and Figure 112 with yellow circles, until the fluid runs clear for 5 seconds.
To avoid damage to the CVT and potential drivability concerns, do not
apply brake cleaner or compressed air to passages shown in red.
92. Apply compressed air in the same passages to remove remaining brake cleaner and
debris.
To avoid the risk of minor personal injury, do not stand in front of the
passages while using compressed air.

Figure 111

Figure 112

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93. Spray brake cleaner into the reverse
brake tube.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Reverse brake
tube

Figure 113
94. Clean the input shaft bearing bore area (Figure 114 and Figure 115).
Input shaft
bearing bore

Figure 114

Figure 115

95. Spray brake cleaner into the high clutch
fluid passage on the torque converter
housing.



To avoid the risk of minor personal
injury, take care when cleaning
passages as brake cleaner will exit
the passage shown as “fluid
discharge” in Figure 116.



Apply compressed air in the same
passages to remove the remaining
cleaner and debris.

High clutch
fluid passage

Fluid discharge
Figure 116

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Reduction
gear bearing
fluid passage

96. Spray brake cleaner into the reduction
gear bearing fluid passage on the torque
converter housing. Then apply
compressed air in the same passages to
remove remaining cleaner and debris.



To avoid the risk of minor personal
injury, do not face the passage
indicated in red of Figure 117 when
cleaning passages as brake cleaner
will exit the passage.

Fluid discharge
Figure 117

97. Clean the passages of the oil pump
cover as follows:

Input shaft

Oil pump cover

a. Remove the input shaft from the oil
pump cover.
Do not drop the counter bearing
outer race (roller bearing type only)
as damage or contamination could
occur.

Figure 118

b. Note the orientation and then remove
the thrust bearing.

Thrust bearing

o Do NOT discard. This will be
reused at a later step.

Figure 119

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c. Remove the washer.
o Do NOT discard. This will be
reused at a later step.

Washer

d. Spray brake cleaner into the oil pump
cover oil passages indicated in
yellow shown in Figure 121.
e. Apply compressed air in the same
passages to remove the remaining
cleaner and debris.
Figure 120

To avoid the risk of minor personal injury, do not face the passage indicated in white
in Figure 121 and Figure 122 while cleaning.
Oil pump cover

Oil pump cover

Fluid discharge

Fluid discharge
Figure 122

Figure 121

f. Install the original washer.
HINT:
 Orientation is NOT critical for the
washer.
 Apply petroleum jelly to the washer to
hold it in place during assembly.

Washer

Figure 123

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g. Install the original thrust bearing in the correct orientation as shown in Figure 124
and Figure 125.


Apply petroleum jelly or equivalent to hold in place.

The thrust washer is direction specific. Install in the correct orientation. If the thrust
washer is incorrectly installed, damage to the CVT may occur.

Oil pump cover
Thrust bearing

Figure 125

Figure 124

h. Insert the input shaft into the oil pump cover (Figure 126 and Figure 127).
IMPORTANT:
 Apply petroleum jelly to the sealing ring on the input shaft before installation.
 The sealing ring is hidden behind the input gear in Figure 126.


Make sure all exposed internal areas of the CVT (including the oil pan and
magnets) have been thoroughly cleaned.



To avoid damage to the CVT, use care while assembling the input shaft to the
oil pump cover as the input shaft sealing ring may become damaged.
 To avoid damage to the CVT when not being worked on, cover all parts with a
lint-free covering to prevent contamination.
Input shaft
Sealing ring location

Oil pump
cover

Thrust bearing

Figure 127

Figure 126
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Measuring the CVT Sub-assembly Case Depth

Torque converter
housing

98. Temporarily install the torque converter
housing to the CVT case with two (2)
bolts at opposite corners, hand tight
(Figure 128).


Use the original bolts to secure.

Figure 128
99. Reposition the CVT on the work bench
with the torque converter housing side
facing down (Figure 129).
100. Clean and then zero the Digital Depth
Gauge J-50272.
101. Set the digital gauge to millimeters.

Figure 129
102. Clean the Gauge Block J-50271.

Gauge Block
J-50271

HINT: If Gauge Block J-50271 is not
used, the thickness of the substitute
measuring bar (measurement “X”) will
need to be measured. (Figure 133,
page 64). This can be done either with
a set of calipers or with Digital Depth
Gauge
J-50272.
103. Confirm the sealing surfaces of the
CVT case are clean.
104. Place Gauge Block J-50271 across the
sub-assembly sealing surface as
shown in Figure 130.
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Figure 130

NTB20-035a

105. Measure the average distance (Y) shown in Figure 133 as follows:


Refer to Figure 131, Figure 132 and Figure 133, then proceed to page 65.



Measure only from areas that do not have any signs of contact.



Refer to “Measuring area” referenced in green to measure “Y”.

Measuring area

Figure 131

Do not measure
in this area

Figure 132

Y = The distance between the upper surface of the Gauge Block J-50271 and the
surface where the snap ring seats.

