Thrust
bearing race
Figure 54

Figure 53
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Oil pan gasket
surface

Top of
CVT

32.

Remove the oil pump as follows:
a. Remove the fitting bolt located
above the corner of the oil pan
gasket surface (Figure 55).

Fitting bolt

Figure 55

b. Remove the three oil pump
Allen™-head bolts, and remove
the oil pump (Figure 56).
NOTE:
o Do NOT discard the Allenhead bolts. Bolts will be reused.
o New oil pump will be installed
at later steps.
Figure 56

33.

Remove CVT fluid filter as follows:

a. Remove the four (4) bolts and then
remove the CVT fluid filter cover
(Figure 57).
NOTE: Bolts will be reused.
CVT fluid filter cover
Figure 57
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Fluid filter

b. Remove the CVT fluid filter with
grommet seal and O-ring seal
(Figure 58).


Discard the oil filter and seal.
They will be replaced.
O-ring seal
Figure 58

Grommet



Grommet is fitted to the bottom
end of the filter and is included
with replacement filter
(Figure 59).

Figure 59

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Clean the CVT Case Surfaces

34.

Thoroughly clean the mating surfaces of the CVT case and Torque Converter
Housing.


A plastic scraper can be used.

CAUTION:
 DO NOT use sanding discs, similar abrasive tools, or metal blades.

35.



Use brake spray or equivalent solvent and lint-free towels only.



Make sure brake spray or solvents used are compatible with local regulations.



Avoid debris entering into the inside of the CVT.



Make sure rust and debris have been cleaned off of dowel pins and receiving
holes (Figure 60).

Clean the dowel pins and dowel pin receiving holes of any rust or debris with emery
cloth (Figure 60).
NOTE: Use small wire brush or similar tool at the inside surface of dowel pin holes.
DO NOT SCRAPE CVT CASE mating surfaces.

Clean dowel pin
receiving holes
Clean
dowel pin

Figure 60

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Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT Filter Area

In the following steps:


Brake cleaner and compressed air will be used to clean out oil passages in the CVT
assembly.



Make sure the brake cleaner or solvents are compatible with local regulations.
WARNING: Wear eye / face protection when using compressed air and cleaning
fluids.
CAUTION:
 Regulate air pressure up to a maximum of 75 PSI.


36.

Clean within
this area

Clean the area where the CVT fluid
filter fits (Figure 61).


37.

Do not use water-based (aqueous) cleaners.

Make sure the old filter grommet
seal is removed.

Clean the fluid passages to and from
the filter (Figure 61).

Fluid
passages
Figure 61

38.

Clean filter cover (Figure 62).

Figure 62
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39.

Spray brake clean in all oil passages of the CVT case where shown in Figure 63 and
Figure 64.

40.

Remove lip seal if not already removed.

41.

Apply compressed air in the same passages.
NOTE:
 Do not stand in front of the passages while using compressed air.
 Do not spray brake clean directly into clutch pack.

Lip seal

Figure 63

Apply cleaner, and then
75 PSI maximum air
pressure in these
passages.
Air pressure comes
out these passages.

Figure 64

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New Oil Pump Installation

42.

Install the new oil pump using three (3)
original Allen-head bolts (Figure 65).
NOTE:


Finger tighten the Allen-head bolts
at this time.

IMPORTANT: A Parts Kits Reference Table
is provided on page 109.


Use the check off column on the left to
ensure the correct new part is installed
at each step.



Attach this to the repair order.

Figure 65

Fitting bolt

43.

Place a new O-ring on the fitting bolt,
and coat with CVT fluid (Figure 66).

O-ring

Figure 66

44.

Fitting
bolt

Install the fitting bolt finger tight
(Figure 67).

Figure 67

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45.

Torque the three (3) Allen head bolts and fitting bolt.
 Allen head bolt torque: 17.6 – 20.6 N•m (1.79 – 2.1 kg-m, 13.0 – 15.2 ft-lb)
 Fitting bolt torque: 26.0 – 30.0 N•m (2.65 – 3.06 kg-m, 19.2 – 22.1 ft-lb)

46.

Install the original snap ring
(Figure 68).

Snap ring
Figure 68
47.

Install the CVT fluid filter and components (Figure 69 and Figure 70).


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

CVT fluid filter cover
Figure 70

Figure 69

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Replace the Side Cover – Pulleys and Chain (sub-assembly)

48.

Temporarily install the dummy cover
with 3 bolts, finger tight (Figure 71).
IMPORTANT:


Do not install any thrust bearing
to the clutch assembly bore at this
time.



If the cover does not seat flush
see TROUBLESHOOTING The
Dummy Cover Will Not Sit
Flush on page 105.

