Subassembly

To avoid damage to the primary speed
sensor, make sure it is removed from
the sub-assembly.


The speed sensor will be reused.



DO NOT discard the speed sensor.



This sub-assembly will not be
reused.

Figure 81
63.

Remove the lifting fixture from the sub-assembly.


64.

Reinstall all six (6) original bolts into the old sub-assembly.

Thoroughly clean the mating surfaces of the CVT case (Figure 82) that the subassembly was just separated from (a plastic scraper can be used).


Confirm that the dowel pins have remained in the CVT case. If not, remove them
from the sub-assembly and reattach them back to the CVT case.

HINT: The Guide Pins can be temporarily removed for cleaning purposes.
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 towels only.
Make sure rust and debris have been removed from the dowel pins and receiving
holes.

Mating surfaces

Figure 82
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65.

Replace the O-ring on the CVT case
side with a new one (Figure 83).


Coat the O-ring with CVT fluid
before installing.

O-ring
Figure 83

66.

Remove the thrust bearing from the
planetary carrier plate (Figure 84).


This thrust bearing will be
reused. DO NOT discard.

HINT: If not found on the planetary
carrier plate, the thrust bearing may
still be attached to the primary pulley.

Thrust bearing
Figure 84

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67.

Rotate the shift select lever counterclockwise to the “L” range position
(Figure 85), so that the parking pawl is at its lowest position (Figure 86).

Parking
pawl

Shift select lever

Figure 85
68.

Figure 86

Attach the Lifting Fixture to the new sub-assembly, and then raise the sub-assembly
out of the shipping box.


First, remove the six (6) bolts from the new sub-assembly, and then remove their
O-rings before installing the Lifting Fixture.
 These bolts will be reused.
 These O-rings will not be reused.

To avoid damage to the side cover, start the lifting fixture bolts by hand.


Refer to the Sub-assembly Lifting Fixture procedure on page 39 for correct Lifting
Fixture installation.

Lifting Fixture

Sub-assembly
Figure 87

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69.

Apply one continuous 2.0 mm diameter bead of sealant along the center of the CVT
case side mating surface (Figure 88).
Sealant:
 Loctite 5460 (see PARTS INFORMATION on page 86).
 Color: Pink
IMPORTANT:
 Confirm that the mating surfaces are clean before applying sealant.
 Make sure that the starting point and the ending point of the sealant is between
two bolt holes. Overlap both ends of the bead by 3 – 5 mm.

To prevent possible leaks, be careful not to contact or contaminate the sealant. If the
sealant has been disturbed or contaminated in any way before case assembly,
thoroughly clean the mating surfaces of the CVT case and restart from step 69.

Figure 88

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70.

Install the original thrust bearing on the primary pulley of the new sub-assembly
(Figure 89).
HINT:
 The thrust bearing surface must lay flush with the primary pulley. Any additional
height will affect the total end play that is measured later in this procedure.


The thrust bearing has two sides. Reference Figure 90 for bearing orientation.



Apply a small amount of petroleum jelly or equivalent to the original thrust bearing
to hold it in place on the primary pulley.

Primary pulley

Thrust bearing; must sit
flush with primary pulley
surface

Thrust bearing

Figure 90

Figure 89

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71.

Coat the primary pulley bearing, secondary pulley gear teeth, and the secondary
bearing with CVT fluid prior to installation (Figure 91 and Figure 92).
HINT: DO NOT drip any CVT fluid onto the sealant.

The following figures are for reference only and may or may not have the sealant in
place or have the old sealant removed. Clean the surfaces and apply sealant when
and where instructed.

Coat these
surfaces with
CVT fluid

Output gear

Figure 91
72.

Figure 92

While lowering the sub-assembly, route the Guide Pins into the appropriate CVT bolt
holes, one at a time (the Guide Pins are different lengths for easy assembly).
HINT: DO NOT allow the output gear to contact the lubrication tube when the side
cover is positioned over the guide pins (Figure 93 and Figure 94).

Lubrication
tube

Figure 93

Figure 94

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F.

IMPORTANT:
Before continuing, it is recommended that you review and understand the instructions on
pages 48 through 52.
The sub-assembly will lower into the CVT case without applying extra vertical force.
IF THE SUB-ASSEMBLY DOES NOT LOWER COMPLETELY,
INTERFERENCE IS PRESENT.

! PHYSICAL

Key Technique: Raise to remove weight on interference, adjust as necessary, and
then lower again.

Use the “visual gap size” below (Figure 95 and Figure 96), between the sub-assembly and
the CVT case, to determine the cause of interference.

44 mm - Page 49
38 mm - Page 50

CASE GAP = ?

19 mm - Page 51
6 mm Page 52

Figure 95

Case gap

Figure 96

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73.

Carefully, lower the Lifting Fixture to install the sub-assembly into the CVT case until a
38 mm (1.5 inch) gap is present between the sub-assembly and CVT case
(Figure 101 on page 50).


