drum
Figure 1GG
1. Clean and then zero the Digital Depth Gauge (part #: J-50272). See pages 60-61.
 Set Digital Depth Gauge to millimeters.
2. Clean Gauge Block J-50271.
3. Confirm that the CVT case and the dummy cover mating surfaces are clean.
CAUTION: Do NOT use sanding discs or similar abrasive tools.
 Use brake spray or equivalent solvent and lint-free towels only.
 Make sure the brake spray or solvents used are compatible with local regulations.

67/105

NTB17-039e

4. Calculate the “average clutch assembly
surface depth” (D) as follows:
IMPORTANT: Measurements are
required from two opposite ends to obtain
the average

Figure 2GG

Gauge Block
a. Position the Gauge Block over the
clutch assembly on the surface that
the dummy cover seats.
IMPORTANT: This surface is lower
than the the CVT case to torque
converter housing.

Figure 3GG
b. Confirm the Gauge Block is not sitting
on the clutch assembly or against the
input shaft.

Input shaft

NOTE:
 The top surface of the clutch
assembly must be 1-3 mm
below the CVT case surface,
where the dummy cover seats.


If the clutch assembly is sitting
higher than the dummy cover
surface, see trouble shooting
The Dummy Cover Will Not
Sit Flush on page 98.

68/105

Clutch assembly
Figure 4GG

NTB17-039e

c. Position the Depth Gauge on the Gauge Block.
NOTE: Make sure the depth gauge’s datum level is flush on top of the Gauge Block.
d. Carefully slide the gauge down until it bottoms out on the upper surface of the clutch
drum where thrust bearing seats, where shown in Figure 5GG. Write this
measurement as D1 (use millimeters).

Measure 180
degrees apart

Figure 5GG

e. Measure this same distance on the opposite side (180 degrees) of the clutch
assembly surface 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

69/105

NTB17-039e

5. Measure the average (H) dummy cover
height where case seats as follows;

Clean here

Clean surfaces

a. Clean the dummy cover surface that
contact the CVT case and depth
gauge.
CAUTION: Use brake spray (or
equivalent) and lint-free towel only.
Make sure the brake spry or solvents
used are compatible with local
regulations.
b. Place the dummy cover upside down
on a workbench, and place the Gauge
Block onto the top surface.

Clean here
Figure 6GG

c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover.
NOTE: Make sure the Depth Gauge’s datum level is flush with the top of the Gauge
Block.
d. Carefully side 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 write it as
H2.

Measure opposite sides
Figure 7GG
f. Using the formula below, calculate the average and then write down the calculated
value as H.
(H1 + H2)
H = --------------2

Write the measurement for “H” here _____ mm

70/105

NTB17-039e

6. Measure the average (J) dummy cover height where thrust race seats as follows:
a. Carefully slide the Depth Gauge down until it contacts the dummy cover surface that
mates with the thrust race. Write this measurement as J1 (use millimeters).
b. Measure this same distance on the opposite side (180 degrees) of the dummy cover
and then write as J2.

Measure 180
degrees apart

Figure 8GG

c. Using the formula below, calculate the average and then write down the calculated
value as J.
(J1 + J2)
J = --------------2

Write the measurement for “J” here _____ mm

7. Calculate gap G.
Gap G = J – H
 Fill in the measurements below for “J” and “H” to calculate for “G”.
J measurement ______ mm
– H measurement ______ mm
= G ------------------- ______ mm

71/105

NTB17-039e

8. Measure thickness of the thrust bearing ONLY (without original race) as follows:
a. Place the thrust bearing roller side down on the Gauge Block (Figure 9GG).
IMPORTANT: Roller side of thrust bearing must face down and be flat on the Gauge
Block to accurately measure thickness.
b. Measure at two different positions of the thrust bearing that are 180 degrees apart.
c. Add the two measurements, and then divide by two. Write down the calculated value
as E.
(E1 + E2)
E = --------------2

