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.

Spacer

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.

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
Example only. Do
1.65
not use in your
1.69
calculations.
1.73
1.77
1.79

Table A
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
1.65
1.69
1.73
1.77
1.79

118. Open the plastic bag (with snap rings) that was removed from the shipping box in step
109 on page 67 and then choose the correct Part Number selected from Table A.
HINT: There are six individually packed snap rings in the plastic bag. See Reference #
5 in the KIT PARTS REFERENCE TABLE.
119. Measure the new snap ring and confirm its thickness is equal to the Snap Ring
Reference in Table A.
120. Install the selected snap ring onto the secondary pulley front bearing of the new subassembly.
HINT: Discard unused snap rings.

Selected snap ring
Figure 145

Figure 146

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Install Sub-assembly to CVT Case

CVT case
sealing surface
121. Make sure the CVT case sealing
surface of the side cover is thoroughly
cleaned.

122. Make sure the dowel pins are cleaned
and any rust has been removed.

Figure 147
Torque converter
housing
123. Flip the CVT case over on the work
bench with the torque converter
housing side facing up.
To avoid possible
contamination and damage to the
CVT, ensure the work bench surface is
thoroughly cleaned before flipping the
CVT case.
124. Remove the two (2) temporary bolts
and then remove the torque converter
housing from the CVT case.
Figure 148

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CVT case
125. Install the CVT case onto the new subassembly as follows:
NOTE: Sealant will be applied
between these components at a later
step.
a. Slowly lower the CVT case onto the
sub-assembly.
To avoid damage to
the CVT:


Only use the weight of the
CVT case when installing it to
the sub-assembly.



Do NOT use any other
external force to seat the CVT
case to the sub-assembly.

b. Align the primary pulley front
bearing bore of the CVT case to the
primary pulley front bearing of the
sub-assembly.

New subassembly

Figure 149
Primary pulley
sub-assembly

CVT case

HINT: Figure 150 is shown looking
down into the CVT case while it is
being lowered.
Primary pulley
front bearing bore
Figure 150
c. Align one of two dowel pin holes
found on the CVT case to the subassembly.

CVT case

Dowel pin
New sub-assembly
Figure 151

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d. Align the second dowel pin of the
sub-assembly with the hole on the
opposite side of the CVT case and
seat CVT case.

Dowel pin
Figure 152
e. If the CVT case will not seat on the
sub-assembly:
1) Access the counter driven gear
through the top of the CVT case,
and
2) Rotate the counter driven gear on
the primary pulley back and forth.
HINT: This will allow the splines
of the secondary pulley and the
planetary carrier plate to align.
See Figure 154.

Counte
Counter
r driven
driven
gear

Figure 153

Secondary
pulley splines
Figure 154

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f. Confirm that the mating surface of the CVT case is seated to the sub-assembly
completely.


If the CVT case does not sit completely flush with the sub-assembly, DO NOT
apply any vertical force to seat it.
1) If this occurs, first lift the CVT case up slightly and then lower.
2) Repeat until the CVT case and sub-assembly sit flush with each other.

CVT case

No gap

New sub-assembly
Figure 155
g. Rotate the counter driven gear back and forth by hand to confirm its rotation is
smooth.

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126. Temporarily install two (2) original bolts hand tight to hold the sub-assembly to the
CVT case.
CVT case

New sub-assembly
Bolts

Figure 157

Figure 156

127. Lift the sub-assembly / CVT case away
from the cradle and set aside. Discard
the cradle.


Leave the sub-assembly side cover
facing down as shown in Figure
158.



Weight: 29 kg (64 lbs.)

Sub-assembly
side cover

76/148

Figure 158

NTB20-036a

Install the Oil Pump and the Manual Shaft

128. Install the oil pump gasket to the CVT
case.


Use a new gasket (non-reusable).



Apply CVT fluid before installation.

CVT case

HINT: See Reference # 14 in the KIT
PARTS REFERENCE TABLE.
Oil pump
gasket

Figure 159
129. Remove the hand tight transmission
range switch bolts and then slide the
manual shaft out only far enough to
install the oil pump. See Figure 90 on
page 48.

CVT case

Manual shaft

Oil pump


Do not remove the manual shaft
completely from the CVT case. If
the retaining pin slot contacts the
seal, damage may occur.

130. Install a new oil pump to the CVT case.



Reuse the three original Allen®
bolts for the oil pump.

Figure 160

35 mm (1.4 inches) long bolt.
 Bolt torque:
20.3 N•m (2.1 kg-m, 15 ft-lbs.)

HINT: See Reference # 13 in the KIT
PARTS REFERENCE TABLE.
131. Install the snap ring that came out of
the original oil pump to the new oil
pump.
Snap ring
Figure 161

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Manual shaft

132. Slide the manual shaft back to the
original position.

Oil pump
Figure 162
Retaining
pin

133. Install the original retaining pin as
shown in Figure 163.


Align the manual shaft groove
(Figure 164) to allow the retaining
pin (Figure 163) to go through
completely.
Manual shaft

Figure 163

Groove for the retaining pin (straight pin)

Figure 164
Slide
direction

Hole for the roll pin

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To prevent CVT operational issues, use care when assembling the manual shaft and detent
plate.
 Do not drive the roll pin flush with the detent plate.
 If the roll pin is driven flush, it will be overextended on the opposite side and the
manual shaft/detent plate assembly will not rotate.
 The roll pin MUST be the same length on both sides of the detent plate after it is
installed through the detent plate and manual shaft.

134. Install the new roll pin through the
detent plate and manual shaft.


The roll pin must be inserted
through the detent plate so that
both ends are the same length.



Use a new roll pin (non-reusable).



Punch size: Diameter 3 mm,
Length 20 mm or longer.

Roll pin