Before inspecting, make sure the
camera handle’s AA batteries are
fresh and the LCD monitor’s battery
is charged.

Camera
flexible tube

a. Insert the camera lens between the
CVT case and pulley where shown in
Figures 3A and 4A.
 Insert the lens approximately seven
(7) inches, and then view the side
of the belt that contacts the pulley.

Front

Figure 4A

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NTB16-110i

b. Slowly and carefully turn the front left
tire one full turn in the forward rotation
to view all of the belt.


Holding the borescope with one
hand allows for turning the tire with
the other hand (see Figure 5A).

CAUTION: If the tire is rotated in the
rearward rotation, the camera lens
may get caught between the belt and
pulley.
c. If the inspection result is OK, inspect
the other side of the belt.


Figure 5A

Insert the camera lens in the
second location where shown
in Figure 3A and 6A, and then
perform step 6b again.

Pulley

d. If the inspection result is OK 360° on
both sides of the belt, proceed to step
7 on the next page.


Front

For additional information, see
video # 544: “CVT Belt Inspection”.
This video is located under the
TECH TRAINING GARAGE
VIDEOS tab in Virtual Academy.

e. If the inspection result is NG, proceed
to step 8 on the next page.

11/97

Figure 6A

NTB16-110i

7. If the belt inspection result is OK, replace only the valve body, and then check step 6 on
page 80 to confirm if a TCM reprogram is available.


For valve body replacement, go to page 71, Control Valve (Valve Body) Strainer
and Pan Installation.

8. If the belt inspection result is NG, replace the CVT sub-assembly and valve body, and
then check step 6 on page 80 to confirm if a TCM reprogram is available.


Go to CVT Assembly Removal, page 17.

Inspect these sides

Do not inspect
these sides

Figure 7A

12/97

NTB16-110i

Figure 8A: New belt

Figure 9A: Close-up of section to be inspected

13/97

NTB16-110i

Pictures in Figures 10A and 11A were taken with borescope J-51951.

OK

Visual
lines

Figure 10A: Belt is OK

OK

Visual
lines

Figure 11A: Belt is OK
14/97

NTB16-110i

NG

Scuffing

Figure 12A: Example of NG belt

NG

Lines
“smeared”

Figure 13A: Example of NG belt

15/97

NTB16-110i

Pictures in Figures 14A-16A were taken with borescope J-51951.

NG

Figure 14A: Example of NG belt

NG

Figure 15A: Example of NG belt

NG

Figure 16A: Example of NG belt
16/97

NTB16-110i

CVT Assembly Removal
Overview of Sub-assembly Repair
1. Apply rust penetrant as necessary to the dowel pins on the converter
housing side and sub-assembly side cover
2. Removal of the CVT from the vehicle
3. Remove the Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump
and Oil Filter
4. Clean the CVT case surfaces
5. Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT
Filter Area
6. Check initial pulley movement characteristics
7. New Pump Installation
8. Replace the Side Cover – Pulleys and Belt
9. Confirm shift selector movement
10. Recheck new pulley movement characteristics matches that of the
original assembly
11. Clutch Total Endplay Adjustment – Thrust Bearing Selection
12. Clean the Converter Housing Passages
13. CVT Reassembly
14. Control Valve (Valve Body) Strainer and Pan Installation
15. Install the CVT Assembly
NOTE: For additional information review video # 547: “CVT Belt and Pulley
Replacement”.
 This video is located under the TECH TRAINING GARAGE VIDEOS tab
in Virtual Academy.

17/97

NTB16-110i

1. Temporarily install the oil pan gasket and oil pan with four oil pan bolts to corners of the
oil pan, hand tight (Figure 1B).
NOTE: If the control valve has not yet been reinstalled, it is not necessary to do so. A
new one will be installed later in this service procedure.

Figure 1B

2. Remove the CVT from the vehicle.


Refer to the Electronic Service Manual (ESM), section TM-Transaxle &
Transmission for removal information.

AWD Vehicles
CAUTION:


Use extreme care when moving the axle in and out of the transfer assembly.



To avoid seal damage or deformation, properly support and guide the axle.

18/97

NTB16-110i

3. Place the CVT on a workbench with the
oil pan side down.


Use wood or plastic blocks to keep
the CVT steady.
CAUTION: Do not deform the oil pan.

4. Remove the torque converter.

Figure 2B

5. Drain CVT fluid out of the torque
converter.
Torque
converter
Figure 3B

Primary speed
sensor

6. Remove the primary speed sensor.
IMPORTANT: The speed sensor will be
re-used.

Figure 4B

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NTB16-110i

Remove the Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump and Oil Filter

1. Remove all 23 converter housing
mounting bolts (see Figure 1C).
NOTE:


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



Apply rust remover to the dowel
pins if needed.

