IMPORTANT:
 Lathe cut seals (white seals) must
be in their appropriate slots.
Carefully reposition seals as
necessary.


Input shaft

Input shaft lathe cut seals
(white seals) correctly
located in slots

This area
must remain
clear

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

Figure 134

103. Install the dummy cover first, then
baffle plate C, and then the related
bolts finger tight (Figure 135).
IMPORTANT: Visually check that the
dummy cover is fully seated on the
CVT case. If it is not, refer to Dummy
Cover Troubleshooting on page 33.




Do not force the dummy cover into
place.
Make sure the dummy cover is fully
seated before installing the bolts.
Do not torque these bolts at this
time.

104. Install baffle plate B and “L” bracket
with the related bolts finger tight
(Figure 136).

Dummy
cover, baffle
plate C, and
bolts
Figure 135

Baffle plate B
and bolts

105. Torque the bolts from steps 103 and
104 in the following order:
2

a. Baffle plate B bolts: 5.9 N•m (0.6
kg-m, 52.2 in-lb.)
b. “L” bracket bolts: 25.5 N•m (2.6 kgm, 19 ft- lb). Torque 11 and then
22 .
c. Dummy cover and baffle plate C
bolts torque: 19.0 N•m (1.9 kg-m,
14 ft-lb.)

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1

“L” bracket
and bolts

Figure 136

NTB19-060

Thrust washer
106. Install the thrust washer onto the
dummy over (Figure 137).


Use petroleum jelly or equivalent to
hold the thrust washer in place.



Make sure the tabs fit into the
holes.

Tabs
Figure 137

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Drive sprocket
Chain
Driven sprocket

107. Install the drive sprocket, driven
sprocket, and chain as an assembly
(Figure 138).


Make sure the raised edge (wider
edge) on the drive sprocket is
facing up (Figure 139).

Figure 138

Raised
edge

Figure 139

a. Expand the snap ring with a suitable

tool, and then push down on the
driven sprocket until it bottoms out
(Figure 140).

Driven
sprocket

Snap ring
ends

b. Release the snap ring and then pull

up on the driven sprocket until the
snap ring locks into its groove.
NOTE: A click sound is heard when
the snap ring locks in place.
Figure 140

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Baffle plate
A nuts

108. Install baffle plate A with two nuts
(Figure 141).


Nut torque: 5.9 N•m (0.6 kg-m,
52.2 in-lb.)

Figure 141

109. Install a new O-ring on the input shaft
(Figure 142).


O-ring

Apply CVT fluid to the O-ring and Oring groove before installing.

Figure 142
110. Install the differential assembly and the reduction gear assembly into the CVT case
(Figure 143 and Figure 144).


Thoroughly clean each assembly before installing.



Oil the bearings and gear teeth with CVT fluid before installing.
Reduction gear
assembly

Differential
assembly

Figure 143

Figure 144

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111. Install the CVT fluid filter and components (Figure 145 and Figure 146).


Install a new filter with grommet (one part).



Install a new O-ring.



Confirm that all components and areas where components fit are thoroughly clean.



Apply CVT fluid to the grommet seal and O-ring before installing.



Install the filter cover.
 Bolt torque 4.2 N•m (0.43 kg-m, 37.2 in-lb.)

Fluid filter

O-ring seal
Figure 145

CVT fluid filter cover
Figure 146

112. Confirm the pin (Figure 147) is located
in the CVT case prior to installation of
the converter housing.

Pin

NOTE: Apply petroleum jelly or
equivalent to keep it in place if
necessary.

Figure 147

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113. Apply one continuous 2.0 mm (0.8 inches) diameter bead (Figure 148) of pink colored
Loctite 5460 Sealant (see PARTS INFORMATION on page 91).


Before sealant application, make sure the mating surfaces are clean from oil, dirt,
old sealant, etc. (Figure 148).
IMPORTANT: Have the converter housing ready for installation prior to applying
the sealant.

NOTE:
 Start applying sealant where shown, making sure that the starting point and the
ending point are about the middle between the bolt holes.
 Overlap both ends of the bead by 3-5 mm (0.12-0.20 inches).
 Make sure to apply sealant around the center bolt hole.

Also apply sealant
around this bolt hole

Figure 148

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114. Install the converter housing onto the CVT case (see Figure 149 for torque sequence):


Install the 23 new bolts.
a. Torque the first six (6) bolts with symbol
below).

in numbered sequence (see

b. Torque the remaining bolts with symbol
below).

in numbered sequence (see

 Use a short socket on the bolts indicated by this symbol:
 All bolts are 30 mm (1.2 inches) in length.
 Bolt torque: 45.0 N•m (4.6 kg-m, 33.2 ft-lb.)
IMPORTANT: Make sure to torque the bolts in the sequence shown
(Figure 149).

Figure 149
115. Clean off the excess sealant.

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Control Valve Strainer and Pan Installation

IMPORTANT:


Installation steps in this bulletin may contain different style parts than what were
originally installed in the CVT. Pay careful attention, REASSEMBLY MAY NOT BE
IDENTICAL TO DISASSEMBLY.



