11. Drain plug

13.

Magnet

14. Spring washer

15. Manual plate

16.

Lip seal

17. Snap ring

18. Overflow plug

19.

O-ring

12. Drain plug gasket

: Always replace after every disassembly.
: Nꞏm (kg-m, ft-lb)
: Nꞏm (kg-m, in-lb)
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4. Secure the front right tire with a suitable
strap, so that it cannot rotate.


This will assist in making the belt
turn.

5. Mark the front left tire with a suitable
marking.


This will assure all 360° of the belt is
inspected.
Figure 10

6. Using borescope J-51951 with mirror
attachment, inspect the entirety of the
two sides of the belt that come in contact
with the pulleys (see page 12, Figure
15).
 Reference the Figures on pages 12
through 16 for comparison of an OK
and NG belt condition.

Belt
Pulley
Case

NOTE:
o Be sure to remove the protective film
from the mirror before the first use.
o Clean the camera lens and mirror
before each inspection. Use 90%
isopropyl alcohol and a lens swab
from Lens Swab packet J-51963
listed in the PARTS INFORMATION.
o Before inspecting, make sure the
camera handle’s AA batteries are
charged and the LCD monitor’s
battery is charged.
a. Insert the camera lens between the

Step 6a

Step 6c

Figure 11

Camera
flexible tube
Front

CVT case and pulley where shown in
Figure 11 and Figure 12.
 Insert the lens approximately
seven (7) inches, and then view
the side of the belt that contacts
the pulley.
Figure 12
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b. Slowly and carefully turn the front left

tire one full turn in the forward
rotation to view all of the belt.


Holding the borescope with one
hand allows for turning the tire
with the other hand
(see Figure 13).

CAUTION: If the tire is rotated in the
rearward rotation, the camera lens
may get caught between the belt and
pulley.
Figure 13

c. If the inspection result is OK, inspect

the other side of the belt.


Insert the camera lens in the
second location where shown
in Figure 11 and Figure 14, and
then perform step 6b again.

Pulley
Front

d. If the inspection result is OK 360° on

both sides of the belt, proceed to
step 7 on the next page.


For additional information, see
video # 544: “CVT Belt
Inspection”. This video is located
under the TECH TRAINING
GARAGE VIDEOS tab in Virtual
Academy.

Figure 14

e. If the inspection result is NG,

proceed to step 8 on the next page.

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7. If the belt inspection result is OK, replace only the valve body, and then reprogram the
TCM if applicable.


For valve body replacement, go to page 71, Control Valve (Valve Body) Strainer
and Pan Installation.



Check TCM part number (step 139 on page 80) and if needed perform
reprogramming (step 139 on Page 80) if applicable.
IMPORTANT: Reprogramming, if needed, must be done before performing
additional services.

8. If the belt inspection result is NG, replace the CVT sub-assembly and valve body, and
then check step 139 on page 80 to confirm if a TCM reprogram is available.


Go to CVT Assembly Removal, page 17.

Inspect these sides

Do not inspect
these sides

Figure 15

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Figure 16: New belt

Figure 17: Close-up of section to be inspected

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Pictures in Figure 18 and Figure 19 were taken with borescope J-51951.

OK

Visual
lines

Figure 18: Belt is OK

OK

Visual
lines

Figure 19: Belt is OK
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NG

Scuffing

Figure 20: Example of NG belt

NG

Lines
“smeared”

Figure 21: Example of NG belt

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A.

Pictures in Figure 22-Figure 24 were taken with borescope J-51951.

NG

Figure 22: Example of NG belt

NG

Figure 23: Example of NG belt

NG

Figure 24: Example of NG belt
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CVT Assembly Removal

Overview of Sub-assembly Repair

1. Apply rust penetrant as necessary to the dowel pins on the converter
housing side and sub-assembly side cover
2. Remove CVT from the vehicle
3. Remove the Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump and
Oil Filter
4. Clean the CVT case surfaces
5. Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT Filter
Area
6. Check initial pulley movement characteristics
7. New Pump Installation
8. Replace the Side Cover – Pulleys and Belt
9. Confirm shift selector movement
10. Recheck new pulley movement characteristics matches that of the original
assembly
11. Clutch Total Endplay Adjustment – Thrust Bearing Selection
12. Clean the Converter Housing Passages
13. CVT Reassembly
14. Control Valve (Valve Body) Strainer and Pan Installation
15. Install the CVT Assembly
NOTE: For additional information review video # 547: “CVT Belt and Pulley
Replacement”.
 This video is located under the TECH TRAINING GARAGE VIDEOS tab
in Virtual Academy.