Write the measurement for “E” here _____ mm

Roller side

Gauge
Block
Thrust
bearing
Figure 9GG
9. Choose the thrust bearing race to adjust Clutch Total Endplay (C) as follows:
a. Calculate C (clearance).
Total Clearance C = D – T + G – E
NOTE: “T “ is the Thickness of the Gauge Block (J-50271: 20mm).
 Fill in the measurements below for “D”, “G” and “E” from pages 69-72 to calculate
for “C”.
D measurement
– T measurement
+ G measurement
– E measurement
= C----------------

______ mm
_ 20 __ mm
______ mm
______ mm
______ mm

Please print this page and
attach it to the repair order.

EXAMPLE: If D = 23.81, G = 0.41, E = 2.57
C = D – 20 + G – E = 23.81 - 20 + 0.41 - 2.57
C = 1.65
72/105

NTB17-039e

b. Choose an appropriate thrust bearing race from Table B below based on C (seven
different thrust bearing “race thicknesses” are available).
Example: If C = 1.65 mm, it falls between the lower and upper clearances for race
thickness 1.2 mm.
c. Measure and confirm that the selected thrust bearing race is the correct thickness
before installing (Figure 10GG).
IMPORTANT: Do not measure from the thrust bearing race lip (Figure 11GG).

Table B
PART #: 31435-

CLEARANCE (C)
C=D–T+G–E

RACE
THICKNESS

3WX0A

0.90 – 1.08 mm

0.6 mm

3WX0B
3WX0C
3WX0D

1.09 – 1.29 mm
1.30 – 1.50 mm
1.51 – 1.70 mm

0.8 mm
1.0 mm
1.2 mm

3WX1A
3WX1B
3WX1C

1.71 – 1.90 mm
1.91 – 2.10 mm
2.11 – 2.30 mm

1.4 mm
1.6 mm
1.8 mm

Incorrect

Correct

Thrust bearing
race lip
Do not measure
from thrust
bearing race lip

Thrust bearing
race
Figure 10GG

Figure 11GG

73/105

NTB17-039e

10. Install the thrust bearing onto the clutch
drum.
IMPORTANT: The thrust bearing has two
sides.
 The needle bearing side is the
upper side.
 The race side mates with the
clutch drum surface.

Thrust
bearing
Figure 12GG

11. Install the bearing race onto the dummy
cover with applying petroleum jelly or
equivalent to thrust race to hold in place
on the dummy cover.
Thrust
bearing race
Figure 13GG

74/105

NTB17-039e

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

b. Remove the bolt and then remove the
lubrication tube and its bracket
(Figure 2H).

Lubrication
tube,
tube
bracket,
and
and
bracket
bolt

Figure 2H

2. Clean all baffle plates.

75/105

NTB17-039e

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

76/105

NTB17-039e

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).


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



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



Proceed to step 3.

J-8092

Converter
housing
Figure 2I

77/105

NTB17-039e

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.
IMPORTANT:
 Confirm that the lathe cut seals (white
seals) are in their appropriate slots.
Carefully reposition seals as
necessary.


Lathe cut seals must be in correct
positions during final assembly to
prevent drivability issues.

This area must
remain clear
Figure 3I
Dummy cover lathe cut
seals (white seals)

4. Confirm that the input shaft’s lathe cut
seals are in the correct locations.

Input shaft

Input shaft lathe cut seals
(white seals) correctly
located in slots

IMPORTANT:
 Lathe cut seals (white seals) must be
This area must
in their appropriate slots. Carefully
remain clear
reposition seals as necessary.


Lathe cut seals must be in correct
positions during final assembly to
prevent drivability issues.
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 98-99.




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.
78/105

Dummy
cover, baffle
plate C, and
bolts
Figure 5I
NTB17-039e

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

79/105

NTB17-039e

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

a. Expand the snap ring with a suitable

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

Snap ring
ends

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

80/105

NTB17-039e

First baffle
plate nuts

10. Install baffle plate A with two nuts