NTB19-060B

Inspect
these sides

Do not inspect
these sides

Figure 12

7.

Inspect the entire side of the belt by,
slowly and carefully, turning the front
left tire one full rotation in the forward
direction.


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



Reference the Figures on pages
14 through 16 for a comparison
of an OK and NG belt condition.

CAUTION: If the tire rotates in the
rearward direction, the camera lens
may be caught between the belt and
pulley.

Figure 13

 If the inspection result is OK, inspect the other side of the belt in step 8.
 If the inspection result is NG, replace the CVT sub-assembly (page 17), control valve
(page 72) and, if applicable, reprogram the TCM (page 79).

11/98

NTB19-060B

8.

Insert the camera lens in the second
location where shown in Figure 10 and
Figure 14, and then perform step 7
again.

Pulley
Front

Figure 14

 If the inspection result is OK on both sides of the belt, replace the control valve
(page 72) and, if applicable, reprogram the TCM (page 79).
 If the inspection result is NG, replace the CVT sub-assembly (page 17), control valve
(page 72) and, if applicable, reprogram the TCM (page 79).

12/98

NTB19-060B

Figure 15: New belt

Figure 16: Close-up of section to be inspected

13/98

NTB19-060B

Pictures in Figure 17 and Figure 18 were taken with borescope J-51951.

OK

Visual
lines

Figure 17: Belt is OK

OK

Visual
lines

Figure 18: Belt is OK
14/98

NTB19-060B

NG

Scuffing

Figure 19: Example of NG belt

NG

Lines
“smeared”

Figure 20: Example of NG belt

15/98

NTB19-060B

A.

Pictures in Figure 21-Figure 23 were taken with borescope J-51951.

NG

Figure 21: Example of NG belt

NG

Figure 22: Example of NG belt

NG

Figure 23: Example of NG belt
16/98

NTB19-060B

CVT Assembly Removal
Overview of Sub-assembly Repair
Steps 1-15 below are an overview of the CVT sub-assembly repair. The procedure for this
bulletin continues on the next page with step 9.

1. Apply rust penetrant as necessary to the dowel pins on the converter
housing side and sub-assembly side cover
2. Remove the 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 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.

17/98

NTB19-060B

9.

Temporarily install the oil pan gasket and oil pan with four oil pan bolts to corners of
the oil pan, hand tight (Figure 24).
NOTE: It is not necessary for the control valve to be installed, a new one will be
installed later in the service procedure.

Figure 24

10.

Remove the CVT from the vehicle.


For CVT removal, refer to the ESM: section Transaxle & Transmission.

18/98

NTB19-060B

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 25

13.

Drain the CVT.

Torque
converter
Figure 26

Primary speed
sensor
14.

Remove the primary speed sensor.
IMPORTANT: The speed sensor will
be reused.

Figure 27

19/98

NTB19-060B

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

15.

Remove all 23 converter housing
mounting bolts (see Figure 28).
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 28

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
J-51923 at the cut-out areas similar to the one shown in Figure 29 and Figure 30.
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 29

Figure 30

20/98

NTB19-060B

17.

Note the location of the pin shown in Figure 31 and Figure 32.
CAUTION: This pin can slip out during movement of the CVT while the converter
housing is removed.

Figure 32

Figure 31

18.

Remove the O-ring from the input
shaft.


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

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 34

Figure 35
21/98

NTB19-060B

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.

Figure 38

22/98

NTB19-060B

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 6-pt 10 mm socket.

Baffle
plate nuts

Baffle
plate A
Figure 39

23.

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

Spread the snap ring to remove the 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

Snap ring

Oil pump chain

Figure 41

Figure 40

23/98

NTB19-060B

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

26.

Remove the oil pump bracket (Figure
44).


Oil pump
bracket

Retained by two bolts.

Figure 44
24/98

NTB19-060B

27.

Remove the three (3) bolts from baffle
plate B, and then remove baffle plate
B (Figure 45).
Baffle
plate B

Figure 45
28.

Remove the two (2) bolts from baffle
plate C, and then remove baffle plate
C (Figure 46).
Baffle
plate C

29.

Remove the five (5) 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.



Lathe cut seals must be in their correct positions during final assembly to
prevent drivability issues.
Dummy
cover

Do not lift here

Lathe cut seals
(white seals)

Dummy
cover
Figure 47

Figure 48
25/98

NTB19-060B

30.

Lathe cut seals
(white seals)

Remove the thrust bearing from the
clutch assembly bore (Figure 49).
NOTE: Take care when removing the
thrust bearing so that the lathe cut
seals are not knocked out of their
grooves.
IMPORTANT:
 The thrust bearing has two
different sides. As the thrust
bearing is removed, note the thrust
bearing orientation so that the new
bearing can be installed in the
same orientation.


Thrust bearing
Secondary
speed sensor
Figure 49

This bearing will not be reused.

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).
NOTE:


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