Figure 133

Proceed to the next page.

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Secondary pulley bearing snap ring surface
Do not measure
into this groove

Measure to this slightly
raised machined surface
Figure 135

Figure 134

a. Measure between the top of the Gauge Block (J-50271) to where the snap ring on
the secondary pulley bearing seats in three (3) locations to calculate the average
value, “Y”. Refer to Figure 134 and Figure 135.
Y1_________, Y2________, Y3_________
b. Calculate the average, "Y", using the formula below and then record it below.
Y=

ሺ௒ଵା௒ଶା௒ଷሻ
ଷ

(millimeter)

Y = _________
c. Calculate case depth “D” as follows:
IMPORTANT: Essential tool Gauge Block (J-50271) is 20 mm thick.


Average depth calculated in step 105b →



Subtract the Gauge Block thickness

→

Y__________
─ X__________
-------------------------------------------------



→

Calculated depth

= D__________

D = Distance between the sub-assembly sealing surface and the secondary pulley
front bearing surface with the snap ring attached.
EXAMPLE:
Y = 61.39 mm
─ X = 20.00 mm
___________

D = 41.39 mm
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New Snap Ring Selection and Installation to the New Sub-assembly

106. Remove the top of the shipping box of
the new sub-assembly.

Top of the
shipping box

HINT: The outer cardboard of the
shipping box can be disassembled for
easy removal of the sub-assembly by
removing the shipping tape.

Figure 136
107. Remove the upper board with foam
spacer assembly.


The packing material may be
different then what is shown in
Figure 137.

Upper board

Figure 137
108. Locate the data sheet in the shipping
box and place it in a safe place.


This data sheet is required for
snap ring selection in the following
steps.

Figure 138

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109. Locate the plastic bag that contains
the snap rings (Figure 139).


There are six individual snap rings
in the plastic bag.



Take the plastic bag out of the
shipping box, and put aside on the
work bench.

HINT: See Reference # 5 in the KIT
PARTS REFERENCE TABLE.
Snap ring set
Figure 139

110. Take the new sub-assembly out of the
shipping box and place it on the work
bench.
To avoid possible
damage to the CVT:


Hold the sub-assembly by the
side cover ONLY when removing
it from the shipping box.



DO NOT handle the belt or
pulleys of the sub-assembly when
removing from the shipping box.



DO NOT BREAK the foam
cushion in the shipping box. This
will be used as a stabilizer for the
sub-assembly during the repair.

New sub-assembly
Figure 140

HINT: See Reference # 4 in the KIT PARTS REFERENCE TABLE.

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111. Take the lower board with foam cushion (lower board) out of the shipping box shown
in Figure 142.
HINT: Step 112 is for kits that have a
separate spacer (Figure 141). In later
kits this spacer will be part of the lower
board and step 112 will not be used.

112. Take the spacer (Figure 141) out of the
shipping box and place on the work
bench where the sub-assembly will be
installed, and then place the lower
board on top of the spacer as shown in
Figure 142.

Spacer

Figure 141

HINT: The spacer will be the last item
that is removed from the shipping box
and is approximately 1 inch thick.


Position the lower board so that it hangs over the spacer.



Align the lower board so that the left and the right cut-outs are even with the
spacer.

NOTE: The positioning of the lower board with foam cushion will allow the CVT case
enough clearance from the work bench to allow it to seat flush with the sub-assembly.
Cut-out even
with spacer

Lower board with
foam cushion

Lower board
over-hang

Cut-out even
with spacer

Cut-out even
with spacer
Figure 142
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113. Remove the sub-assembly from the
plastic bag.

114. Place the new sub-assembly onto the
lower board.


The sub-assembly must be level
and oriented as shown in Figure
143 for proper seating of the CVT
case later in this procedure.
Lower board
and spacer

115. Remove the snap ring from the
secondary pulley front bearing of the
new sub-assembly.


Figure 143

New sub-assembly

A new snap ring will be installed
later in the procedure.

Snap ring
Figure 144

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116. Calculate “E” for snap ring selection as follows:

HINT: For the value of “B1”, refer to the data sheet that was put aside when the subassembly shipping box was opened.


Calculated case depth from step c on page 65

→



Subtract constant value

→ ─
41.30
------------------------------------



Subtotal

→



Add value for “B1” from data sheet

→ + B1 ___________
------------------------------------



Total calculated depth

→

D ___________

=

___________

= E ___________

E = This will be used to select a snap ring from Table A on page 71.

EXAMPLE:
If D = 41.39 mm
Constant
= 41.30 mm (subtracted)
And B1 = 1.56 mm (added)
____________________
E = 1.65 mm

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117. Select the appropriate Part Number from Table A shown below, based on the
calculated result of “E” in step 116 on page 70.
EXAMPLE: If E = 1.65, and is between or equal to 1.64 to 1.67, choose new snap
ring Part Number “31506 3JX9C”.
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61