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
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 Fluid discharge
will exit the passage.
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 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.
Washer

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

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.
Sealing ring location

Thrust bearing

Input shaft

Oil pump
cover
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
gauge block will need to be measured.
The thickness of the gauge block is
shown as “X” in Figure 133 on page
64.
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.

Figure 130

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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 103b →



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