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

e. Install the original washer.
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.
Be careful not to damage the sealing ring while assembling the input shaft to
the oil pump cover.
Apply petroleum jelly to the sealing ring on the input shaft before installation.
 Sealing ring is hidden behind input gear in Figure 16L.
Oil pump cover
Thrust bearing

Sealing ring location
Figure 16L

Figure 17L

 Make sure all exposed internal areas of the CVT (including the oil pan and magnets)
have been thoroughly cleaned.
 Cover all parts with a lint-free covering, when not being worked on, to prevent
contamination which could cause drivability concerns.
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Measuring the CVT Sub-assembly Case Depth

Torque converter
housing
1. Temporarily install the torque converter
housing to the CVT case with two (2)
bolts at opposite corners, hand tight
(Figure 1M).


Use original bolts to secure.

Figure 1M

2. Reposition the CVT on the work bench
with the torque converter housing side
facing down (Figure 2M).
3. Clean and then zero the Digital Depth
Gauge (J-50272).
4. Set the Digital Gauge to millimeters.

Figure 2M
5. Clean the Gauge Block (J-50271).
NOTE: Only if a Gauge Block (J-50271)
is not available, measurement “X” (Figure
5M, page 59) will need to be determined
for the measuring bar being used. This
can be done either with a set of calipers
or with Digital Depth Gauge (J-50272).

Gauge Block
(J-50271)

6. Confirm the sealing surfaces of the CVT
case are clean.
7. Place Gauge Block (J-50271) across
sub-assembly sealing surface as shown
in Figure 3M.
Figure 3M

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8. Measure the average distance (Y) shown in Figure 5M as follows:


Refer to the Figures 4M and 5M and then proceed to page 60.



Measure only from areas that do not have any signs of contact.
IMPORTANT: Please refer to Figure 4M for acceptable areas (highlighted in green)
to measure “Y”.
Measuring area

Do not measure in this
area
Figure 4M
Y = The distance between the upper surface of the Gauge Block and the surface where
snap ring seats.

Figure 5M

Proceed to the next page.

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Secondary pulley bearing snap ring surface
Do not measure
into this groove.

Measure to this slightly
raised machined surface
Figure 6M
a. Measure between the top of the Gauge Block (J-50271), to where the snap ring on
the secondary pulley bearing seats (Figure 6M).


This will be measured in three locations to calculate an average for “Y”.

Y1_________, Y2________, Y3_________
b. Calculate the average for “Y” with the formula below and then record it below.

Y=

(millimeter)

Y = _________
c. Calculate case depth “D” as follows:
IMPORTANT: Essential tool Gauge Block (J-50271) is 20 mm thick.


Average depth calculated in step 8b →



Subtract Gauge Block thickness

→

Y__________
─ X__________
-------------------------------------------------



Calculated depth

→

= D__________

D = Distance between the sub-assembly sealing surface and the secondary pulley
front bearing surface with the snap ring attached.
EXAMPLE:
If
Y = 61.39 mm
And ─ X = 20.00 mm
___________

D = 41.39 mm
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New Snap Ring Selection and Installation to the New Sub-assembly

1. Remove the top of the shipping box of
the new sub-assembly.

Top of the
shipping box

NOTE: The outer cardboard of the
shipping box can be disassembled for
easy removal of the sub-assembly by
removing the shipping tape.

Figure 1N

2. Remove the upper board with foam
spacer assembly.


Packing material may be different
then what is shown in Figure 2N.
Upper board

Figure 2N
3. Locate the data sheet in the shipping box
and place it in a safe place.


This data sheet is required for snap
ring selection in the following steps.

Figure 3N

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4. Locate the plastic bag which contains the
snap rings (Figure 4N).


There are six individual snap rings in
the plastic bag.



Take the plastic bag out of the
shipping box, and put aside on the
work bench.

NOTE: See Reference # 5 in the KIT
PARTS REFERENCE TABLE.

Snap ring set
Figure 4N

5. Take the new sub-assembly out of the
shipping box and place it on the work
bench.
CAUTION:


Hold the sub-assembly by the side
cover ONLY when removing it
from the shipping box.



DO NOT handle the belt or pulleys
of the sub-assembly when
removing from the shipping box.



DO NOT BREAK the foam cushion
in the shipping box. This will be
used as a stabilizer for the subassembly during the repair.

New sub-assembly
Figure 5N

NOTE: See Reference # 4 in the KIT
PARTS REFERENCE TABLE.

