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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NTB21-083A

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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NTB21-083A

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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NTB21-083A

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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NTB21-083A

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
60/91

Please print this page and
attach it to the repair order.
NTB21-083A

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 90 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 #: 314071XZ0B or X270A
1XZ0C or X270B
1XZ0D or X270C
1XZ0E or X270D
1XZ1A or X270E
1XZ1B or X271A
1XZ1C or X271B
1XZ1D or X271C

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 mm
3.75 mm
3.93 mm
4.1 mm
4.28 mm
4.46 mm
4.61 mm
4.79 mm
Figure 118

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NTB21-083A

94.

Install the thrust bearing flush to the clutch assembly bore (Figure 119, Figure 120,
and Figure 121).


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. Ensure orientation is correct (Figure 119
through Figure 122).

Figure 119

Silver
Silver surface
surface
faces
faces
UPUP

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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NTB21-083A

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

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

Lubrication
tube, bracket,
and bolt

Figure 124

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NTB21-083A

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 (3)
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

NTB21-083A

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
the seal lip surfaces.

J-52284
Seal installer

J-8092
Driver
handle

Converter
housing
Figure 132

100. Apply petroleum jelly or equivalent to
the dummy cover’s lathe cut seals
(Figure 133) before installing the
dummy cover to the CVT case.
To prevent drivability issues, confirm
that the lathe cut seals (white seals)
are in their appropriate slots. Carefully
reposition the seals as necessary.

This area must
remain clear
Figure 133
Dummy cover lathe cut
seals (white seals)

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NTB21-083A

Input shaft

101. Confirm that the input shaft’s lathe cut
seals are in the correct position
(Figure 134).

This area
must remain
clear

To prevent drivability issues, confirm
that the lathe cut seals (white seals)
are in their appropriate slots. Carefully
reposition the seals as necessary. Input shaft lathe cut seals
(white seals) correctly
located in slots
Figure 134
102. Install the dummy cover first, then
baffle plate C, and then the related
bolts finger tight (Figure 135).
IMPORTANT: Visually check that the
dummy cover is fully seated on the
CVT case. If it is not, refer to Dummy
Cover Troubleshooting on page 34.




Do not force the dummy cover into
place.
Make sure the dummy cover is fully
seated before installing the bolts.
Do not torque these bolts at this
time.

103. Install baffle plate B and “L” bracket
with the related bolts finger tight
(Figure 136).

Dummy
cover, baffle
plate C, and
bolts
Figure 135

Baffle plate B
and bolts

104. Torque the bolts from steps 102 and
103 in the following order:
2

a. Baffle plate B bolts: 5.9 N•m (0.6
kg-m, 52.2 in-lb)
b. “L” bracket bolts: 25.5 N•m (2.6 kgm, 228 in- lb). Torque 11 and then
22 .
c. Dummy cover and baffle plate C
bolts torque: 19.0 N•m (1.9 kg-m,
168 in-lb)

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1

“L” bracket