and the oil pump
cover (dummy cover)

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Figure 79

NTB20-035a

58. Confirm the “type” of bearing used on the end of the input shaft, and then proceed to the
indicated step.


For type “A” roller bearing proceed to step 59.



For type “B” ball bearing skip to step 61 on page 45.



For type “C” sealed ball bearing skip to step 61 on page 45.

Bearing type A

Figure 80

Bearing type B and C
 Type C shown

59. Remove the outer race of the roller
bearing from the counter bearing bore of
the CVT case by hand.
Do not use excessive force
to remove the bearing race as damage
to the CVT may occur. A magnet can be
used to lift this bearing if needed.
HINT: The outer race of the roller
bearing might remain on the shaft when
removing the input shaft and dummy
cover.

CVT case

Outer race
Figure 81

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60. Inspect type “A” bearing (Roller bearing)
as follows:


Inspect the bearing outer race and
input shaft for flaking or pitting.



Install the bearing outer race onto the
input shaft assembly with the
“bearing number” facing the gear,
and then rotate the bearing while
applying an axial load by hand to
check for any abnormality.

Input shaft
Figure 82

DO NOT drop the outer race of the bearing to avoid damage and/or
contamination.
 Were any abnormalities found or felt in the bearing (sound, flat spots, flaking)?
o NO: Put bearing and shaft aside and then skip to step 62 on page 45.
o YES:
a. Document the abnormalities found with a video and then contact the PCC
for authorization to replace the CVT. See page 147 for PCC contact
information.
b. Refer to steps 203 - 206 on page 105 when replacing the CVT.
c. After CVT replacement, perform ADDITIONAL SERVICE WHEN
REPLACING CONTROL VALVE OR TRANSAXLE ASSEMBLY on
page 106.
d. Loosely reassemble the original CVT in the reverse order of disassembly
with the original parts.

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61. Inspect type “B” and type “C” bearings
(ball bearing) as follows:


Apply an axial load and rotate the
bearing by hand to check for any
abnormality (sound, flat spot, flaking).

Figure 83
 Were any abnormalities observed in the bearing when applying an axial load
(sound, flat spots, flaking)?
o NO: Proceed to step 62.
o YES:
a. Document the abnormalities found with a video and then contact the PCC
for authorization to replace the CVT. See page 147 for PCC contact
information.
b. Loosely re-assemble the CVT in the reverse order of disassembly with the
original parts.
c. Refer to steps 203 - 206 on page 105 when installing the CVT.
d. After CVT replacement, perform ADDITIONAL SERVICE WHEN
REPLACING CONTROL VALVE OR TRANSAXLE ASSEMBLY on page
106.

62. If the bearing is judged to be OK,
remove the shim (Figure 84) from the
bottom of the counter bearing bore.

Counter
bearing bore



A magnet can be used to remove the
shim if needed.



This shim will be reused later in this
procedure.

Shim
Figure 84

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63. Remove the differential side oil seal from
the CVT case by driving it away from the
case with a suitable tool.


The differential side oil seal is a onetime use part. Do not reuse.



Take care not to damage the
seal-to-case surface when removing
seal.

CVT case

Differential side oil seal
Figure 85
Park position

3 mm punch
64. Rotate the manual shaft (Figure 86) until
it stops in the Park position (see
Figure 87).

Roll pin

Confirm that the detent
plate is in the Park position before
proceeding. Do not remove the roll
pin in any other position. This will
allow pin removal and avoid damage
to the case.
65. Remove the roll pin completely from the
manual shaft with a 3 mm punch.


Manual shaft
Figure 86

The roll pin is a one-time use part.
Do not reuse.

Use a 3 mm punch. If a
larger sized punch is used, the hole may
become enlarged and damage the
manual shaft.
66. Remove the detent spring bolt shown in
Figure 87 and then remove the detent
spring from the CVT case.


Detent spring

Park position

Do not discard the bolt. It will be
reused during reassembly.

Figure 87
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67. Remove the manual shaft retaining pin
(straight pin) from the CVT case by
grasping and pulling vertically by hand.


Retaining pin

Do not discard the pin. It will be
reused during reassembly.

Manual shaft

Figure 88

68. Remove the two (2) bolts shown in
Figure 89 for the transmission range
switch.


Do not discard the bolts. They will be
reused during reassembly.

HINT:


DO NOT remove the manual
shaft lock nut at this step.



DO NOT try to remove the
transmission range switch from
the manual shaft.
Transmission range
switch

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Figure 89

NTB20-035a

CVT case

5.3 inches

69. Slide the manual shaft approximately 5.3
inches (135 mm) out of the CVT case to
allow removal of the oil pump (step 70).
Do not remove the manual shaft
completely from the CVT case. If the
retaining pin slot contacts the seal,
damage may occur.

Manual shaft
Figure 90

70. Remove the three (3) Allen® bolts
shown in Figure 91 and then remove the
oil pump from the CVT case.


This oil pump will not be reused, it
will be replaced with a new one.



Do not discard Allen® bolts. They will
be reused during reassembly.

Oil pump

3 Allen® bolts
Figure 91

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71. Remove the snap ring from the original
oil pump.
HINT: DO NOT discard the removed
snap ring. This snap ring will be reused.

Snap-ring

Figure 92

72. Remove the oil pump gasket from the
CVT case.


Oil pump
gasket

The oil pump gasket is a one-time
use part. Do not reuse.

