Slide the Second Groove Seal Tool
(#J-52595-2) over the reduction gear
shaft.


Confirm that it is completely
seated.

Reduction
gear assembly
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Figure 20R

NTB17-034j

Seal Driver (#J-52595-3)
k. Place one (1) Ring Seal onto the
Second Groove Seal Tool.
l.

Slide the Seal Driver (#J-52595-3) over
the Second Groove Seal Tool.

m. Gently push the Ring Seal onto the
second groove.

Ring
Seal

Second
groove

n. Remove the Second Groove Seal
Tool.


Figure 21R

Confirm that both of the Ring Seals are not protruding in any direction.
NOTE: If the reduction gear shaft is not going to be immediately installed, the
Split Ring Seal Cover (#J-52595-4) can be slid over both Ring Seals to prevent
damage.

CAUTION: In the following step use extreme care when installing the final drive and
reduction gear assembly.


The machine cut seals are VERY delicate and will damage easily if forced.



The reduction gear assembly should seat without any additional force.



If the reduction gear assembly does not seat, remove it and confirm that machine cut
seals are in place and centered in their grooves.

23. Confirm that the thrust bearing is in place
in the bottom of the reduction gear
assembly bore.

Thrust bearing

Reduction gear
assembly bore
Figure 22R

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NTB17-034j

24. Install the final drive and reduction gear
assembly together into the CVT case.


If the reduction gear assembly does
not seat, remove it and confirm that
machine cut seals are in place and
centered in their grooves.

25. Rotate the final drive by hand to confirm
that it rotates freely.

Final drive
Figure 23R

Install the Torque Converter Housing

1. Place the original thrust washer on the
torque converter housing.


Torque converter
housing

Thrust washer

Apply petroleum jelly to the mating
surface side of the washer to hold the
washer on the converter housing.

NOTE: Both sides of the thrust washer
are the same, orientation is not critical.

Figure 1S

2. Remove any remaining CVT fluid on the sealing surfaces of the torque converter
housing and the CVT case.
NOTE: Brake cleaner is acceptable to remove remaining CVT fluid.
CAUTION: Avoid any debris from dropping into the torque converter housing or the
CVT case.

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NTB17-034j

3. Apply sealant to the CVT case side of the torque converter housing to CVT case mating
surface.


Sealant bead diameter: 2.0 mm

Sealant:
 Loctite 5460 (See the PARTS INFORMATION section of this bulletin)
 Color: Pink
IMPORTANT:
 Confirm that the mating surfaces are clean before applying sealant.
 Make sure that the starting point and the ending point of the sealant is
between two bolt holes. Overlap both ends of the bead by 3 – 5 mm.
 If the Guide Pins were removed to clean the case surfaces, reinstall them
now.
CAUTION: Be careful not to contact or contaminate the sealant. If the sealant has
been disturbed or contaminated in any way before case assembly, remove the
sealant completely and re-apply.

Overlap
3-5 mm

Figure 2S

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4. Install the torque converter housing onto the CVT case with nineteen (19) new bolts and
torque to the pattern shown in Figure 3S.
NOTE: If the torque converter housing does not fully seat, the CVT may not be in
DRIVE.


Use new bolts.
NOTE: See Reference # 9 in the KIT PARTS REFERENCE TABLE.
 Bolt torque: 27.1 N•m (2.8 kg-m, 20 ft-lbs.)
IMPORTANT: Tighten the bolts in specific order shown below.

1

5
17

3

11
18

10
16
9

15

12
8
7
6

4

19

14

13

2
Figure 3S

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Install the Control Valve and Oil Pan

Terminal
assembly

1. Rotate the CVT assembly so that the
torque converter housing side is facing
down.

O-ring

2. Make sure that the terminal assembly is
attached to the bracket of the new control
valve (Figure 1T).
NOTE:



Bracket

Apply CVT Fluid to the O-ring of
the terminal connector.
See Reference # 1 in the KIT
PARTS REFERENCE.

Figure 1T

3. Install the new control valve assembly to
the CVT case.


Insert the terminal assembly through
the hole of the CVT case, and then
push the new control valve
horizontally with even pressure to
seat the control valve completely.
NOTE: A clicking sound may be
heard as the new control valve is
seated to the CVT case.

Figure 2T

4. First tighten all eleven (11) original
control valve bolts finger tight by hand,
and then tighten to the specified bolt
torque below.

Control valve bolts

CAUTION: These bolts are easily
stripped. Use care to not over-torque.


87 mm (3.4 inches) long bolt.
11 pieces
 Bolt torque:
7.9 N•m, (0.80 kg-m, 70 in-lbs.)

CAUTION: Manual valve may slide down
and interfere with CVT case.

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Manual valve

Figure 3T

NTB17-034j

5. Install the original manual plate to the
manual shaft with the original spring
washer and lock nut.


Use a crescent wrench on the
transmission range switch side of the
manual rod to keep the shaft from
rotating while torqueing.