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9. Temporarily install the oil pan gasket and oil pan with four oil pan bolts to corners of the
oil pan, hand tight (Figure 25).
NOTE: It is not necessary for the control valve to be installed, a new one will be
installed later in the service procedure.

Figure 25

10. Remove the CVT from the vehicle.


Refer to NTB18-019 for CVT removal.

AWD Vehicles
CAUTION:
o Use extreme care when moving the axle in and out of the transfer case assembly.
o To avoid seal damage or deformation, properly support and guide the axle.

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11. Place the CVT on a workbench with the
oil pan side down.


Use wood or plastic blocks to keep
the CVT steady.
CAUTION: Do not deform the oil
pan.

12. Remove the torque converter.
Figure 26

13. Drain CVT fluid out of the torque
converter.

Torque
converter
Figure 27

Primary speed
sensor

14. Remove the primary speed sensor.
IMPORTANT: The speed sensor will be
re-used.

Figure 28

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Remove the Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump and Oil Filter

15. Remove all 23 converter housing
mounting bolts (see Figure 29).
NOTE:



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

Dowel Pin

Apply rust remover to the dowel pins
if needed.

Figure 29

16. Separate and then remove the converter housing from the CVT case.


Use Slide Hammer J-25721-A and Slide Hammer Bolt J-50255-UPD with J-Hook J51923 at the cut out areas similar to the one shown in Figure 30 and Figure 31.
CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the converter
housing from the CVT case.

J-25721-A
-----

J-50255-UPD
-----

J-51923

One of three
cutout areas

Figure 30

Figure 31

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17. Note the location of the pin shown in Figure 32.
CAUTION: This pin can slip out during movement of the CVT while converter housing is
removed.

Figure 32

O-ring
18. Remove the O-ring from the input shaft.


This O-ring will be replaced with a
new one.

Figure 33
19. Carefully remove the reduction gear assembly (Figure 34).
20. Carefully remove the differential assembly (Figure 35).
Reduction gear
assembly

Differential
assembly

Figure 35

Figure 34
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21. Remove the following oil seals using
suitable tools:
CAUTION: Be careful not to damage
any of the seal bore surfaces.

a. CVT case differential side oil seal

(drive shaft seal).


See Figure 36.
Figure 36

b. Torque converter seal (Figure 37).

Figure 37

c. Converter housing differential side oil

seal (drive shaft seal).


See Figure 38.

NOTE: All wheel drive transfer case
O-ring will be replaced later in this
procedure.

Figure 38

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22. Remove the two (2) nuts from baffle
plate A, and then remove baffle plate A
(see Figure 39).
CAUTION: To avoid rounding off these
nuts, it is best to use a 3/8 inch drive 6pt 10 mm socket.

Baffle
plate nuts

Baffle
plate A
Figure 39

23. Remove the oil pump chain, driven and drive sprockets as one assembly (Figure 40).


Spread the snap ring to remove sprocket (Figure 41).

IMPORTANT: The drive sprocket has a specific top and bottom. Keep the sprockets
and chain together after removed.

Drive sprocket

Driven sprocket

Oil pump chain

Snap ring

Figure 40

Figure 41

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Thrust washer

24. Remove the “Pump cover” (dummy
cover) thrust washer (Figure 42).


This thrust washer will be reused.
Dummy cover

Figure 42

Snap ring
25. Remove the Oil pump snap ring
(Figure 43).


Lightly push the ends of the snap
ring together, rotate one side
upwards while pulling the snap ring
towards the pump opening.

Figure 43

Oil pump
bracket

26. Remove the Oil pump bracket
(Figure 44).


Retained by two bolts.

Figure 44
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27. Remove the three bolts from baffle plate
B, and then remove baffle plate B
(Figure 45).

Baffle
plate B

Figure 45
28. Remove the two bolts from baffle plate
C, and then remove baffle plate C
(Figure 46).
Baffle
plate C
29. Remove the five dummy cover bolts, and
then remove the dummy cover. See
Figure 47.
NOTE: These bolts will be reused.
Figure 46

IMPORTANT:


Lift the dummy cover from sides ONLY. Do NOT lift from the input shaft (Figure 47).
This can lift the clutch pack out.



Do NOT remove the lathe cut seals (white seals in Figure 48) from the dummy
cover. These seals will be reused.