bore
Gauge Block

NOTE: Do not measure from the
clutch assembly bore shown in red
(Figure 135).

Figure 134

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

Measure here; D2

Measure here; D1

Figure 135
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.
(D1 + D2)
D =

---------------------------

Write the measurement for “D” here _____ mm

2
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109. Measure the average (H) dummy
cover height (Figure 137) as follows:
Clean surfaces
Clean here
a. Clean the dummy cover surfaces
that contact the CVT case and
thrust bearing (Figure 136).
CAUTION: Use brake cleaner (or
equivalent) and a lint-free towel
only. Make sure the brake spray or
solvents used are compatible with
local regulations.
b. Place the dummy cover upside
Clean here
down on a work bench, and place
the Gauge Block onto the thrust
bearing surface (Figure 137).
Figure 136
c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover (Figure 137).
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 as
H2 (Figure 137).
Gauge Block

Measure opposite sides
Figure 137
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
110. 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 64 and 65 to
calculate for “A”.
D measurement ______ mm
– H measurement ______ mm
= A - - - - - - - - - - - - - - - - ______ mm
65/113

Please print this page and
attach it to the repair order.
NTB17-039g

b. Choose the appropriate bearing from Table A below, based on A (eight different

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 PARTS INFORMATION for Thrust Bearing part numbers by thickness.

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

before installing (Figure 9G).
Table A
PART #: 314071XZ0B
1XZ0C
1XZ0D
1XZ0E
1XZ1A
1XZ1B
1XZ1C
1XZ1D

A=D-H
BEARING
CLEARANCE (A) THICKNESS
3.87 - 4.06 MM
4.07 - 4.22 mm
4.23 - 4.42 mm
4.43 - 4.57 mm
4.58 - 4.77 mm
4.78 - 4.93 mm
4.94 - 5.08 mm
5.09 - 5.29 mm

3.57
3.75
3.93
4.1
4.28
4.46
4.61
4.79
Figure 138

111.

Install the thrust bearing flush to the clutch assembly bore as shown in Figure 139.
 Install thrust bearing in area shown in green so that it is centered by the four
tabs.
CAUTION: The thrust bearing has two sides. See image below for appropriate
orientation.

Four Alignment
tabs.
(One not shown).

Silver surface
faces UP

Black surface
faces DOWN
Thrust bearing

This gap should
face down

Correct installation

Incorrect installation
Figure 139
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Pages 67-74 are for Type 2 Thrust Bearing (with bearing race) ONLY. Proceed to
page 62 if working with Type 1 Thrust Bearing.
Type 2 CVT: Clutch Total Endplay Adjustment – Bearing Race Selection
IMPORTANT: The clutch total endplay (Figure 130) must always be adjusted when a new
sub-assembly is installed.


The Type 2 CVT uses the thrust bearing race thickness between the clutch drum
of clutch assembly and the oil pump cover (dummy cover) to adjust the total
endplay.

Thrust Bearing Race Selection
There are seven (7) thicknesses of thrust bearing races available for total endplay
adjustment.

CVT
case

Bearing
race

Dummy
cover

Thrust
bearing

Clutch
drum
Figure 140
112. Clean and then zero the Digital Depth Gauge (part #: J-50272). See pages 60-61.


Set Digital Depth Gauge to millimeters.

113. Clean Gauge Block J-50271.
114. Confirm that the CVT case and the dummy cover mating surfaces are clean.
CAUTION: Do NOT use sanding discs or similar abrasive tools.
 Use brake spray or equivalent solvent and lint-free towels only.
 Make sure the brake spray or solvents used are compatible with local regulations.
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115. Calculate the “average clutch
assembly surface depth” (D) as
follows:
IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.

Figure 141

Gauge Block
a. Position the Gauge Block over the
clutch assembly on the surface
that the dummy cover seats.
IMPORTANT: This surface is lower
than the CVT case to torque
converter housing.

Figure 142
b. Confirm the Gauge Block is not
sitting on the clutch assembly or
against the input shaft.

Input shaft

NOTE:
 The top surface of the clutch
assembly must be 1-3 mm
below the CVT case surface,
where the dummy cover seats.


If the clutch assembly is sitting
higher than the dummy cover
surface, see
TROUBLESHOOTING The
Dummy Cover Will Not Sit
Flush on page 105.

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Clutch assembly
Figure 143

NTB17-039g

c. Position the Depth Gauge on the Gauge Block.
NOTE: Make sure the depth gauge’s datum level is flush on top of the Gauge Block.
d. Carefully slide the gauge down until it bottoms out on the upper surface of the clutch
drum where thrust bearing seats, where shown in Figure 144. Write this
measurement as D1 (use millimeters).

