2
6

Torque un-numbered bolts
in clockwise direction

3
1
5
7
Figure 107
81.

Remove the Lifting Fixture.

82.

Install six (6) new O-rings to the six (6) new pulley bearing retainer bolts that were
removed from the new sub-assembly in step 69 on page 45.

83.

Install the six (6) new pulley bearing
retainer bolts finger tight.


Do not use tools to install.

Figure 108

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84.

Confirm the rotational smoothness of the primary pulley as follows:
a. With a clean hand, access the primary pulley from the bottom of the CVT.
b. Rotate the primary pulley by hand and confirm that the characteristic is the same
as previously checked at step 55 on page 38, prior to removing the original subassembly.


If the rotational characteristic is the same or better, continue to step 85.



If the rotational characteristic is worse (stiffer):
1) Remove the sub-assembly from the CVT case.
2) Wipe and clean the sealant from the CVT case and side cover rim.
3) Restart the procedure from step 70 on page 46.

85.

Torque all six (6) bolts.


Bolt torque: 28 N•m (2.8 kg-m,
20 ft-lbs).

Figure 109

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J-52283
Seal
Installer
86.

87.

88.

Install the CVT case side axle seal
(Figure 110).


Use Seal Installer J-52283 and
Driver Handle J-8092.



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

J-8092
Driver Handle

CVT
case

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

Remove the converter housing, which
was temporarily installed with three (3)
bolts.

Figure 110

Bolts

Converter housing
Figure 111

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Clutch Total Endplay Adjustment – Thrust Bearing Selection

IMPORTANT: Using thrust bearings, the clutch total endplay (Figure 112) must always be
adjusted between the clutch drum and the dummy cover when a new sub-assembly is
installed.
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 112

89.

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

Set the Digital Depth Gauge to millimeters.

90.

Clean Gauge Block J-50271.

91.

Confirm the mating surfaces of the CVT case are clean.

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CVT case
Oil Pump
92.

Gauge block

Calculate the average clutch assembly
bore depth (D) (Figure 113) as follows:
IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.

D

Clutch drum of clutch assembly
Figure 113

Clutch assembly
bore
a. Place the Gauge Block on the
surface where the dummy cover
seats and over the clutch assembly
bore (Figure 114).

HINT:





This surface is lower than the
CVT case to torque converter
housing surface.

Gauge Block
Figure 114

The clutch assembly should sit 23 mm lower than the dummy
cover seat (Figure 115).

Dummy
cover seat

Dummy
cover seat

b. Confirm the Gauge Block is not
sitting on the clutch assembly or
against the input shaft.
HINT: If the clutch assembly is sitting
higher than the dummy cover
surface, see Dummy Cover
Troubleshooting on page 34.
Clutch assembly
Figure 115

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c. Position the Depth Gauge on the

Depth Gauge

Gauge Block (Figure 116).

Datum level

HINT: 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

HINT: Do not measure from the
clutch assembly bore shown in red
(Figure 117).

Figure 116

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

Measure here; D2

Measure here; D1

Figure 117

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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93.

Clean surfaces
Measure the average dummy cover
Clean
here
height (H) (Figure 119) as follows:
a. Clean the dummy cover surfaces
that contact the CVT case and
thrust bearing (Figure 118).
IMPORTANT: Use brake cleaner
(or equivalent) and a lint-free
towel only. Make sure the brake
cleaner or solvents used are
compatible with local regulations.
b. Place the dummy cover upside
Clean here
down on a work bench, and place
the Gauge Block onto the thrust
Figure 118
bearing surface (Figure 119).
c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover (Figure 119).
HINT: 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 119).
Gauge Block

Figure 119
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
94.

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 60 and 61 to
calculate for “A”.
D measurement ______ mm
– H measurement ______ mm
= A - - - - - - - - - - - - - - - - ______ mm
61/100

Please print this page and
attach it to the repair order.
NTB20-091

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

calculated on the previous page (eight 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 the THRUST BEARINGS table on page 98 for Thrust Bearing part
numbers by thickness.

c. Measure and confirm that the selected thrust bearing is the correct thickness before

installing (Figure 120).
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 120

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95.

Install the thrust bearing flush to the clutch assembly bore as shown in the Figures
below.


Install the thrust bearing in the area shown in green so that it is centered by the
four tabs.

HINT: The thrust bearing has two sides. See Figure 121 through Figure 124 for the
correct orientation.

Figure 121

Four Alignment tabs.
(One not shown).

Silver surface
faces UP

Figure 122

Black surface
faces DOWN
Thrust bearing

Correct installation

This gap should
face down

Incorrect installation

Figure 123

Figure 124

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Clean the Converter Housing Passages

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

96.

Remove the baffle plate and
lubrication tube as follows:
Baffle plate
and bolts
a. Remove the three (3) bolts, and
then remove the baffle plate from
the converter housing (Figure 125).

Figure 125

Lubrication tube,
bracket, and bolt
b. Remove the bolt and then remove
the lubrication tube and its bracket
(Figure 126).

Figure 126

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97.

Clean the oil passages of the converter housing, lubrication tube and dummy cover
with brake cleaner (or equivalent) where shown in Figure 127 through Figure 130
below.

To avoid being struck by debris, do not stand in front of the passages 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 128

Figure 127
Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages
Figure 129
98.

Figure 130

Install the lubrication tube, bracket and bolt, and then the baffle plate with three (bolts
(Figure 131 and Figure 132).


Bolt torque: 5.9 N•m (0.6kg-m, 52 in-lb.)

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 131

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Figure 132

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CVT Reassembly

99.

Install the torque converter seal
(Figure 133).


Place the torque converter housing
flat during installation.



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



The torque converter seal will be
0.5 mm (0.020 inches) below the
bore’s surface when the seal
installer bottoms out.

J-50818
Seal
installer

Figure 133
100. Install the torque converter housing side
axle seal (Figure 134).


For 2WD vehicles, use Seal
Installer J-52284 and Driver
Handle J-8092.

J-52284
Seal installer