removed in step 64 on page 47, finger tight.


The transmission range switch will be permanently installed later in this procedure.

49/153

NTB22-021

Remove the Sub-assembly
IMPORTANT: Steps 72 through 80 are ONLY to separate the sealant of the side cover.
The sub-assembly with belt and pulley CANNOT be removed from the CVT while in this
orientation and will be removed from the case at a later step.

70.

Reposition the torque converter
housing onto the CVT.

Torque
converter
housing

Figure 94

71.

Install and hand tighten two (2) of the
original torque converter housing
bolts.

Torque converter
housing bolts (2)

Figure 95

72.

Reposition the CVT on the work bench
with the torque converter housing side
down.
HINT: A wood block may be used to
stabilize the CVT during
disassembly/reassembly.

Figure 96

50/153

NTB22-021

73.

Pulley bearing
retainer bolts (2)

Remove the two (2) pulley bearing
retainer bolts shown in Figure 97.


Do not discard bolts. They will be
temporarily installed during a later
step.

Figure 97
Side cover
bolts (12)
74.

Remove the twelve (12) side cover
bolts (Figure 98).


Retain two (2) of these bolts. They
will be temporarily installed during
a later step.

Figure 98

51/153

NTB22-021

75.

Remove the side cover with a slide hammer J-25721-A to separate the side cover and
CVT case.


There are three slide hammer tool points, as shown in Figure 99.



The mating surfaces will be cleaned at a later step.



This step will help with sub-assembly removal at a later step.



To avoid damage to the CVT, do not use the speed sensor bore for slide hammer
tool location.



Do not pry the surfaces apart as internal CVT damage may result.

Side cover

Figure 99

52/153

NTB22-021

76.

Case Orings

Remove the two (2) case O-rings
(Figure 100).


The case O-rings are one-time use
parts. Do not reuse.

HINT: This helps alignment of the
bearing retainer bolt threads after
reinstalling the original side cover.

Figure 100

77.

Align the primary pulley bearing
retainer bolt holes with the bolt hole on
the case (Figure 101).
HINT: This helps alignment of the
bearing retainer bolt threads after
reinstalling the original side cover.

Figure 101

53/153

NTB22-021

To avoid damage to the pulse gear, do not allow the Assembly Guide Pin to contact the
pulse gear during installation, as shown in Figure 102.
78.

Install one of the “Assembly Guide Pins, Pulley Bracket” (Guide Pin J-52272) to one
of the two pulley bearing retainer bolt holes.


This will assist in installation of the original side cover to the pulley assembly.

Assembly guide
pins, pulley bracket,
(Guide Pin J-52272)

Figure 102

OK

NG

Guide pin
contacting
pulse gear

Guide pin NOT
contacting
pulse gear

54/153

NTB22-021

79.

Assembly guide
pins, pulley bracket,
(Guide Pin J-52272)

Place the original side cover onto the
CVT case.


Position the primary pulley bearing
retainer to allow the guide pin to be
inserted through the bolt hole of
the side cover.

Side
cover
Figure 103
80.

Install the two (2) original pulley bearing retainer bolts (Figure 104) as follows:


Use the original bolts and O-rings at this step.
a. Install one pulley bearing retainer bolt finger tight into open bearing retainer
bolt hole.
b. Remove the guide pin from the other bearing retainer bolt hole.
c. Install the other bearing retainer bolt by hand (finger tight).

81.

Temporarily reattach the removed side cover onto the CVT case with two (2) original
bolts on opposite corners, hand tight.
Pulley bearing
retainer bolts (2)

Side cover

Side cover
bolts (2)
Figure 104
55/153

NTB22-021

82.

Reposition the CVT with the side
cover facing down.

Side cover
Figure 105

83.

Remove the two (2) torque converter
housing bolts and set the torque
converter housing aside.

Torque converter
housing bolts (2)

HINT: The CVT case will be placed
onto the removed torque converter
housing later in this procedure.

Figure 106

56/153

NTB22-021

84.

Remove the two (2) side cover bolts
which were temporarily installed to
hold the side cover to the CVT in
step 81 on page 55 (Figure 107 and
Figure 108).

Side
cover bolt
Figure 107

Side
cover bolt
Figure 108

57/153

NTB22-021

85.

Lift the CVT case vertically off of the
sub-assembly and side cover.


Weight 17.4 kg (38.4 lbs.)



This sub-assembly will not be
reused.

IMPORTANT: The sub-assembly must
be separated from the case as shown
in Figure 109.

