NTB19-060

84.

Confirm the rotational smoothness of the primary pulley as follows:
a. With a clean hand, access the primary pulley from the bottom of the CVT.
b. Rotate the primary pulley by hand and confirm that the characteristic is the same
as previously checked at step 56 on page 37, prior to removing the original subassembly.


If the rotational characteristic is the same or better, continue to step 85.



If the rotational characteristic is worse (stiffer):
1) Remove the sub-assembly from the CVT case.
2) Wipe and clean the sealant from the CVT case and side cover rim.
3) Restart the procedure from step 70 on page 44.

85.

Torque all six (6) bolts.


Bolt torque: 28 N•m (2.8 kg-m,
20 ft-lbs).

Figure 107

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NTB19-060

J-52281
Seal
Installer
86.

87.

88.

Install the CVT case side axle seal
(Figure 108).


Use Seal Installer J-52281 and
Driver Handle J-8092.



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

J-8092
Driver Handle

CVT
case

Place the CVT on the work bench
with the side cover facing down on the
bench.

Remove the converter housing, which
was temporarily installed with three
bolts.

Figure 108

Bolts

Converter housing
Figure 109

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NTB19-060

Clutch Total Endplay Adjustment – Thrust Bearing Selection

IMPORTANT: Using thrust bearings, the clutch total endplay (Figure 110) must always be
adjusted between the clutch drum and the dummy cover when a new sub-assembly is
installed.
There are eight (8) thicknesses of thrust bearings available for total endplay adjustment.


For additional information, see video # 547: “CVT Belt and Pulley Replacement”
and fast forward to minute marker 13:22. This video is located under the TECH
TRAINING GARAGE VIDEOS tab in Virtual Academy.

Dummy
cover

CVT case

Total
endplay

Clutch
drum

Thrust
bearing

Figure 110
89.

Clean and then zero the Digital Depth Gauge (part #: J-50272).


Set the Digital Depth Gauge to millimeters.

90.

Clean Gauge Block J-50271.

91.

Confirm the mating surfaces of the CVT case are clean.

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NTB19-060

CVT case
92.

Calculate the average (D) clutch
assembly bore depth (Figure 111) as
follows:

Oil Pump

IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.

Gauge block

D

Clutch drum of clutch assembly
Figure 111

Clutch assembly
bore
a. Place the Gauge Block on the
surface where the dummy cover
seats and over the clutch assembly
bore (Figure 112).
IMPORTANT: This surface is lower
than the CVT case to torque
converter housing surface.
Gauge Block
Figure 112
NOTE: The clutch assembly should
sit 2-3 mm lower than the dummy
cover seat (Figure 113).

Dummy
cover seat

Dummy
cover seat

b. Confirm the Gauge Block is not
sitting on the clutch assembly or
against the input shaft.
NOTE: If the clutch assembly is
sitting higher than the dummy cover
surface, see Dummy Cover
Troubleshooting on page 33.
Clutch assembly
Figure 113

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NTB19-060

c. Position the Depth Gauge on the

Depth Gauge

Gauge Block (Figure 114).

Datum level

NOTE: Make sure the Depth
Gauge’s datum level is flush with the
top of the Gauge Block.
d. Carefully slide the gauge down until it

bottoms out on the bottom of the
clutch assembly bore. Write this
measurement as D1 (use
millimeters).

Clutch assembly
bore
Gauge Block

NOTE: Do not measure from the
clutch assembly bore shown in red
(Figure 115).

Figure 114

Do not measure
from this raised step
(highlighted in red).

Measure here; D2

Measure here; D1
Figure 115
e. Measure this same distance on the opposite side (180 degrees) of the clutch
assembly bore and write it as D2.
f. Using the formula below, calculate the average and write down the calculated value
as D.
D =

(D1 + D2)
-------------2

Write the measurement for “D” here _____ mm

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NTB19-060

93.

