NTB16-110n

J-52281

83. Install the CVT case side axle seal
(Figure 105).


Use Seal Installer J-52281 and Driver
Handle J-8092.



Apply a light coat of CVT fluid to the
seal lip surfaces.

J-8092

CVT
case

Figure 105
84. Place the CVT on the work bench with
the side cover facing down on the
bench.

85. Remove the converter housing which
was temporarily installed with three
bolts.

Bolts

Converter housing
Figure 106

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Clutch Total Endplay Adjustment – Thrust Bearing Selection

IMPORTANT: The clutch total endplay (Figure 107) must always be adjusted between the
clutch drum and the dummy cover when a new sub-assembly is installed and is adjusted
with thrust bearing thickness.
There are eight (8) thicknesses of thrust bearings available for total endplay adjustment.


For additional information, see video # 547: “CVT Belt and Pulley Replacement”
and fast forward to minute marker 13:22. This video is located under the TECH
TRAINING GARAGE VIDEOS tab in Virtual Academy.

Dummy
cover

CVT case

Total
endplay

Clutch
drum

Thrust
bearing

Figure 107

86. Clean and then zero the Digital Depth Gauge (part #: J-50272).


Set Digital Depth Gauge to millimeters.

87. Clean Gauge Block J-50271.

88. Confirm the mating surfaces of the CVT case are clean.

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89. Calculate the average (D) clutch
assembly bore depth (Figure 108) as
follows:
IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.

Figure 108

Clutch assembly
bore
a. Place the Gauge Block on the
surface where the dummy cover
seats, and over the clutch assembly
bore (Figure 109).
IMPORTANT: This surface is lower
than the CVT case to torque
converter housing surface.
Gauge Block
Figure 109

NOTE: The clutch assembly should
sit 2-3 mm lower than the dummy
cover seat (Figure 110).

Dummy
cover seat

Dummy
cover seat

b. Confirm the Gauge Block is not
sitting on the clutch assembly or
against the input shaft.
NOTE: If the clutch assembly is
sitting higher than the dummy cover
surface, see Troubleshooting - The
Dummy Cover Will Not Sit Flush
on page 90.

Clutch assembly
Figure 110

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c. Position the Depth Gauge on the

Depth Gauge

Gauge Block (Figure 111).

Datum level

NOTE: Make sure the Depth
Gauge’s datum level is flush with the
top of the Gauge Block.
d. Carefully slide the gauge down until it

bottoms out on the bottom of the
clutch assembly bore. Write this
measurement as D1 (use
millimeters).

Clutch assembly
bore
Gauge Block

NOTE: Do not measure from the
clutch assembly bore shown in red
(Figure 112).

Figure 111

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

Measure here; D2

Measure here; D1

Figure 112

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.
D =

(D1 + D2)
-------------2

Write the measurement for “D” here _____ mm

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Clean surfaces
90. Measure the average (H) dummy cover
Clean
here
height (Figure 114) as follows:
a. Clean the dummy cover surfaces
that contact the CVT case and thrust
bearing (Figure 113).
CAUTION: Use brake spray (or
equivalent) and lint-free towel only.
Make sure the brake spray or
solvents used are compatible with
local regulations.
b. Place the dummy cover upside down
Clean here
on a work bench, and place the
Gauge Block onto the thrust bearing
Figure 113
surface (Figure 114).
c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover (Figure 114).
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 (Figure 114).
Gauge Block

Figure 114
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
91. 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 58 and 59 to calculate
for “A”.
D measurement ______ mm
– H measurement ______ mm
= A - - - - - - - - - - - - - - - - ______ mm
59/103

Please print this page and
attach it to the repair order.
NTB16-110n

b. Choose the appropriate bearing from Table A below, based on the Total Endplay (A)

calculated on the previous page (8 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 115).
d. Circle the thrust bearing part number that was selected in Table A.
Table A
PART #: 314071XZOB
1XZ0C
1XZ0D
1XZ0E
1XZ1A
1XZ1B
1XZ1C
1XZ1D

A=D-H
BEARING
CLEARANCE (A) THICKNESS
3.87 - 4.07 MM
4.08 - 4.23 mm
4.24 - 4.43 mm
4.44 - 4.58 mm
4.59 - 4.78 mm
4.79 - 4.94 mm
4.95 - 5.09 mm
5.10 - 5.29 mm

3.57
3.75
3.93
4.1
4.28
4.46
4.61
4.79
Figure 115

92. Install the thrust bearing flush to the clutch assembly bore as shown in Figure 116.
 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 116
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Clean the Converter Housing Passages

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

93. 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 117).

Figure 117

Lubrication
tube, bracket,
and bolt

b. Remove the bolt and then remove
the lubrication tube and its bracket
(Figure 118).

Figure 118

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94. Clean the oil passages of the converter housing, lubrication tube and dummy cover with
brake spray (or equivalent) where shown in Figure 119 and Figure 120 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 119

Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages
Figure 120
95. Install the lubrication tube, bracket and bolt, and then the baffle plate with three bolts
(Figure 121).
 Bolt torque: 5.9 N•m (0.6kg-m, 52 in-lb.)

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 121

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CVT Reassembly

96. Install a new torque converter seal with
Seal Installer J-50818 (Figure 122).


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 seal
installer bottoms out.

J-50818

Figure 122

97. Is this vehicle an all-wheel drive (AWD)?

J-52282

YES: Proceed to step 98.
NO: Install the torque converter housing
side axle seal (Figure 123).


Use Seal Installer J-52282 and Driver
Handle J-8092.



Apply a light coat of CVT fluid to the
seal lip surfaces.



J-8092

Converter
housing

Proceed to step 98.
Figure 123

98. Apply petroleum jelly or equivalent to the
dummy cover’s lathe cut seals (Figure
124) before installing the dummy cover
to the CVT case.
IMPORTANT:
 Confirm that the lathe cut seals
(white seals) are in their appropriate
slots. Carefully reposition seals as
necessary.


This area must
remain clear

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

Figure 124
Dummy cover lathe cut
seals (white seals)
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Input shaft lathe cut seals
(white seals) correctly
located in slots

99. Confirm that the input shaft’s lathe cut
seals are in the correct positions
(Figure 125).

Input shaft

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

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

Figure 125

100. Install the dummy cover first, then
baffle plate C, and then the related
bolts finger tight (Figure 126).
IMPORTANT: Visually check that the
dummy cover is fully seated on the
CVT case. If it is not, refer to Trouble
Shooting pages 90 – 91.




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.

Dummy
cover, baffle
plate C, and
bolts
Figure 126

101. Install baffle plate B and “L” bracket
with the related bolts finger tight
(Figure 127).

Baffle plate B
and bolts

102. Torque the bolts from steps 100 and
101 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.)

1

“L” bracket
and bolts

Figure 127

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Thrust washer
103. Install the thrust washer onto the
dummy cover (Figure 128).


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