Figure 93

73. Temporarily install the transmission range switch with the two (2) original bolts removed
in step 68 on page 47, finger tight.


The transmission range switch will be permanently installed later in this procedure.

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Remove the Sub-assembly
IMPORTANT: Steps 74 through 81 are ONLY to separate the sealant of the side cover.
The sub-assembly with belt and pulley CANNOT be removed from the CVT while in this
orientation and will be removed from the case at a later step.
74. Reposition the CVT on the work bench
with the torque converter housing side
down.
HINT: A wood block may be used to
stabilize the CVT during
disassembly/reassembly.

Figure 94
75. Remove the two (2) pulley bearing
retainer bolts shown in Figure 95.


Do not discard bolts. They will be
temporarily installed during a later
step.

Figure 95
76. Remove the eleven (11) side cover bolts
shown in Figure 96.


Retain two (2) of these bolts. They
will be temporarily installed during a
later step.

Figure 96

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77. Remove the side cover with a slide hammer J-25721-A to separate the side cover and
CVT case.


There are three slide hammer tool points shown in Figure 97.



The mating surfaces will be cleaned at a later step.



This step will help with sub-assembly removal at a later step.
 To avoid damage to the CVT, do not use the speed sensor bore for slide
hammer tool location.
 Do not pry the surfaces apart as internal CVT damage may result.

Side cover

Figure 97
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78. Align the primary pulley bearing retainer
bolt holes with the bolt hole on the case
as shown in Figure 98.
HINT: This helps alignment of the
bearing retainer bolt threads after
reinstalling the original side cover.

Figure 98

79. Install one of the “Assembly Guide Pins,
Pulley Bracket” (Guide Pin
J-52272) to one of the two pulley
bearing retainer bolt holes.


Assembly guide
pins, pulley bracket,
(Guide Pin J-52272)

This will assist in installation of the
original side cover to the pulley
assembly.

Figure 99

Side cover

80. Place the original side cover onto the
CVT case.


Position the primary pulley bearing
retainer to allow the guide pin to be
inserted through the bolt hole of the
side cover.

Figure 100

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81. Install the two (2) original pulley bearing retainer bolts (Figure 101) as follows:


Use the original bolts and O-rings at this step.
a. Install one pulley bearing retainer bolt finger tight into open bearing retainer bolt
hole.
b. Remove the guide pin from the other bearing retainer bolt hole.
c. Install the other bearing retainer bolt by hand (finger tight).

82. Temporarily reattach the removed side cover onto the CVT case with two (2) original
bolts on opposite corners, hand tight.

Pulley bearing
retainer bolts

Side cover

Side cover
bolts
Figure 101

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83. Reposition the CVT with the side cover
facing down.

Side cover
Figure 102
84. Remove the two (2) side cover bolts
which were temporarily installed to hold
the side cover to the CVT in step 82 on
page 53.
HINT: Only one (1) bolt is shown in
Figure 103 and is for reference only.

Side cover
bolt
Figure 103

85. Lift the CVT case vertically off of the
sub-assembly and side cover.


Weight 17.4 kg (38.4 lbs.)



This sub-assembly will not be
reused.

IMPORTANT: The sub-assembly must
be separated from the case as shown in
Figure 104.

Figure 104

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86. Place the CVT case on the work bench
with the torque converter side facing
down.

Figure 105

87. Remove the lubrication tube bolt shown
in Figure 106 and then remove the
lubrication tube from the CVT case.


Lubrication tube

Do not discard the bolt or lubrication
tube. These will be reused during
reassembly.

To prevent drivability
concerns, ensure that the lubrication
tube is not bent during sub-assembly
installation.

Lubrication
tube bolt
Figure 106

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Clean the CVT Surfaces
To avoid damage to the CVT and potential drivability concerns:


Prevent any debris from dropping into the torque converter housing, side cover or
the CVT case.



Use brake cleaner to remove the remaining CVT fluid and any residual sealant.



Do not use sanding discs, abrasive tools, or metal blades on sealing surfaces.



Clean dowel pins with a mild abrasive sandpaper to remove all rust and debris.
 This will assist at a later step when mating the CVT case to the sub-assembly
and again when mating the CVT case to the torque converter housing.
CVT case
sealing surface

88. Remove any sealant that remains on the
sealing surface of the CVT case where it
seals with the sub-assembly side cover.


A plastic scraper can be used.



Use ONLY brake cleaner to clean
surfaces.



Clean with a lint-free paper towel.

Figure 107
89. Remove any sealant that remains on the sealing surfaces of the torque converter
housing and CVT case using a plastic scraper, and then clean with a lint-free paper
towel.


Use ONLY brake cleaner to clean surfaces.
CVT case
sealing surface

Figure 108

Torque converter
housing sealing
surface

Figure 109
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Clean Oil Passages in CVT Case and Oil Pump Cover

In the following steps:


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

 To avoid the risk of minor personal injury, wear eye/face protection when using
compressed air and cleaning fluids.
 To avoid risk of minor personal injury, regulate air pressure up to a maximum of
75 PSI.

90. Confirm the CVT case is on the work
bench with sub-assembly side down.


Use wood blocks as necessary to
stabilize the assembly during these
steps.

Make sure the surface of
the work bench has been cleaned to
avoid contamination of components.

Figure 110

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91. Spray brake cleaner into each oil passage of the CVT case, where shown in Figure 111