Figure 109

86.

Place the removed CVT case onto the
torque converter housing, for
temporary storage in stable condition.

Figure 110

58/153

NTB22-021

Clean the CVT Surfaces
To avoid damage to the CVT and potential drivability concerns:


Prevent any debris from dropping into the torque converter housing, side cover or
the CVT case.



Use brake cleaner to remove the remaining CVT fluid and any residual sealant.



Do not use sanding discs, abrasive tools, or metal blades on sealing surfaces.



Clean dowel pins with a mild abrasive sandpaper to remove all rust and debris.
o This will assist at a later step when mating the CVT case to the sub-assembly
and again when mating the CVT case to the torque converter housing.

87.

CVT case
sealing surface

Remove any sealant that remains on
the sealing surface of the CVT case
where it seals with the sub-assembly
side cover.


A plastic scraper can be used.



Use ONLY brake cleaner to clean
surfaces.



Clean with a lint-free paper towel.

Figure 111
88.

Remove any sealant that remains on the sealing surfaces of the torque converter
housing and CVT case using a plastic scraper, and then clean with a lint-free paper
towel.


Use ONLY brake cleaner to clean surfaces.

CVT case
sealing surface

Figure 112

Torque converter
housing sealing
surface

Figure 113

59/153

NTB22-021

Clean Oil Passages in CVT Case and Oil Pump Cover

In the following steps:


Brake cleaner and compressed air will be used to clean out oil passages in the
CVT assembly.

o To avoid the risk of minor personal injury, wear eye/face protection when using
compressed air and cleaning fluids.
o To avoid risk of minor personal injury, regulate air pressure up to a maximum of
75 PSI.

89.

Confirm the CVT case is on the work
bench with sub-assembly side down.


Use wood blocks as necessary to
stabilize the assembly during these
steps.

To avoid damage to the CVT, ensure
the surface of the work bench has
been cleaned to avoid contamination
of the components.
Figure 114

60/153

NTB22-021

90.

Spray brake cleaner into each oil passage of the CVT case, where shown in
Figure 115 and Figure 116 with green circles, until the fluid runs clear for 5 seconds.
To avoid damage to the CVT and potential drivability concerns, do not apply brake
cleaner or compressed air to passages shown in red.

91.

Apply compressed air in the same passages to remove remaining brake cleaner and
debris.
To avoid the risk of minor personal injury, do not stand in front of the passages while
using compressed air.

Figure 115

Figure 116
61/153

NTB22-021

92.

Spray brake cleaner into the reverse
brake tube.


Apply compressed air in the same
passages to remove remaining
cleaner and debris.
Reverse brake
tube

Figure 117
93.

Clean the input shaft bearing bore area (Figure 118 and Figure 119).
Input shaft
bearing bore

Figure 119

Figure 118

94.

Spray brake cleaner into the high
clutch fluid passage on the torque
converter housing.

High clutch
fluid passage



To avoid the risk of minor personal
injury, take care when cleaning
passages as brake cleaner will exit
the passage shown as “fluid
discharge” in Figure 120.



Apply compressed air in the same
passages to remove the remaining
cleaner and debris.

62/153

Fluid discharge
Figure 120

NTB22-021

95.

To avoid the risk of minor personal
injury, do not face the passage
indicated in red of Figure 121 when
cleaning passages as brake cleaner
will exit the passage.

96.

Reduction
gear bearing
fluid passage

Spray brake cleaner into the reduction
gear bearing fluid passage on the
torque converter housing. Then apply
compressed air in the same passages
to remove remaining cleaner and
debris.

Fluid discharge
Figure 121

Clean the passages of the oil pump
cover as follows:

Input shaft

a. Remove the input shaft from the oil
pump cover.
Do not drop the counter bearing
outer race (roller bearing type only)
as damage or contamination could
occur.

Oil pump cover
Figure 122

b. Note the orientation and then
remove the thrust bearing.

Thrust bearing

o Do NOT discard. This will be
reused at a later step.

Figure 123

63/153

NTB22-021

c. Remove the washer.
o Do NOT discard. This will be
reused at a later step.

Washer

d. Spray brake cleaner into the oil
pump cover oil passages indicated
in green in Figure 125.
e. Apply compressed air in the same
passages to remove the remaining
cleaner and debris.
Figure 124

To avoid the risk of minor personal injury, do not face the passage indicated in
red in Figure 125 and Figure 126 while cleaning.
Oil pump cover

Oil pump cover

Fluid discharge

Fluid discharge