Look into the bearing bore to confirm the output gear is centered (Figure 98).



Place hands on top of the sub-assembly to keep it level and guide it into the
CVT case.


If the sub-assembly will not lower farther than 44 mm (1.75 inches) the
output gear did not clear the bearing bore (Figure 97).

Sub-assembly will not lower past 44 mm (1.75 inches)?


Interference is present between the output gear and bearing bore.

Sub-assembly

44 mm (1.75
inch) gap

CVT case

Output gear

Bearing bore
Output gear

Figure 97

Bearing bore
CVT case
Figure 98

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In the following steps be careful not to contact or contaminate the sealant or a leak may
occur. If the sealant has been disturbed or contaminated in any way, remove the sealant
completely and restart from step 69 on page 45.
74.

Align the parking rod with the parking pawl as follows:
IMPORTANT: Perform step 74 while there is a 38 mm (1.5 inch) gap between the
sub-assembly and CVT case (Figure 101).
a) Rotate the shift select lever clockwise on the side of the CVT to adjust the parking
rod to the highest position.
b) Use a magnet to align the parking rod in the CVT case (
in Figure 100) with the
opening in the parking pawl (
in Figure 99) in the side cover.
HINT: If the parking rod is not located correctly it will keep the case from lowering.

The following figures are for reference only.
Side cover

Parking pawl
Parking rod
Pocket
magnet
Figure 99

CVT case
Figure 100

Sub-assembly

38 mm (1.5
inch) gap

CVT case
Figure 101

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75.

Continue to slowly lower the sub-assembly into the CVT case.


If the primary and the secondary pulley bearings do not align properly with their
bores (Figure 102) or are at an angle, a gap of 19 mm (0.75 inches) may be
present.
 As needed, level the sub-assembly as it is lowered into the CVT case to help
the primary and the secondary pulley bearings align in their bores.
 MINOR LEVELING ADJUSTMENTS with limited weight on the sub-assembly
will help the installation. Vertical force is not needed.
 Once the sub-assembly is LEVEL, the primary and the secondary pulley
bearings will smoothly align while lowering.

Sub-assembly will not lower past 19 mm (0.75 inches)?


If this occurs Do NOT force the sub-assembly into the case.
a.

Raise the sub-assembly slightly.

b.

Level the sub-assembly (visually check the gap between case and subassembly side cover and confirm that it is even all around).

c.

Gently lower the sub-assembly.

d.

Gently shake the sub-assembly horizontally, lower, raise and repeat as
needed to help align.

e.

Lower to engage the dowel pins and a 6 mm (0.25 inch) gap is between the
sub-assembly and CVT case.

Sub-assembly

Primary
pulley bearing

19 mm (0.75
inch) gap

Secondary
pulley bearing
Bearing bore
CVT Case

Bearing bore
Figure 102

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IMPORTANT: In the following steps the case halves must sit flush against each other
without a gap before installing the bolts. The bolts CANNOT be used to draw the cases
together. DO NOT APPLY VERTICAL FORCE.
76.

Once the dowel pins are cleared, ease the sub-assembly down onto the CVT case
until the case halves are flush.


Confirm the dowel pins are clean and aligned and are not catching on the subassembly case cover.

To avoid personal injury, ensure your fingers are not between the CVT case and the
sub-assembly. They may become pinched while seating the components together.
Sub-assembly will not lower past 6 mm (0.25 inches)?
If the sub-assembly will not lower past 6 mm (0.25 inches), the primary pulley splines are
not aligned.


If this occurs Do NOT force sub-assembly into the case.
a. Raise the sub-assembly slightly so the weight is not completely on the
primary pulley splines.
b. Slightly rotate the primary pulley through the bottom of the CVT and then
lower the sub-assembly.
c.

Repeat as needed.

Sub-assembly

Primary pulley
6 mm (0.25
inch) gap
Belt
element
CVT
case

Primary pulley
splines

Touch side of primary
pulley to align splines
Planetary
carrier splines

Do not place fingers
below primary pulley

Figure 103
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Rotate the shift select lever

77.

Confirm the parking rod operation as
follows:
a. Rotate the shift select lever

counterclockwise and confirm that
all detents for each of the P-R-N-D
are felt.
b. Rotate the lever clockwise to return

the rod back to the P position.
c. Are all of the detents felt?

 YES: Proceed to step 78.
Figure 104
 NO: If the lever does not rotate
or if all detents are not felt:
1) Raise the sub-assembly and remove all sealant.
2) Restart from step 69 on page 45.

78. Remove the guide pins.

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79.

Install the new side cover bolts (Figure 105).


Torque the first eight (8) bolts marked as
in the sequence numbered in
Figure 105 below, and then torque the rest of the bolts in a clockwise direction.
 Bolt torque: 45 N•m (4.6 kg-m, 33 ft-lb) 19 pieces.

4

8

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.

Pulley bearing
retainer bolts (6)
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-lb)

Figure 107

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J-52283
Seal
Installer
85.

86.

87.