31.

Wipe any metallic debris from the face
of the secondary speed sensor
(Figure 49).

32.

Remove the oil pump as follows:

Top of
CVT

Oil pan gasket
surface

a. Remove the fitting bolt located
above the left rear corner of the oil
pan gasket surface (Figure 50).

Fitting bolt

Figure 50

b. Remove the three (3) oil pump
Allen®-head bolts, and remove the
oil pump (Figure 51).


Do NOT discard the Allen®head bolts. These bolts will be
reused.



A new oil pump will be installed
later in this bulletin.

Figure 51

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33.

Remove the CVT fluid filter as follows:

a. Remove the four (4) bolts and then
remove the CVT fluid filter cover
(Figure 52).


These bolts will be reused.
CVT fluid filter cover
Figure 52

b. Remove the CVT fluid filter with
grommet seal and O-ring seal
(Figure 53).

Fluid filter



Do not reuse the oil filter and
seal. They will be replaced
later.



The grommet seal is fitted to
the bottom end of the filter and
is included with the
replacement filter (Figure 54).

O-ring seal
Figure 53

Grommet
Seal

Figure 54

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Clean the CVT Case Surfaces

34.

Thoroughly clean the mating surfaces of the CVT case and torque converter housing.


A plastic scraper can be used.

To prevent debris from entering the CVT and causing damage:
 DO NOT use sanding discs, similar abrasive tools, or metal blades.
 Use brake cleaner or equivalent solvent and lint free towel only.
 Make sure rust and debris have been cleaned off of dowel pins and receiving
holes (Figure 55 and Figure 56).

35.

Clean the dowel pins and dowel pin receiving holes of any rust and debris (Figure 55
and Figure 56).

HINT: Use a small wire brush or similar tool at the inside surface of the dowel pin holes.
DO NOT SCRAPE THE CVT CASE mating surfaces.

Clean dowel pin
receiving holes
Dowel pin

Figure 56

Figure 55

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Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT Filter Area

In the following steps, brake cleaner or a suitable cleaning solvent and compressed air will
be used to clean out the oil passages in the CVT assembly.

To prevent debris from entering your eyes and causing personal injury, wear eye / face
protection when using compressed air and cleaning fluids, and regulate the air pressure up
to a maximum of 75 PSI.

36.

Clean the area where the CVT fluid
filter fits (Figure 57).


37.

Clean within
this area

Make sure the old filter grommet
seal is removed (Figure 54).

Clean the fluid passages to and from
the filter (Figure 57).

Fluid
passages
Figure 57

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38.

Use brake cleaner in all oil passages of the CVT case where shown in Figure 58.


39.

Do not spray brake cleaner into the clutch pack.

Apply compressed air in the same passages.

To avoid being struck by debris, do not stand in front of the passages while using
compressed air.

Figure 58

Apply cleaner, and then
75 PSI maximum air
pressure in these
passages.

Air pressure comes out
of these passages.

Figure 59
40.

Temporarily install the fluid filter cover.

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New Oil Pump Installation

41.

Install the new oil pump using the
three (3) original Allen®-head bolts
(Figure 60).


Finger tighten the Allen®-head
bolts at this time.



The oil pump kit includes a new oil
pump, O-ring, and snap ring.

Figure 60
Fitting bolt

42.

Place a new O-ring on the fitting bolt,
and then coat the O-ring with CVT
fluid (Figure 61).

O-ring

Figure 61

43.

Install the fitting bolt finger tight
(Figure 62).

Fitting
bolt

Figure 62

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44.

45.

Torque the three (3) Allen®-head bolts and fitting bolt.


Allen®-head bolt torque: 17.6 – 20.6 N•m (1.79 – 2.1 kg-m, 13.0 – 15.2 ft-lb)



Fitting bolt torque: 26.0 – 30.0 N•m (2.65 – 3.06 kg-m, 19.2 – 22.1 ft-lb)

Install the new snap ring (Figure 63).

Snap ring
Figure 63

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Replace the Side Cover – Pulleys and Belt (sub-assembly)

Review video # 547: “CVT Belt and Pulley Replacement” and fast forward to minute
marker 3:14. This video is located under the TECH TRAINING GARAGE VIDEOS tab
in Virtual Academy.

46.

Temporarily install the dummy cover
with three (3) bolts, finger tight
(Figure 64).
IMPORTANT:




Do not install the thrust bearing to
the clutch assembly bore at this
time.
If the cover does not sit flush,
continue to Dummy Cover
Troubleshooting, below.
Otherwise, skip to step 53.

