Figure 126

Figure 125

f. Install the original washer.
Washer

HINT:
o Orientation is NOT critical for
the washer.
o Apply petroleum jelly to the
washer to hold it in place during
assembly.

Figure 127
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g. Install the original thrust bearing in the correct orientation as shown in Figure 128
and Figure 129.
o Apply petroleum jelly or equivalent to hold in place.
The thrust washer is direction specific. Install in the correct orientation. If the thrust
washer is incorrectly installed, damage to the CVT may occur.
Thrust bearing

Oil pump cover

Figure 129

Figure 128

h. Insert the input shaft into the oil pump cover (Figure 130).
IMPORTANT:
o Apply petroleum jelly to the sealing ring on the input shaft before installation.
 The sealing ring is hidden behind the input gear in Figure 130.
o Make sure all exposed internal areas of the CVT (including the oil pan and
magnets) have been thoroughly cleaned.

o To avoid damage to the CVT, use care while assembling the input shaft to the
oil pump cover as the input shaft sealing ring may become damaged.
o To avoid damage to the CVT when not being worked on, cover all parts with a
lint-free covering to prevent contamination.
Sealing ring location

Oil pump
cover

Thrust bearing
Figure 130

Figure 131
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Measuring the CVT Sub-assembly Case Depth
Torque converter
housing bolts (2)
97.

Temporarily install the torque
converter housing to the CVT case
with two (2) bolts at opposite corners,
hand tight (Figure 132).


Use the original bolts to secure.

Figure 132

98.

Reposition the CVT on the work bench
with the torque converter housing side
facing down (Figure 133).

99.

Clean and then zero the digital
depth gauge J-50272.

100. Set the digital gauge to millimeters.

Figure 133
101. Clean the Gauge Block J-50271.

Gauge Block
J-50271

HINT:
 If Gauge Block J-50271 is not
used, the thickness of the
substitute gauge block will need
to be measured.
 The thickness of the gauge block
is shown as “X” (Figure 137 on
page 67).
102. Confirm the sealing surfaces of the
CVT case are clean.

Figure 134

103. Place the Gauge Block J-50271
across the sub-assembly sealing
surface (Figure 134).

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104. Measure the average distance (Y) shown in Figure 137 as follows:
 Refer to Figure 135, Figure 136 and Figure 137, then proceed to page 68.
 Measure only from areas that do not have any signs of contact.
 Refer to “Measuring area” referenced in green to measure “Y”.

Measuring area

Figure 135

Do not measure
in this area
Figure 136

Y = The distance between the upper surface of the Gauge Block J-50271 and the
surface where the snap ring seats.

Figure 137
Proceed to the next page.

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Secondary pulley bearing snap ring surface
Do not measure
into this groove

Measure to this slightly
raised machined surface
Figure 139

Figure 138

a. Measure between the top of the Gauge Block (J-50271) to where the snap ring on
the secondary pulley bearing seats in three (3) locations to calculate the average
value, “Y”. Refer to Figure 138 and Figure 139.
Y1_________, Y2________, Y3_________
b. Calculate the average, "Y", using the formula below and then record it below.
Y=

ሺ௒ଵା௒ଶା௒ଷሻ
ଷ

(millimeter)

Y = _________
c. Calculate case depth “D” as follows:
IMPORTANT: Essential tool Gauge Block (J-50271) is 20 mm thick.
o Average depth calculated in step 103b →
o Subtract the Gauge Block thickness

→

Y__________
─ X__________
-------------------------------------------------

→

o Calculated depth

= D__________

D = Distance between the sub-assembly sealing surface and the secondary pulley
front bearing surface with the snap ring attached.
EXAMPLE:
Y = 61.39 mm
─ X = 20.00 mm
___________

D = 41.39 mm
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New Snap Ring Selection and Installation to the New Sub-assembly

Top of the
shipping box

105. Remove the top of the shipping box
of the new sub-assembly.
HINT: The outer cardboard of the
shipping box can be disassembled
for easy removal of the sub-assembly
by removing the shipping tape.

Figure 140

106. Remove the upper board with foam
spacer assembly.


The packing material may be
different then what is shown in
Figure 141.

Upper board

Figure 141

107. Locate the data sheet in the
shipping box and place it in a safe
place.


This data sheet is required for
snap ring selection in the
following steps.

Figure 142

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108. Locate the plastic bag that contains
the snap rings (Figure 143).


There are six (6) individual snap
rings in the plastic bag.



Take the plastic bag out of the
shipping box, and put aside on
the work bench.