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6. Take the lower board with foam cushion (lower board) out of the shipping box (shown in
Figure 7N).
IMPORTANT: Step 7 is for kits that have a
separate spacer (Figure 6N). In later kits
this spacer will be part of the lower board
and step 7 will not be used.
7. Take the spacer (Figure 6N) out of the
shipping box and place on the work
bench where the sub-assembly will be
installed, and then place the lower board
on top of the spacer as shown in Figure
7N.
NOTE: The spacer will be the last item
that is removed from the shipping box
and is approximately 1 inch thick.

Spacer

Figure 6N



Position the lower board so that it hangs over the spacer.



Align the lower board so that the left and right cut outs are even with the spacer.

NOTE: The positioning of the lower board with foam cushion will allow the CVT case
enough clearance from the work bench to allow it to seat flush with the sub-assembly.
Cut out even
with spacer

Lower board with
foam cushion

Lower board
over-hang

Cut out even
with spacer

Cut out even
with spacer
Figure 7N

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8. Remove the sub-assembly from the
plastic bag.

9. Place the new sub-assembly onto the
lower board.


The sub-assembly must be level and
oriented as shown in Figure 8N for
proper seating of the CVT case later
in this procedure.

Lower board
and spacer

10. Remove the snap ring from the
secondary pulley front bearing of the new
sub-assembly.


Figure 8N

New sub-assembly

Discard the removed snap ring.

Snap ring
Figure 9N

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11. Calculate “E” for snap ring selection as follows:
NOTE: For the value of “B1”, refer to the data sheet that was put aside when the subassembly shipping box was opened.


Calculated case depth from step 8c on page 61

→

D ___________



Subtract constant value

→

─
41.30
------------------------------------



Subtotal

→



Add value for “B1” from data sheet

→ + B1 ___________
------------------------------------



Total calculated depth

→

=

___________

= E ___________

E = This will be used to select a snap ring from Table A on page 67.

EXAMPLE:
If D = 41.39 mm
Constant
= 41.30 mm (subtracted)
And B1 = 1.56 mm (added)
____________________
E = 1.65 mm

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12. Select the appropriate Part Number from Table A shown below, based on the calculated
result of “E” in step 11 on the previous page.
EXAMPLE: If E = 1.65, and is between or equal to 1.64 to 1.67, choose new snap ring
Part Number “31506 3JX9C”.
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
1.65
1.69
1.73
1.77 Example only. Do
1.79 not use in your
calculations.

Table A
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
1.65
1.69
1.73
1.77
1.79

13. Open the plastic bag (with snap rings) that was removed from the shipping box in step
4, and then choose the correct Part Number selected from Table A.
NOTE: There are six individually packed snap rings in the plastic bag. See Reference #
5 in the KIT PARTS REFERENCE TABLE.
14. Measure the new snap ring and confirm its thickness is equal to the Snap Ring
Reference in Table A.
15. Install the selected snap ring to the secondary pulley front bearing of the new subassembly.
NOTE: Discard unused snap rings.

Selected snap ring
Figure 10N

Figure 11N
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Install Sub-assembly to CVT Case

CVT case sealing
surface
1. Make sure the CVT case sealing surface
of the side cover is thoroughly cleaned.
2. Make sure the dowel pins are cleaned
and any rust has been removed.

Figure 1P
Torque converter
housing
3. Flip the CVT case over on the work
bench with the torque converter housing
side facing up.
CAUTION: Make sure the work bench
surface is thoroughly cleaned before
flipping the CVT case.
4. Remove the two (2) temporary bolts and
then remove the torque converter
housing from the CVT case.


Discard these bolts.
Figure 2P

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5. Install the CVT case onto the new subassembly as follows:

CVT case

NOTE: Sealant will be applied between
these components at a later step.
a. Slowly lower the CVT case onto the
sub-assembly.
IMPORTANT:


Only use the weight of the
CVT case when installing it to
the sub-assembly.



Do NOT use any other
external force to seat the CVT
case to the sub-assembly.

New
sub-assembly

Figure 3P
Primary pulley
sub-assembly

b. Align the “primary pulley front
bearing bore” of the CVT case to the
primary pulley front bearing of the
sub-assembly.

CVT case

NOTE: Figure 4P is shown looking
down into the CVT case while it is
being lowered.

Primary pulley
front bearing bore
Figure 4P

c. Align one of two dowel pin holes
found on the CVT case to the subassembly.