Do NOT discard the Allen®head bolts. These bolts will be
reused.



A new oil pump will be installed
later in this bulletin.
Figure 51

26/98

NTB19-060

33.

Remove the CVT fluid filter as follows:

a. Remove the four (4) bolts and then
remove the CVT fluid filter cover
(Figure 52).
NOTE: These bolts will be reused.
CVT fluid filter cover
Figure 52

b. Remove the CVT fluid filter with
grommet seal and O-ring seal
(Figure 53).

Fluid filter



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



The grommet seal is fitted to
the bottom end of the filter and
is included with the
replacement filter (Figure 54).

O-ring seal
Figure 53

Grommet

Figure 54

27/98

NTB19-060

Clean the CVT case surfaces

34.

Thoroughly clean the mating surfaces of the CVT case and torque converter housing.


A plastic scraper can be used.

CAUTION:
o DO NOT use sanding discs, similar abrasive tools, or metal blades.
o Use brake cleaner or equivalent solvent and lint-free towels only.
o Make sure brake cleaner or solvents used are compatible with local regulations.

35.

o

Prevent debris from entering in the CVT.

o

Make sure rust and debris have been cleaned off of dowel pins and receiving
holes (Figure 55 and Figure 56).

Clean the dowel pins and dowel pin receiving holes of any rust and debris (Figure 55
and Figure 56).
NOTE: Use a 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
Dowel pin

Figure 56

Figure 55

28/98

NTB19-060

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

Brake cleaner or a suitable cleaning solvent 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.

36.

Clean the area where the CVT fluid
filter fits (Figure 57).


37.

Clean within
this area

Make sure the old filter grommet
seal is removed.

Clean the fluid passages to and from
the filter (Figure 57).

Fluid
passages
Figure 57

29/98

NTB19-060

38.

Use brake cleaner in all oil passages of the CVT case where shown in Figure 58 and
Figure 59.


39.

Do not spray brake cleaner into the clutch pack.

Apply compressed air in the same passages.
NOTE: Do not stand in front of the passages while using compressed air.

Figure 58

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

Figure 59
40.

Temporarily install the fluid filter cover.

30/98

NTB19-060

New Oil Pump Installation
IMPORTANT: For the following service procedures a PARTS KITS REFERENCE TABLE
is provided on page 95.


41.

Use the check off column on the left to ensure the correct new part is installed at each
step, and then attach it to the repair order.

Install the new oil pump using three
original Allen®-head bolts (Figure 60).
NOTE:


Finger tighten the Allen®-head
bolts at this time.



The oil pump kit includes a new oil
pump, O-ring, and snap ring.

Figure 60
Fitting bolt

42.

Place a new O-ring on the fitting bolt,
and then coat the O-ring with CVT
fluid (Figure 61).

O-ring

Figure 61

43.

Install the fitting bolt finger tight
(Figure 62).

Fitting
bolt

Figure 62
31/98

NTB19-060

44.

45.

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)

Install the new snap ring (Figure 63).

Snap ring
Figure 63

32/98

NTB19-060

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

Review video # 547: “CVT Belt and Pulley Replacement” and fast forward to minute
marker 3:14. This video is located under the TECH TRAINING GARAGE VIDEOS tab
in Virtual Academy.

46.

Temporarily install the dummy cover
with three (3) bolts, finger tight
(Figure 64).
IMPORTANT:




Do not install the thrust bearing to
the clutch assembly bore at this
time.
If the cover does not sit flush,
continue to step 47 for Dummy
Cover Troubleshooting.
Otherwise, skip to step 54.

Bolts

Dummy cover
Figure 64

Dummy Cover Troubleshooting
47.

If the dummy cover does not sit flush, the clutch pack may not be fully seated.


Figure 65 shows the clutch pack
fully seated.



The clutch pack is not fully seated
if it is not below the surface that the
dummy cover bolts to.



Use the instructions below to fully
seat clutch pack.

Clutch pack
seated correctly

NOTE: Always handle the clutch pack by
the input shaft.

Surface dummy
cover seats on
Figure 65

33/98

NTB19-060

Dummy cover

48.

Remove the dummy cover.

Figure 66

Clutch pack
49.

Pull up the clutch pack by the input
shaft to remove the entire clutch pack.


Make sure the O-ring is not
installed at this time, or it could be
damaged during reassembly.

Input shaft

Figure 67
Clutch pack
Clutch pack layers
50.

Using an appropriate tool, gently align
the layers of the clutch pack.


Bottom of the clutch pack shown in
Figure 68.

Appropriate
tool
Align layers
Figure 68

34/98

NTB19-060

51.

Re-insert the entire clutch pack while
holding the input shaft.

52.

Gently jiggle the input shaft until the
clutch pack seats below case lip.


If the clutch pack does not seat,
rotate back and forth from the input
shaft and jiggle.



If the clutch pack still does not
seat, repeat from step 49.

Input shaft

Clutch pack
Figure 69

53.

Return to step 46.

54.

Temporarily install the converter
housing onto the CVT case with three
(3) bolts finger tight (Figure 70).
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 70

35/98

NTB19-060

55.

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

CVT lifter bracket J-51595 and
CVT Lifting Eye/Swivel Assembly
J-51595-1 can be used for this
step. See Figure 72.

Manual shaft

CAUTION:




Figure 71

Do not hit the manual shaft
(Figure 71) while rotating the
CVT; the manual shaft is longer
than the oil pan mating surface.
Use plastic / wooden blocks to
support as needed.

CVT Lifting Eye/Swivel
Assembly J-51595-1

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.

CVT Lifter Bracket J-51595
Figure 72

36/98

NTB19-060

56.

Rotate the primary pulley by hand to
check the pulley’s rotational
characteristics.
IMPORTANT: Remember the pulley’s
rotational characteristics. This will be
used as a reference after the new side
cover pulleys and belt sub-assembly
(sub-assembly) have been installed.

Rotate the primary
pulley by hand
Figure 73

WARNING: Do not place fingers
between the pulley and the CVT
case.
Do not place fingers
under pulley
Figure 74

57.

Remove the nineteen (19) side cover
fixing bolts (Figure 75).


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

Figure 75

37/98

NTB19-060

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

58.

Remove the six (6) pulley bracket bolts.


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

Figure 76

59.

Attach CVT Lifting Fixture J-52082 with spacers J-52082-2 to the side cover as shown
in Figure 77 on the next page.
NOTE: Install and tighten by hand only.

38/98

NTB19-060

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 77.
c. Install the Lifting Fixture to the CVT case at the six (6) bolt holes shown in Figure 76.
d. Tighten the wing-nut bolts on the Lifting Fixture finger tight in the following order:
1) Tighten the lower six (6) wing-nut bolts.
2) Tighten the two (2) joint to triangle brackets.
3) Tighten the top two (2) wing-nut bolts, and then proceed to step 60 on the next
page.
CAUTION: Do not cross thread the bolts when attaching to the CVT side
cover.
Triangle
bracket

Lower wing-nut
bolt

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

Longer legs

Top wing-nut
bolt

Triangle
bracket joint

Lifting Fixture J-52082
Figure 77

39/98

NTB19-060

Guide Pin

60.

Install the two CVT Assembly Guide
Pins (J-51959 - Guide Pins) as shown
in Figure 78 and Figure 79.


Dowel Pin
Pins

The Guide Pins must be located