Bolts

Dummy cover
Figure 71

49.

Temporarily install the converter
housing onto the CVT case with three
bolts finger tight (Figure 72).
IMPORTANT:


When fitting the CVT case
surfaces, DO NOT use the bolts
to draw in the case halves.



Make sure the case surfaces are
flush, and have no gaps prior to
installing the bolts.

Bolts

Converter housing
Figure 72

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50.

Flip the CVT case so that the
converter housing faces down and
side-cover faces up.


Lifting fixture J-51595 can be used
for this step. This tool is not shown
in Required Tools / Materials.
Manual shaft

CAUTION:
 Do not hit the manual shaft
(Figure 73) while flipping the CVT;
the manual shaft protrudes past
the CVT case. Use a plastic /
wooden block to support as
needed.


51.

Figure 73

Note the location of the terminal
connector harness. Do not pinch
the terminal connector harness
between the CVT case and work
bench or supporting blocks.

Rotate the primary pulley by hand to
check the pulleys rotational
characteristics.

Rotate the primary
pulley by hand

IMPORTANT:




Remember the pulley’s rotational
characteristics. This will be used
as a reference after the new side
cover-pulleys and belt subassembly (sub-assembly) have
been installed.

Figure 74

This will be used as a reference
later in the procedure to
determine if the sub-assembly
installation is successful or not.

WARNING: Do not place fingers
between the pulley and the CVT case.
Do not place fingers
under pulley
Figure 75

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NOTE: When working with sub-assembly install, uninstall, and bracket attachment, it is
critical that CVT and sub-assembly are level. If not level, the pulleys and bearings can sit
slightly at an angle and will hinder installation.

52.

Remove the nineteen (19) side cover
bolts (Figure 76).


Loosen the bolts with hand tools
only.



These bolts will be replaced with
new ones and will not be reused.

Figure 76

53.

Remove the six (6) pulley bracket
bolts.


These bolts will be reinstalled to
the original pulley and belt subassembly.

Figure 77

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54.

Attach universal Lifting Fixture J-52082 with spacers J-52082-2 to the side cover as
shown in Figure 78.
NOTE: Install and tighten by hand only.
a. Loosen all of the wing-nut bolts on the Lifting Fixture.
b. Confirm that three (3) spacers (# J-52082-2) are present between the longer legs
and triangle bracket as shown in Figure 78.
c. Install the Lifting Fixture to the CVT case at the six (6) bolt holes shown in
Figure 77 on page 35.
d. Tighten the two (2) joints to the triangle brackets.
e. Tighten the wing-nut bolts on the Lifting Fixture finger tight.
CAUTION: Do not cross-thread the bolts when attaching to the CVT side
cover.

(3) Spacers
(# J-52082-2)

Triangle
bracket

Lifting Fixture J-52082
Longer legs
55.

Triangle
bracket joint

Figure 78

Install the two CVT Assembly Guide Pins (J-51959 - Guide Pins) as shown in
Figure 79 and Figure 80.


The Guide Pins must be located next to the dowel pins.
Guide Pin

Guide Pin

Guide Pin

Dowel Pin
Pins
Dowel Pin
Figure 79

Figure 80
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56.

Raise the Lifting Fixture so that the CVT assembly weight is mostly supported by the
Lifting Fixture and just slightly raised off of the work surface (using Tool #: J-52082).

57.

Loosen the side cover with a slide hammer at the three points shown in Figure 81.


Rotate between the 3 locations on the side cover until the CVT case separates
from the sub-assembly; this can take more than one rotation to loosen the sealant.
CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from
the CVT case.
NOTE: Apply rust penetrant to the two dowel pins as needed.

The following Figure is for reference only and does not show the lifting device attached.
Tool location
marks

Dowel
pin

Dowel
pin

58.

Figure 81

Raise the lifting fixture to remove the
“side cover with pulleys and chain subassembly” (sub-assembly) from the
CVT case (Figure 82) and set aside.
CAUTION: Make sure the primary
speed sensor is removed from the
sub-assembly.

59.

Sub-assembly



The speed sensor will be reused.



DO NOT discard the speed
sensor.



This sub-assembly will not be
reused.

Remove the lifting fixture from the subassembly and replace all six (6)
original bolts.

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Figure 82
CVT case

NTB17-039h

60.

Thoroughly clean the mating surfaces of the CVT case (Figure 83) that the subassembly was just separated from (a plastic scraper can be used).


Clean off the dowel pins.



Confirm that the dowel pins have remained in the CVT case. If not, remove them
from the sub-assembly and relocate back to the CVT case.



Reinstall the guide pins if they were removed during case cleaning.

CAUTION:
 DO NOT use sanding discs, similar abrasive tools, or metal blades.