Bolts

Dummy cover
Figure 64

Dummy Cover Troubleshooting


If the dummy cover does not sit flush, the clutch pack may not be fully seated.



Figure 65 shows the clutch pack
fully seated.



The clutch pack is not fully seated
if it is not below the surface that the
dummy cover bolts to.



To fully seat the clutch pack, follow
the instructions in steps 47-51.

Clutch pack
seated correctly

HINT: Always handle the clutch pack by the
input shaft.

Surface dummy
cover seats on
Figure 65

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Dummy cover

47.

Remove the dummy cover.

Figure 66

Clutch pack
48.

Pull the clutch pack by the input
shaft to remove the entire clutch pack.


Make sure the O-ring is not
installed at this time, or it could be
damaged during reassembly.

Input shaft

Figure 67
Clutch pack
Clutch pack layers
49.

Using an appropriate tool, gently align
the layers of the clutch pack.


The bottom of the clutch pack is
shown in Figure 68.

Appropriate
tool
Align layers
Figure 68

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50.

Reinsert the entire clutch pack while
holding the input shaft.

51.

Gently jiggle the input shaft until the
clutch pack seats below the case lip.


If the clutch pack does not seat,
rotate back and forth from the input
shaft and jiggle.



If the clutch pack still does not
seat, repeat from step 48.

Input shaft

Clutch pack
Figure 69

52.

Temporarily install the dummy cover with three (3) bolts, finger tight.

53.

Temporarily install the converter
housing onto the CVT case with three
(3) bolts finger tight (Figure 70).
Bolts

To prevent CVT damage when fitting the
CVT case surfaces, DO NOT use the bolts
to draw in the case halves. Make sure the
case surfaces are flush and have no gaps
prior to installing the bolts.

Converter housing
Figure 70

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54.

Rotate the CVT case so that the
converter housing faces down and
side-cover faces up.






CVT lifter bracket J-51595 and
CVT Lifting Eye/Swivel Assembly
J-51595-1 can be used for this
step. See Figure 72.

Use plastic or wood blocks to
support the CVT while rotating to
prevent contact with the manual
shaft and damage to the CVT
(Figure 71). The manual shaft is
longer than the oil pan mating
surface.

Manual shaft

Figure 71

CVT Lifting Eye/Swivel
Assembly J-51595-1

To avoid damage to the CVT, note
the location of the terminal
connector harness so that the
terminal connector harness does
not become pinched between the
CVT case and the work bench or
supporting blocks.
CVT Lifter Bracket J-51595
Figure 72

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55.

Rotate the primary pulley by hand to
check the pulley’s rotational
characteristics.
IMPORTANT: Remember the pulley’s
rotational characteristics. This will be
used as a reference after the new side
cover pulleys and belt assembly (subassembly) have been installed.

Rotate the primary
pulley by hand
Figure 73

To avoid personal injury, do not place
fingers between the pulley and the CVT
case or they may become pinched.
Do not place fingers
under pulley
Figure 74

56.

Remove the nineteen (19) side cover
fixing bolts (Figure 75).


These bolts will be replaced with
new ones and will not be reused.

Figure 75

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Sub-assembly Lifting Fixture Procedure
HINT: When working with the sub assembly
install, uninstall, and bracket
attachment, it is critical that the CVT
and sub-assembly are level. If not
level, the pulleys and bearings can sit
slightly at an angle and will hinder
installation.
57.

Remove the six (6) pulley bracket
bolts (Figure 76.
 These bolts will be reinstalled to
the original pulley and belt subassembly.

58.

Attach universal Lifting Fixture J52082 with spacers J-52082-2 to the
side cover as shown in Figure 77.

Figure 76

a. Loosen all of the wing-nut bolts on the Lifting Fixture.
b. Confirm that three (3) spacers (# J-52082-2) are present between the longer legs
and triangle bracket as shown in Figure 77.
c. Install the Lifting Fixture to the CVT case at the 6 bolt holes shown in Figure 76.
d. Tighten the wing-nut bolts on the Lifting Fixture finger tight in the following order:
1. Tighten the lower six (6) wing-nut bolts.
2. Tighten the two (2) joint to triangle brackets.
3. Tighten the top 2 wing-nut bolts, and then proceed to step 59 on page 40.
Use caution when attaching the side cover to avoid cross threading and damage to the
lifting fixture.
Triangle
bracket

Top wing-nut
bolt
Lower wing-nut
bolt

Lifting Fixture J-52082
Longer legs

Triangle
bracket joint

Figure 77

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