Nut torque:
21.7 N•m (2.2 kg-m, 16 ft-lbs.)
Nut and washer

Manual plate

Figure 4T

6. Confirm that the new O-ring is on the new
oil strainer.


Apply CVT Fluid to the O-ring before
installation.

NOTE:



The new oil strainer comes with a
new O-ring.
See Reference # 3 in the KIT
PARTS REFERENCE TABLE.

O-ring

Figure 5T

7. Install the new oil strainer to the control
valve with the three (3) original bolts.


12 mm (0.5 inches) long bolt.
3 pieces

3 bolts

 Bolt torque:
7.9 N•m (0.80 kg-m, 70 in-lbs.)

Oil strainer
Figure 6T

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NTB17-034j

8. Install the original oil pan with a new oil
pan gasket using the original bolts.
 Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)
NOTE: See Reference # 2 in the KIT
PARTS REFERENCE TABLE.

Figure 7T

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Seal the Sub-assembly Cover
1. Confirm the torque converter housing
side is facing down.

Side cover

2. Remove the two temporary side cover
bolts.

Figure 1U

Pulley bearing
retainer bolts

3. Remove the two pulley bearing retainer
bolts.


These bolts will be reused later in this
procedure.

Figure 2U

4. Remove the side cover.


Use a slide hammer (J-25721-A) if
needed.



There are three slide hammer tool
locations on the side cover.

NOTE: Figure 3U shown with side cover
removed.

Figure 3U

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5. Install the original lubrication tube into the
CVT case.


Place the fluid jet nozzle under the
CVT belt and then insert the
lubrication tube into the CVT case.

Lubrication
tube

CAUTION: Take care not to contact the
CVT belt with any tools during tube
installation.
Figure 4U

Lubrication
tube bolt

6. Install the original lubrication tube bolt.


16 mm (0.6 inch) long bolt.
 Bolt torque:
6.8 N•m (0.70 kg-m, 60 in-lb)

Lubrication
tube
Figure 5U

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7. Apply sealant to the side cover sealing surface of the CVT case.


Sealant bead diameter: 2.0 mm

Sealant:
 Loctite 5460 (See the PARTS INFORMATION section of this bulletin)
 Color: Pink
IMPORTANT:
 Confirm that the mating surfaces are clean before applying sealant.
 Make sure that the starting point and the ending point of the sealant is
between two bolt holes. Overlap both ends of the bead by 3 – 5 mm.
CAUTION: Be careful not to contact or contaminate the sealant. If the sealant has
been disturbed or contaminated in any way before side cover assembly is installed,
remove the sealant completely and re-apply.

Overlap
3 mm to 5 mm

Figure 6U

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Assembly Guide
Pins, Pulley Bracket
(Guide Pin J-52272)

8. Screw in Guide Pin (J-52272) to either
one of two female bolt threads of the
pulley bearing retainer.


Case bolt
hole

Place the guide pin next to the case
bolt hole as shown in Figure 7U.

Figure 7U

9. Install side cover.
10. Install eleven (11) new side cover bolts,
and then torque all of the side cover
bolts to the specified torque in the
sequence shown in Figure 8U.


1

3

5

9

10

Side cover

32.8 mm (1.3 inches) long bolt.
11 pieces

8

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

11

NOTE: See Reference # 6 in the KIT
PARTS REFERENCE TABLE.

7

6

2

4

Figure 8U

11. Remove the O-rings that came on the
new bearing retainer bolts and replace
them with new O-rings from PARTS
INFORMATION on page 137.
NOTE: See Reference # 8 in the KIT
PARTS REFERENCE TABLE.
12. Screw in one (1) original pulley bearing
retainer bolt, hand tight.
Pulley retainer bolts

Side
cover

Figure 9U

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NTB17-034j

Guide Pin

13. Remove the Guide Pin (J-52272) and
then install the other pulley bearing
retainer bolt, hand tight.

14. Torque the two pulley bearing retainer
bolts to specified torque.
 Bolt torque:
28.8 N•m, (2.90 kg-m, 21 ft-lbs.)

Figure 10U

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NTB17-034j

Install and Adjust the Transmission Range Switch
1. Rotate the manual lever to the “N”
position (two clicks counterclockwise
from the left hard stop).

Manual
lever

Guide hole

2. Remove the lock nut, washer and manual
lever from the manual shaft.


They will be reused.

3. Adjust the transmission range switch
position as follows:
a. Install the alignment pin (#J-52306-2)
into the Transmission Range Switch
Alignment Bracket (#J-52306-1) as
shown in Figure 2V.
b. Attach the combined alignment tool
onto the manual shaft as shown in
Figure 3V with part number facing out.
NOTE: The combined alignment tool
will only insert into the transmission
range switch while in Neutral.



Transmission range switch may
need to be rotated to allow pin to
align.
Alignment pin will insert into guide
hole in the transmission range
switch (Figure 1V).

c. Install the two original bolts for the
transmission range switch
(Figure 3V).

Lock nut,
washer
Figure 1V

Alignment Pin
(#J-52306-2)
Transmission Range Switch
Alignment Bracket (#J-52306-1)

Figure 2V