8

4
2
6

Torque un-numbered bolts
in clockwise direction

3
1
5
7
Figure 105
80.

Remove the Lifting Fixture.

81.

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 68 on page 44.

82.

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

Do not use tools to install.

Figure 106

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83.

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 84.



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 69 on page 45.

84.

Torque all six (6) bolts.


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

Figure 107

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J-52283
Seal
Installer
85.

86.

87.

Install the CVT case side axle seal
(Figure 108).


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 108

Bolts

Converter housing
Figure 109

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Clutch Total Endplay Adjustment – Thrust Bearing Selection

IMPORTANT: Using thrust bearings, the clutch total endplay (Figure 110) 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 110

88.

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

Set the Digital Depth Gauge to millimeters.

89.

Clean Gauge Block J-50271.

90.

Confirm the mating surfaces of the CVT case are clean.

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CVT case
Oil Pump
91.

Gauge block

Calculate the average clutch assembly
bore depth (D) (Figure 111) as follows:
IMPORTANT: Measurements are
required from two opposite ends to
obtain the average.

D

Clutch drum of clutch assembly
Figure 111

Clutch assembly
bore
a. Place the Gauge Block on the
surface where the dummy cover
seats and over the clutch assembly
bore (Figure 112).

HINT:




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

Gauge Block
Figure 112

The clutch assembly should sit 2-3
mm lower than the dummy cover
seat (Figure 113).

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 113

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c. Position the Depth Gauge on the

Depth Gauge

Gauge Block (Figure 114).

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 115).

Figure 114

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

Measure here; D2

Measure here; D1

Figure 115

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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92.

Clean surfaces
Measure the average dummy cover
Clean
here
height (H) (Figure 117) as follows:
a. Clean the dummy cover surfaces
that contact the CVT case and
thrust bearing (Figure 116).
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 116
bearing surface (Figure 117).
c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy
cover (Figure 117).
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 117).
Gauge Block

Figure 117
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
93.

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 59 and 60 to
calculate for “A”.
D measurement ______ mm
– H measurement ______ mm
= A - - - - - - - - - - - - - - - - ______ mm
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Please print this page and
attach it to the repair order.
NTB21-051

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 118).
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 118

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94.

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 119 through Figure 122 for the correct
orientation.

Silver surface
Figure 119faces UP

Four Alignment tabs.
(One not shown).
Figure 120

Black surface
faces DOWN
Thrust bearing

This gap should
face down

Incorrect installation

Correct installation
Figure 121

Figure 122

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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.

95.

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 123).

Figure 123

Lubrication tube,
bracket, and bolt
b. Remove the bolt and then remove
the lubrication tube and its bracket
(Figure 124).

Figure 124

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96.

Clean the oil passages of the converter housing, lubrication tube and dummy cover
with brake cleaner (or equivalent) where shown in Figure 125 through Figure 128
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 126

Figure 125
Air pressure
comes out here

Apply 75 PSI
maximum air pressure
in these passages
Figure 127
97.

Figure 128

Install the lubrication tube, bracket and bolt, and then the baffle plate with three (bolts
(Figure 129 and Figure 130).


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

Baffle plate
and bolts
Lubrication
tube and
bracket

Figure 129

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Figure 130

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CVT Reassembly

98.

Install the torque converter seal
(Figure 131).


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 131
99.

On AWD models, skip to step 100.
On 2WD vehicles, install the torque
converter housing side axle seal
(Figure 132).


Use Seal Installer J-52284 and
Driver Handle J-8092.



Apply a light coat of CVT fluid to