battery.



Look in the PG section index for ADDITIONAL SERVICE WHEN REMOVING
BATTERY NEGATIVE TERMINAL.



This list often includes items such as radio, power windows, clock, sunroof,
etc.

IMPORTANT:
c. Perform ADDITIONAL SERVICE REQUIRED starting on page 97.

Belt Damaged

5. Install the original (removed) oil pan
gasket and oil pan temporarily with at
least two oil pan bolts, hand tight.
IMPORTANT: DO NOT discard the
remaining oil pan bolts. These bolts will
be re-used.

Figure 20C
6. Replace the belt and pulley sub-assembly and valve body.


Go to Remove CVT from the Vehicle and Disassemble External Parts on the
next page.

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NTB17-034i

Remove CVT from the Vehicle and Disassemble External Parts

1. Remove the CVT from the vehicle.


Refer to the ESM, section TM – Transaxle & Transmission for CVT removal.

2. Put the CVT assembly on a work bench
with the oil pan side down.
CAUTION: Take care not to damage the
oil pan.
Torque converter

3. Remove the torque converter.


The torque converter will be reused
during reassembly.

Figure 1D

4. Drain the CVT fluid out of the torque
converter.

Figure 2D

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NTB17-034i

5. Remove the output speed sensor, primary speed sensor and secondary speed sensor
from the CVT (Figure 3D).


These sensors will be reused.



Inspect all three sensors for debris on the magnet and clean as necessary.

6. Remove the O-rings from all three speed sensors.


Discard the removed O-rings. These will be replaced during reassembly.

Primary speed sensor

Secondary speed sensor

Figure 3D

Output speed sensor
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NTB17-034i

Remove the Oil Filter

1. Remove the oil filter from the CVT case
as follows:

Oil filter cover bolt

a. Remove the oil filter cover bolt.


This bolt will be reused.

Oil filter cover
Figure 1E
Locking tab
b. Rotate the oil filter cover
counterclockwise approximately 15
degrees or until the cover clears the
locking tab.

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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NTB17-034i

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
29/138

Tool location is behind
torque converter
housing
NTB17-034i

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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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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NTB17-034i

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 the 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 36.
 For type “B” Ball Bearing skip to step 15 on page 37.
 For type “C” Sealed Ball Bearing skip to step 15 on page 37.

Bearing type A
Figure 12H

35/138

Bearing type B and C.
 Type C shown

NTB17-034i

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.

Input shaft

 Were any abnormalities found or
felt in the bearing (sound, flat
spots, flaking)?

Figure 14H

o NO: Put bearing and shaft aside and then skip to step 16 on page 37.
o YES:
a) Document the abnormalities found with video and then contact the PCC
for authorization to replace the CVT. See page 137 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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NTB17-034i

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 137 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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NTB17-034i

3 mm punch

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

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).
Figure 18H

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

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