Confirm that the QR label, control valve and CD part numbers all match before
installing the control valve (refer to NTB12-103).



For additional information, see video # 547: “CVT Belt and Pulley Replacement” and
fast forward to minute marker 20:09. This video is located under the TECH TRAINING
GARAGE VIDEOS tab in Virtual Academy.

CAUTION: Handle the control valve carefully.

NOTE: If an oil strainer bracket was
removed, discard it. An oil strainer
bracket (Figure 150) will not be used
with the new oil strainer.

Oil strainer
bracket

Figure 150

116. Install a new lip seal (Figure 151).


Do NOT reuse the old lip seal.



Apply a small amount of petroleum
jelly or equivalent to the lip seal to
keep it in place on the CVT.
Lip seal

Figure 151

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25 mm bolts

117. Install the Control Valve with eleven
(11) mounting bolts (Figure 152).
IMPORTANT: Leave four (4)
holes empty at this step.

bolt

CAUTION: Make sure the wiring
harness is not pinched (see
Figure 153 and Figure 154 for correct
routing).


54 mm (2.125 inches) long bolt
7 pieces



44 mm (1.73 inch) long bolt
2 pieces



25 mm (1 inch) long bolt
2 pieces

44 mm bolts

;
Figure 152
;

;

CAUTION: The two 25 mm bolts are installed WITHOUT the strainer bracket.
 Bolt torque: 7.9 N•m (0.81 kg-m, 70 in-lb.)

Correctly routed

Incorrectly routed
Figure 154

Figure 153

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118. Replace the metal bracket of the fluid temperature sensor as follows:
NOTE: The new bracket will be oriented the same way the old bracket was.
a. Cut the old plastic zip tie with an appropriate tool to remove the fluid temperature

sensor’s metal bracket from the terminal harness assembly (Figure 155 and
Figure 156).
CAUTION: Cut the plastic zip tie over the metal bracket to avoid damage to the
fluid temperature sensor.
b. Discard the removed metal bracket and plastic zip tie.

c. Use the new plastic zip tie from the PARTS INFORMATION on page 91 to attach

the fluid temperature sensor of the terminal connector harness to the fluid
temperature sensor’s new metal bracket.
IMPORTANT:


Secure the plastic zip tie at the center notch of three notches on the fluid
temperature sensor (Figure 155).



Tighten the plastic zip tie so that it is oriented as shown in Figure 156.

d. Cut off the plastic zip tie excess.

Fluid temperature
sensor

Plastic zip tie
located at corner
Figure 155

Fluid temperature
sensor

Fluid temperature
sensor’s metal
bracket

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Plastic zip tie
in center notch
Figure 156

NTB19-060

119. Connect the electrical harness
connector (Figure 157).
Harness
connector

Figure 157

120. Install the CVT fluid temperature
sensor bracket to the control valve
with one (1) bolt (Figure 158).
NOTE: Leave one (1) bolt hole empty
as it will be used to secure the oil
strainer at a later step.
 54 mm (2.125 inches) long bolt.

1 bolt

 Bolt torque: 7.9 N•m (0.81 kg-m,
70 in-lb.)

Empty bolt hole
Figure 158

121. Install the new oil strainer with its new
O-ring seal with two (2) bolts
(Figure 159).
NOTE: The replacement strainer
maybe a different shape than the
original.
 54 mm (2.125 inches) long bolt
2 pieces.

54 mm
bolts

;

 Bolt torque: 7.9 N•m (0.81 kg-m,
70 in-lb.)
Figure 159

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122. Install the manual plate, lock washer,
and nut (Figure 160).
NOTE: Make sure the manual plate
fits into the slot of the manual valve
before applying torque to the nut.


Slot and manual
plate end

Manual plate

Lock washer

Reuse the existing manual plate,
lock washer, and nut.

Nut

 Nut torque: 22.1 N•m
(2.3 kg-m, 16 ft-lb.)

Manual valve

123. Clean the original oil pan and magnets
with a suitable cleaner. Visible debris
should not be present at reassembly.

Figure 160

124. Reassemble the original magnets to
their original locations on the oil pan.
125. Install a new oil pan gasket to the oil
pan.

126. Install the oil pan bolts (see
Figure 161).


Reuse the existing oil pan bolts.
 Oil pan bolt torque: 7.9 N•m
(0.81 kg-m, 70 in-lb.)

Figure 161
127. Install a new drain plug washer to the drain plug on the oil pan.
128. Install the primary speed sensor to the CVT assembly.
IMPORTANT: Install a new O-ring to the speed sensor before installation. DO NOT
reuse the old O-ring.
 Bolt torque: 5.9 N•m (0.6 kg-m, 52 in-lb.)

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129. Install the torque converter to the CVT assembly.
 Verify the torque converter is installed at the proper depth (see Figure 162).


A = 14.4 mm

Converter housing

Measure here

Converter front