Retaining pin

21. Remove the manual shaft retaining pin
(straight pin) from the CVT case by
grasping and pulling vertically by hand.


Do not discard the pin. It will be
reused during reassembly.

Manual shaft

Figure 20H

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22. Remove the two (2) bolts shown in Figure
21H for the transmission range switch.


Do not discard the bolts. They will be
reused during reassembly.

CAUTION:


DO NOT remove the manual shaft
lock nut at this step.



DO NOT try to remove the
transmission range switch from the
manual shaft.
Transmission range
switch

Figure 21H
CVT case

5.3 inches
23. Slide the manual shaft approximately 5.3
inches (135 mm) out of the CVT case to
allow removal of the oil pump in step 24.
CAUTION: Do not remove the manual
shaft completely from the CVT case. If
the retaining pin slot contacts the seal
damage may occur.

Manual shaft

Figure 22H

24. Remove the three (3) Allen bolts shown
in Figure 23H and then remove the oil
pump from the CVT case.


This oil pump will not be reused.



Do not discard Allen bolts. They will
be reused during reassembly.

Oil pump

3 Allen bolts
Figure 23H

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Snap ring
25. Remove the snap ring from the original
oil pump.
CAUTION: DO NOT discard the removed
snap ring. This snap ring will be re-used.

Figure 24H

Oil pump
gasket
26. Remove the oil pump gasket from the
CVT case.


Discard the oil pump gasket (nonreusable).

Figure 25H

27. Temporarily install the transmission range switch with the two (2) original bolts removed
in step 22 on page 39, finger tight.


The transmission range switch will be permanently installed later in this procedure.

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Remove the Sub-assembly
IMPORTANT: The following steps (1-8) are ONLY to separate the sealant of the side
cover.
The sub-assembly with belt and pulley CANNOT be removed from the CVT while in this
orientation and will be removed from the case at a later step.

1. Reposition the CVT on the work bench
with the torque converter housing side
down.
NOTE: A wood block may be used to
stabilize the CVT during
disassembly/reassembly.

Figure 1J

2. Remove the two (2) pulley bearing
retainer bolts shown in Figure 2J.


Do not discard bolts. They will be
temporarily installed during a later
step.

Figure 2J

3. Remove the eleven (11) side cover bolts
shown in Figure 3J.


Retain two (2) of these bolts. They will
be temporarily installed during a later
step.

Figure 3J
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4. Remove the side cover with a slide hammer (J-25721-A) to separate the side cover and
CVT case.
 There are three slide hammer tool points shown in Figure 4J.
 The mating surfaces will be cleaned at a later step.
 This step will help with sub-assembly removal at a later step.
CAUTION:
 Do not use the speed sensor bore for slide hammer tool location.
 Do not pry the surfaces apart as internal damage may result.

Side cover

Figure 4J

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5. Align the primary pulley bearing retainer
bolt holes with the bolt hole on the case
as shown in Figure 5J.
NOTE: This helps alignment of the
bearing retainer bolt threads after reinstalling the original side cover.

Figure 5J

Assembly Guide
Pins, Pulley Bracket
(Guide Pin J-52272)
6. Install one of the “Assembly Guide Pins,
Pulley Bracket” (Guide Pin J-52272) to
one of the two pulley bearing retainer bolt
holes.


This will assist in installation of the
original side cover to the pulley
assembly.
Figure 6J

Side cover

7. Place the original side cover onto the
CVT case.


Position the primary pulley bearing
retainer to allow the guide pin to be
inserted through the bolt hole of the
side cover.

Figure 7J

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8. Install the two (2) original pulley bearing retainer bolts (Figure 8J) as follows:


Use the original bolts and O-rings at this step.
a. Install one pulley bearing retainer bolt by hand (finger tight) into open bearing
retainer bolt hole.
b. Remove the Guide Pin from the other bearing retainer bolt hole.
c. Install the other bearing retainer bolt by hand (finger tight).

9. Temporarily reattach the removed side cover onto the CVT case with two (2) original
bolts on opposite corners, hand tight.

Pulley bearing
retainer bolts

Side cover

Side cover
bolts
Figure 8J

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10. Reposition the CVT with the side cover
facing down.

Side cover
Figure 9J

11. Remove the two (2) side cover bolts
which were temporarily installed to hold
the side cover to the CVT in step 9 on the
previous page.
NOTE: Only one (1) bolt is shown in
Figure 10J and is for reference only.

Side cover
bolt
Figure 10J

12. Lift the CVT case vertically off of the subassembly and side cover.


Weight: 17.4 kg (38.4 lbs.)



This sub-assembly will not be reused.

IMPORTANT: The sub-assembly must
be separated from the case as shown in
Figure 11J.

Figure 11J

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13. Place the CVT case on the work bench
with the torque converter side facing
down.