Dowel Pin

Figure 1C

2. Separate and then remove the converter housing from the CVT case.


Use Slide Hammer J-25721-A and Slide Hammer Bolt J-50255-UPD with J-Hook J51923 at the cut out areas similar to the one shown in Figure 2C and Figure 3C.
CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from
the CVT case.

J-25721-A
-----

J-50255-UPD
-----

J-51923

One of three
cutout areas

Figure 2C

Figure 3C

20/97

NTB16-110i

3. Note the location of the pin shown in Figure 4C.
CAUTION: This pin can slip out during movement of the CVT while converter housing is
removed.

Figure 4C

O-ring

4. Remove the O-ring from the input shaft.


This O-ring will be replaced with a
new one.

Figure 5C
5. Carefully remove the reduction gear assembly (Figure 6C).
6. Carefully remove the differential assembly (Figure 7C).
Reduction gear
assembly

Differential
assembly

Figure 6C

Figure 7C
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NTB16-110i

7. Remove the following oil seals using
suitable tools:
CAUTION: Be careful not to damage any
of the seal bore surfaces.
a. CVT case differential side oil seal

(drive shaft seal).


See Figure 8C.

Figure 8C

b. Torque converter seal (Figure 9C).

Figure 9C

c. Converter Housing differential side oil

seal (drive shaft seal).


See Figure 10C.

NOTE: All wheel drive transfer case
O-ring will be replaced later in this
procedure.

Figure 10C

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NTB16-110i

Baffle
plate nuts

8. Remove the two (2) nuts from baffle
plate A, and then remove baffle plate A
(see Figure 11C).
CAUTION: To avoid rounding off these
nuts, it is best to use a 3/8 inch drive 6-pt
10 mm socket.

Baffle
plate A
Figure 11C

9. Remove the oil pump chain, driven and drive sprockets as one assembly (Figure 12C).


Spread the snap ring to remove sprocket (Figure 13C).

IMPORTANT: The drive sprocket has a specific top and bottom. Keep the sprockets
and chain together after removed.

Drive sprocket

Driven sprocket

Snap ring

Oil pump chain
Figure 12C

Figure 13C

23/97

NTB16-110i

Thrust washer

10. Remove the following:

a. “Pump cover” (dummy cover) thrust

washer (Figure 14C).


This thrust washer will be reused.
Dummy cover

Figure 14C

Snap ring

b. Oil pump snap ring (Figure 15C).



Lightly push the ends of the snap
ring together, rotate one side
upwards while pulling the snap
ring towards the pump opening.

Figure 15C

c. Oil pump bracket (Figure 16C).


Oil pump
bracket

Retained by two bolts.

Figure 16C

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NTB16-110i

11. Remove the three bolts from baffle plate
B, and then remove baffle plate B
(Figure 17C).
Baffle
plate B
Figure 17C

12. Remove the two bolts from baffle plate C,
and then remove baffle plate C
(Figure 18C).
Baffle
plate C
13. Remove the five dummy cover bolts, and
then remove the dummy cover. See
Figure 19C.
NOTE: These bolts will be reused.
IMPORTANT:

Figure 18C



Lift the dummy cover from sides ONLY. Do NOT lift from the input shaft (Figure
19C). This can lift the clutch pack out.



Do NOT remove the lathe cut seals (white seals in Figure 20C) from the dummy
cover. These seals will be reused.



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

Do not lift here

Lathe cut seals
(white seals)

Dummy
cover
Figure 19C

Figure 20C
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NTB16-110i

14. Remove the thrust bearing from the
clutch assembly bore (Figure 21C).

Lathe cut seals
(white seals)

NOTE: Take care removing the thrust
bearing so that the lathe cut seals are not
knocked out of their grooves.
IMPORTANT:
 The thrust bearing has two different
sides. As the thrust bearing is
removed, note the thrust bearing
orientation so that the new bearing
can be installed in the same
orientation.


Thrust bearing
Secondary
speed sensor
Figure 21C

This bearing will not be re-used.

15. Wipe any metallic debris from the face of
the secondary speed sensor
(Figure 21C).

Oil pan gasket
surface
Top of
CVT

16. Remove the oil pump as follows:
a. Remove the fitting bolt located above
the left rear corner of the oil pan
gasket surface (Figure 22C).
Fitting bolt

Figure 22C

b. Remove the three oil pump Allenhead bolts, and remove the oil pump
(Figure 23C).
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 23C

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17. Remove CVT fluid filter as follows:

a. Remove the 4 bolts and then remove
the CVT fluid filter cover (Figure 24C).
NOTE: Bolts will be reused.
CVT fluid filter cover
Figure 24C

b. Remove the CVT fluid filter with
grommet seal and O-ring seal
(Figure 25C).

Fluid filter



Discard the oil filter and seal. They
will be replaced.



Grommet is fitted to the bottom
end of the filter and is included
with replacement filter
(Figure 26C).

O-ring seal
Figure 25C

Grommet

Figure 26C

27/97

NTB16-110i

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.