HINT: See Reference # 5 in the KIT
PARTS REFERENCE TABLE on
page 150.

Snap ring set
Figure 143

109. Take the new sub-assembly out of
the shipping box and place it on the
work bench.
To avoid possible damage to the
CVT:


Hold the sub-assembly by the
side cover ONLY when removing
it from the shipping box.



DO NOT handle the belt or
pulleys of the sub-assembly when
removing from the shipping box.



New sub-assembly
Figure 144

DO NOT BREAK the foam
cushion in the shipping box. This
will be used as a stabilizer for the
sub-assembly during the repair.

HINT: See Reference # 4 in the KIT PARTS REFERENCE TABLE on page 150.

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110. Take the lower board with foam cushion (lower board) out of the shipping box shown
in Figure 146.
HINT: Step 111 is for kits that have a
separate spacer (Figure 145). In later kits
this spacer will be part of the lower board
and step 111 will not be used.
111. Take the spacer (Figure 145) out of
the shipping box and place it on the
work bench where the sub-assembly
will be installed, and then place the
lower board on top of the spacer as
shown in Figure 146.

Spacer

Figure 145

HINT: The spacer will be the last
item that is removed from the
shipping box and is approximately 1
inch thick.


Position the lower board so that it hangs over the spacer.



Align the lower board so that the left and the right cut-outs are even with the
spacer.

NOTE: The positioning of the lower board with foam cushion will allow the CVT case
enough clearance from the work bench to allow it to seat flush with the subassembly.
Cut-out even
with spacer

Lower board with
foam cushion

Lower board
over-hang

Cut-out even
with spacer

Cut-out even
with spacer
Figure 146
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112. Remove the sub-assembly from the
plastic bag.

113. Place the new sub-assembly onto the
lower board.


The sub-assembly must be level
and oriented as shown in Figure
147 for proper seating of the CVT
case later in this procedure.
Lower board
and spacer

114. Remove the snap ring from the
secondary pulley front bearing of the
new sub-assembly.


Figure 147

New subassembly

A new snap ring will be installed
later in the procedure.

Snap ring

Figure 148

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115.

Calculate “E” for snap ring selection as follows:

HINT: For the value of “B1”, refer to the data sheet that was put aside when the subassembly shipping box was opened.


Calculated case depth from step c on page 68



Subtract constant value



Subtotal



Add value for “B1” from data sheet



Total calculated depth

→

D ___________

→ ─
37.80
-----------------------------------→

=

___________

→ + B1 ___________
-----------------------------------→

= E ___________

E = This will be used to select a snap ring from Table A on page 74.

EXAMPLE:
If D = 41.39 mm
Constant
= 37.80 mm (subtracted)
And B1 = 1.56 mm (added)
____________________
E = 1.65 mm

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116.

Select the appropriate Part Number from Table A shown below, based on the
calculated result of “E” in step 115 on page 73.
EXAMPLE: If E = 1.65, and is between or equal to 1.64 to 1.67, choose new snap
ring Part Number “31506 3JX9C”.

117.

E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
Example only. Do
1.65
not use in your
1.69
calculations.
1.73
1.77
1.79

Table A
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
1.65
1.69
1.73
1.77
1.79

Open the plastic bag (with snap rings) that was removed from the shipping box in
step 108 on page 70 and then choose the correct Part Number selected from
Table A.
HINT: There are six (6) individually packed snap rings in the plastic bag. See
Reference # 5 in the KIT PARTS REFERENCE TABLE on page 150.

118.

Measure the new snap ring and confirm its thickness is equal to the Snap Ring
Reference in Table A.

119.

Install the selected snap ring onto the secondary pulley front bearing of the new
sub-assembly.
HINT: Discard unused snap rings.

Selected snap ring
Figure 149

Figure 150
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Install Sub-assembly to CVT Case

CVT case
sealing surface
120. Make sure the CVT case sealing
surface of the side cover is
thoroughly cleaned.

121. Make sure the dowel pins are
cleaned and any rust has been
removed.

Figure 151

Torque converter
housing bolts (2)

122. Flip the CVT case over on the work
bench with the torque converter
housing side facing up.
To avoid possible contamination and
damage to the CVT, ensure the work
bench surface is thoroughly cleaned
before flipping the CVT case.
123. Remove the two (2) temporary bolts
and then remove the torque
converter housing from the CVT
case.


Figure 152

Discard these bolts.

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CVT case
124. Install the CVT case onto the new
sub assembly as follows:
NOTE: Sealant will be applied
between these components at a later
step.
a. Slowly lower the CVT case onto
the sub-assembly.