Figure 12J

14. Remove the lubrication tube bolt shown
in Figure 13J and then remove the
lubrication tube from the CVT case.


Lubrication tube

Do not discard the bolt or lubrication
tube. These will be reused during
reassembly.

IMPORTANT: This step is to ensure
that the lubrication tube is not bent
during sub-assembly installation.

Lubrication
tube bolt
Figure 13J

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Clean the CVT Surfaces

CAUTION: During the next two steps;


Avoid any debris from dropping into the torque converter housing, side cover or the
CVT case. It is extremely important to keep any debris away from CVT internals to
prevent drivability concerns.



Use brake cleaner to remove the remaining CVT fluid and any residual sealant.



Do not use sanding discs, abrasive tools, or metal blades on sealing surfaces.



To clean dowel pins a mild abrasive sandpaper can be used to remove all rust and
debris.
 This will assist at a later step when mating the CVT Case to the sub-assembly
and again when mating the CVT Case to the torque converter housing.

1. Remove any sealant that remains on the
sealing surface of the CVT case where it
seals with the sub-assembly side cover.


A plastic scraper can be used.



Use ONLY brake cleaner to clean
surfaces.



Clean with a lint-free paper towel.

CVT case
sealing surface

Figure 1K
CAUTION: Debris must be kept out of the inside of the CVT and transmission range
switch connection to prevent possible drivability concerns.

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2. Remove any sealant that remains on the sealing surfaces of the torque converter
housing and CVT case using a plastic scraper, and then clean with a lint-free paper
towel.


Use ONLY brake cleaner to clean surfaces.

CAUTION: Debris must be kept out of the inside of the CVT and transmission range
switch connection to prevent a future drivability concern.

CVT case
sealing surface

Figure 2K

Torque converter
housing sealing
surface

Figure 3K

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Clean Oil Passages in CVT Case and Oil Pump Cover
In the following steps:


Brake cleaner and compressed air will be used to clean out oil passages in the CVT
assembly.
WARNING: Wear eye/face protection when using compressed air and cleaning
fluids.
CAUTION: Regulate air pressure up to a maximum of 75 PSI.

1. Confirm the CVT case is on the work
bench with sub-assembly side down.


Use wood blocks as necessary to
stabilize the assembly during these
steps.

CAUTION: Make sure the surface of the
work bench has been cleaned.

Figure 1L

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2. Spray brake cleaner into each oil passage, indicated in yellow, of the CVT case where
shown in Figure 2L and Figure 3L, until the fluid runs clear for 5 seconds.
IMPORTANT: Do not apply brake cleaner or compressed air to passages shown in
white.
3. Apply compressed air in the same passages to remove remaining cleaner and debris.
NOTE: Do not stand in front of the passages while using compressed air.

Figure 2L

Figure 3L
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4. Spray brake cleaner into the reverse
brake tube.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.

Reverse brake
tube

Figure 4L
5. Clean the input shaft bearing bore area (Figure 5L).
Input shaft
bearing bore

Figure 5L

6. Spray brake cleaner into the high clutch
fluid passage on the torque converter
housing.

High clutch fluid
passage

CAUTION: Brake cleaner will exit the
passage shown as “fluid discharge” in
Figure 6L while cleaning passage.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.

Fluid discharge
Figure 6L

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7. Spray brake cleaner into the reduction
gear bearing fluid passage on the torque
converter housing.

Reduction
gear bearing
fluid passage

CAUTION: Do not face the passage
indicated in red of Figure 7L while
cleaning.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.

Fluid discharge
Figure 7L

Input shaft

Oil pump cover

8. Clean the passages of the oil pump cover
as follows:
a. Remove the input shaft from the oil
pump cover.
CAUTION: Do not drop the counter
bearing outer race (roller bearing type
only).
Figure 8L

Thrust bearing
b. Note the orientation and then remove
the thrust bearing.


Do NOT discard. This will be
reused at a later step.

Figure 9L

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c. Remove the washer.


Washer

Do NOT discard. This will be
reused at a later step.

d. Spray brake cleaner into the oil pump
cover oil passages indicated in yellow
shown in Figure 11L.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Figure 10L

CAUTION: Do not face the passage indicated in white in Figures 11L and 12L while
cleaning.
Oil pump cover

Oil pump cover

Fluid discharge
Figure 11L

Figure 12L

Washer

e. Install the original washer.
NOTE:


Orientation is NOT critical for
the washer.



Apply petroleum jelly to the
washer to hold it in place
during assembly.
Figure 13L

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f. Install the original thrust bearing.


Orientation IS critical. See Figure 14L and Figure 15L for thrust bearing cross
section.

CAUTION:



The thrust bearing has two sides. Refer to Figures below.
Apply petroleum jelly or equivalent to hold in place.

Oil pump cover

Thrust bearing

Figure 14L

Figure 15L

g. Insert the input shaft to the oil pump cover (Figure 16L).
CAUTION:




The input shaft has a sealing ring.