start bolts by hand.

Sub-assembly
Figure 18E

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19. Install the original thrust bearing onto the primary pulley of the new sub-assembly
(Figure 19E).
CAUTION: The thrust bearing has two different sides. Reference Figure 19E for correct
bearing orientation.


Apply a thin layer of petroleum jelly or equivalent to the original thrust bearing to
hold it in place on the primary pulley.