Clean surfaces
Measure the average (H) dummy
Clean
here
cover height (Figure 117) as follows:
a. Clean the dummy cover surfaces
that contact the CVT case and thrust
bearing (Figure 116).
CAUTION: Use brake cleaner (or
equivalent) and a lint-free towel only.
Make sure the brake cleaner or
solvents used are compatible with
local regulations.
b. Place the dummy cover upside down
Clean here
on a work bench, and place the
Gauge Block onto the thrust bearing
Figure 116
surface (Figure 117).
c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover (Figure 117).
NOTE: Make sure the Depth Gauge’s datum level is flush with the top of the Gauge
Block.
d. Carefully slide 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 (Figure 117).
Gauge Block

Figure 117
f. Using the formula below, calculate the average and then write down the calculated
value as H.
(H1 + H2)(H1 + H2)
H=
H = --------------Write the measurement for “H” here _____ mm
2
94. Choose the thrust bearing to adjust Clutch Total Endplay (A) as follows:
a. Calculate A (Total Endplay):
Total Endplay A = D – H (This will be the thrust bearing thickness).
 Fill in the measurements below for “D” and “H” from pages 58 and 59 to calculate
for “A”.
D measurement ______ mm
– H measurement ______ mm
= A - - - - - - - - - - - - - - - - ______ mm
59/98

Please print this page and
attach it to the repair order.
NTB19-060

b. Choose the appropriate bearing from Table A below, based on the Total Endplay (A)

calculated on the previous page (8 thicknesses of thrust bearings are available).
Example: If A = 4.3 mm, it falls between the lower and upper clearances for bearing
thickness 3.93 mm.


Refer to the PARTS INFORMATION on page 91 for Thrust Bearing part numbers
by thickness.

c. Measure and confirm that the selected thrust bearing is the correct thickness before

installing (Figure 118).
d. Circle the thrust bearing part number that was selected in Table A.

Table A
PART #: 314071XZOB
1XZ0C
1XZ0D
1XZ0E
1XZ1A
1XZ1B
1XZ1C
1XZ1D

A=D-H
BEARING
CLEARANCE (A) THICKNESS
3.87 - 4.07 MM
4.08 - 4.23 mm
4.24 - 4.43 mm
4.44 - 4.58 mm
4.59 - 4.78 mm
4.79 - 4.94 mm
4.95 - 5.09 mm
5.10 - 5.29 mm

3.57
3.75
3.93
4.1
4.28
4.46
4.61
4.79
Figure 118

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95.

Install the thrust bearing flush to the clutch assembly bore as shown in the Figures
below.


Install the thrust bearing in the area shown in green so that it is centered by the
four tabs.

CAUTION: The thrust bearing has two sides. See Figure 119 through Figure 122 for
the correct orientation.

Figure 119

Four Alignment
tabs.
(One not shown).

Silver surface
faces UP

Figure 120

Black surface
faces DOWN
Thrust bearing

This gap should
face down

Incorrect installation

Correct installation
Figure 121

Figure 122

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Clean the Converter Housing Passages

IMPORTANT: Remove as much of the CVT and cleaning fluids as possible, and clean the
related parts in the following steps.

96.

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 123).

Figure 123

b. Remove the bolt and then remove
the lubrication tube and its bracket
(Figure 124).

Lubrication
tube, bracket,
and bolt

Figure 124

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97.

Clean the oil passages of the converter housing, lubrication tube and dummy cover
with brake cleaner (or equivalent) where shown in Figure 125 through Figure 128
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 126

Figure 125
Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages
Figure 127
98.

Figure 128

Install the lubrication tube, bracket and bolt, and then the baffle plate with three bolts
(Figure 129 and Figure 130).


Bolt torque: 5.9 N•m (0.6kg-m, 52 in-lb.)

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 129

Figure 130
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CVT Reassembly

99.

Install a new torque converter seal with
Seal Installer J-50818 (Figure 131).


Place the torque converter housing
flat during installation.



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.

J-50818
Seal
installer

Figure 131
J-52282
Seal installer

100. Install the torque converter housing
side axle seal (Figure 132).


Use Seal Installer J-52282 and
Driver Handle J-8092.



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

J-8092
Driver
handle

Converter
housing
Figure 132
101. Apply petroleum jelly or equivalent to
the dummy cover’s lathe cut seals
(Figure 133) 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 the seals
as necessary.



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

This area must
remain clear
Figure 133
Dummy cover lathe cut
seals (white seals)

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NTB19-060

102. Confirm that the input shaft’s lathe cut
seals are in the correct positions
(Figure 134).