Measure 180
degrees apart

Figure 144

e. Measure this same distance on the opposite side (180 degrees) of the clutch
assembly surface and write it as D2.

f. Using the formula below, calculate the average and write down the calculated value
as D.
(D1 + D2)
D =

---------------------------

Write the measurement for “D” here _____ mm

2

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Clean here

116. Measure the average (H) dummy
cover height where case seats as
follows;

Clean surfaces

a. Clean the dummy cover surface
that contact the CVT case and
depth gauge.
CAUTION: Use brake spray (or
equivalent) and lint-free towel only.
Make sure the brake spry or
solvents used are compatible with
local regulations.
b. Place the dummy cover upside
down on a workbench, and place
the Gauge Block onto the top
surface.

Clean here
Figure 145

c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover.
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.

Measure opposite sides
Figure 146
f. Using the formula below, calculate the average and then write down the calculated
value as H.
(H1 + H2)
H = --------------2

Write the measurement for “H” here _____ mm

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117. Measure the average (J) dummy cover height where thrust race seats as follows:
a. Carefully slide the Depth Gauge down until it contacts the dummy cover surface
that mates with the thrust race. Write this measurement as J1 (use millimeters).
b. Measure this same distance on the opposite side (180 degrees) of the dummy
cover and then write as J2.

Measure 180
degrees apart

Figure 8GG

c. Using the formula below, calculate the average and then write down the calculated
value as J.
(J1 + J2)
J = --------------2

Write the measurement for “J” here _____ mm

118. Calculate gap G.
Gap G = J – H
 Fill in the measurements below for “J” and “H” to calculate for “G”.
J measurement ______ mm
– H measurement ______ mm
= G ------------------- ______ mm

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119. Measure the thickness of the thrust bearing ONLY (without original race) as follows:
a. Place the thrust bearing roller side down on the Gauge Block (Figure 147).
IMPORTANT: Roller side of thrust bearing must face down and be flat on the
Gauge Block to accurately measure thickness.
b. Measure at two different positions of the thrust bearing that are 180 degrees apart.
c. Add the two measurements, and then divide by two. Write down the calculated
value as E.
(E1 + E2)
E = --------------2

Write the measurement for “E” here _____ mm

Roller side

Gauge
Block
Thrust
bearing
Figure 147
120. Choose the thrust bearing race to adjust Clutch Total Endplay (C) as follows:
a. Calculate C (clearance).
Total Clearance C = D – T + G – E
NOTE: “T “ is the Thickness of the Gauge Block (J-50271: 20mm).
 Fill in the measurements below for “D”, “G” and “E” from pages 69-72 to
calculate for “C”.
D measurement
– T measurement
+ G measurement
– E measurement
= C----------------

______ mm
_ 20 __ mm
______ mm
______ mm
______ mm

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

EXAMPLE: If D = 23.81, G = 0.41, E = 2.57
C = D – 20 + G – E = 23.81 - 20 + 0.41 - 2.57
C = 1.65
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b. Choose an appropriate thrust bearing race from Table B below based on C (seven
different thrust bearing “race thicknesses” are available).
Example: If C = 1.65 mm, it falls between the lower and upper clearances for race
thickness 1.2 mm.
c. Measure and confirm that the selected thrust bearing race is the correct thickness
before installing (Figure 148).
IMPORTANT: Do not measure from the thrust bearing race lip (Figure 149).

Table B

3WX0A

CLEARANCE (C)
C=D–T+G–E
0.90 – 1.08 mm

RACE
THICKNESS
0.6 mm

3WX0B
3WX0C
3WX0D

1.09 – 1.29 mm
1.30 – 1.50 mm
1.51 – 1.70 mm

0.8 mm
1.0 mm
1.2 mm

3WX1A
3WX1B
3WX1C

1.71 – 1.90 mm
1.91 – 2.10 mm
2.11 – 2.30 mm

1.4 mm
1.6 mm
1.8 mm

PART #: 31435-

Incorrect

Correct

Thrust bearing
race lip
Do not measure
from thrust
bearing race lip

Thrust bearing
race

Figure 148

Figure 149

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121. Install the thrust bearing onto the
clutch drum.
IMPORTANT: The thrust bearing has
two sides.
 The needle bearing side is the
upper side.
 The race side mates with the
clutch drum surface.

Thrust
bearing
Figure 150

122. Install the bearing race onto the
dummy cover. Apply petroleum jelly or
equivalent to the thrust race to hold in
place on the dummy cover.
Thrust
bearing race
Figure 151

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Clean the Torque Converter Housing, Dummy Cover Passages and Baffle Plates

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

123. 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 152).

Figure 152

b. Remove the bolt and then remove

Lubrication
tube,
tube
bracket,
and
and
bracket
bolt

the lubrication tube and its bracket
(Figure 153).

Figure 153

124. Clean all baffle plates.

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125. Clean the oil passages of the converter housing, lubrication tube and dummy cover
with brake cleaner (or equivalent) where shown in Figure 154 and Figure 155 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 154

Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages
Figure 155
126. Install the lubrication tube and bracket, and then the baffle plate with three bolts
(Figure 156).
 Bolt torque: 5.9 N•m (0.6 kg-m, 52 in-lb.)

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 156
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CVT Reassembly

127. Install a new torque converter seal with
Seal Installer J-50818 (Figure 157).


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