for torque converter
housing removal

Figure 66

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44.

Remove the torque converter housing from the CVT case.


If necessary, use a Slide Hammer J-25721-A at the three locations (highlighted in
green) shown in Figure 66.



The input shaft thrust bearing washer may be attached to the torque converter
housing, remove it and put it aside; it will be reused.

Remove the Oil Seals from the Torque Converter Housing
45.

46.

Remove the torque converter oil seal from the torque converter housing with a
suitable tool.


Take care not to damage the seal-to-case surface when removing seal.



The torque converter oil seal is a one-time use part. Do not reuse.

Remove the differential side oil seal from the torque converter housing with a suitable
tool.


The differential side oil seal is a one-time use part. Do not reuse.

Torque converter housing

Differential side
oil seal
Torque converter
oil seal

Figure 67

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Remove the CVT Internal Components

47.

Remove the final drive assembly and
the reduction gear assembly at the
same time by lifting both straight up.

Reduction gear
assembly

Lip seal

O-ring
Final drive
assembly
48.

Figure 68

Remove the lip seal from the CVT
case.


Lip seal

The lip seal is a one-time use part.
Do not reuse.

Figure 69
49.

Remove the O-ring from the CVT
case.


The O-ring is a one-time use part.
Do not reuse.

O-ring

Figure 70

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50.

Remove the O-ring from the input shaft.


51.

The O-ring is a one-time use part. Do not reuse.

Remove the thrust bearing from the drive sprocket and set aside to reuse during reassembly.
HINT: The thrust washer for the thrust bearing may either be on the drive sprocket or
may have remained with the torque converter housing when it was removed.


The thrust washer will be reused later in this procedure.

Input shaft
O-ring

If present, the thrust
washer would cover
the bearing

Thrust
bearing
Drive
sprocket

Figure 71
52.

Spread the snap ring shown in Figure 72 and Figure 73 then remove both sprockets
and the chain.

Sprockets
and chain

Snap ring
Figure 73

Figure 72

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53.

Remove the parking rod from the
detent plate.


Parking rod

Detent plate

Rotate the parking rod vertically to
align the tab on the parking rod
(Figure 75) with the slot on the
detent plate and then separate from
the detent plate.

Figure 74

Align tab
with slot

Detent plate

Figure 75
Reverse
brake tube
54.

Remove the two (2) bolts shown in
Figure 76, and then remove the
reverse brake tube from the CVT.


Do not discard. These will be
reused during assembly.

2 Bolts

Figure 76

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55.

Remove the sleeve from the reverse
brake tube.


The sleeve is a one-time use part.
Do not reuse.

Sleeve

Figure 77

56.

Remove the six (6) bolts shown in
Figure 78 and then remove the chain
cover.


Do not discard. The bolts and chain
cover will be reused during
assembly.

Chain cover
Figure 78
57.

Remove the input shaft assembly and
the oil pump cover (dummy cover)
from the CVT as a unit.


Hold the input shaft assembly by
the end, as shown in Figure 79,
and pull straight up to remove.

HINT: The dummy cover, shaft and
bearing will separate if the input shaft
is not held at the end.
Input shaft assembly
and the oil pump
cover (dummy cover)

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Figure 79

NTB20-035C

58.

Confirm the “type” of bearing used on the end of the input shaft, and then proceed to
the indicated step.


For type “A” roller bearing proceed to step 59.



For type “B” ball bearing skip to step 61 on page 45.



For type “C” sealed ball bearing skip to step 61 on page 45.

Bearing type A

59.

Figure 80

Bearing type B and C
 Type C shown

Remove the outer race of the roller
bearing from the counter bearing bore
of the CVT case by hand.
CVT case
Do not use excessive force to remove
the bearing race as damage to the
CVT may occur. A magnet can be
used to lift this bearing if needed.
HINT: The outer race of the roller
bearing might remain on the shaft
when removing the input shaft and
dummy cover.

Outer race
Figure 81

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60.

Inspect type “A” bearing (Roller
bearing) as follows:


Inspect the bearing outer race and
input shaft for flaking or pitting.



Install the bearing outer race onto
the input shaft assembly with the
“bearing number” facing the gear,
and then rotate the bearing while
applying an axial load by hand to
check for any abnormality.

Input shaft
Figure 82

DO NOT drop the outer race of the bearing to avoid damage and/or contamination.

o Were any abnormalities found or felt in the bearing (sound, flat spots, flaking)?
 NO: Put bearing and shaft aside and then skip to step 62 on page 45.
 YES:
a. Document the abnormalities found with a video and then contact the PCC
for authorization to replace the CVT. See page 147 for PCC contact
information.
b. Refer to steps 203 - 206 on page 105 when replacing the CVT.
c. After CVT replacement, perform ADDITIONAL SERVICE WHEN
REPLACING CONTROL VALVE OR TRANSAXLE ASSEMBLY on
page 106.
d. Loosely reassemble the original CVT in the reverse order of disassembly
with the original parts.

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61.

Inspect type “B” and type “C” bearings
(ball bearing) as follows:


Apply an axial load and rotate the
bearing by hand to check for any
abnormality (sound, flat spot,
flaking).

Figure 83
o Were any abnormalities observed in the bearing when applying an axial load
(sound, flat spots, flaking)?
 NO: Proceed to step 62.
 YES:
a. Document the abnormalities found with a video and then contact the PCC
for authorization to replace the CVT. See page 147 for PCC contact
information.
b. Loosely re-assemble the CVT in the reverse order of disassembly with the
original parts.
c. Refer to steps 203 - 206 on page 105 when installing the CVT.
d. After CVT replacement, perform ADDITIONAL SERVICE WHEN
REPLACING CONTROL VALVE OR TRANSAXLE ASSEMBLY on
page 106.

62.

If the bearing is judged to be OK,
remove the shim (Figure 84) from the
bottom of the counter bearing bore.


A magnet can be used to remove
the shim if needed.



This shim will be reused later in this
procedure.

Counter
bearing bore

Shim
Figure 84

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63.

Remove the differential side oil seal
from the CVT case by driving it away
from the case with a suitable tool.


The differential side oil seal is a
one-time use part. Do not reuse.



Take care not to damage the
seal-to-case surface when
removing seal.

CVT case

Differential side oil seal
Figure 85
64.

Rotate the manual shaft (Figure 86)
until it stops in the Park position (see
Figure 87).

3 mm punch
Park position

Roll pin

Confirm that the detent plate is in
the Park position before
proceeding. Do not remove the roll
pin in any other position. This will
allow pin removal and avoid
damage to the case.
65.

Remove the roll pin completely from
the manual shaft with a 3 mm punch.


The roll pin is a one-time use part.
Do not reuse.

Manual shaft
Figure 86

Use a 3 mm punch. If a larger sized
punch is used, the hole may become
enlarged and damage the manual
shaft.
HINT: Do not leave the roll pin in the
CVT case.
66.

Detent spring

Park position

Remove the detent spring bolt shown
in Figure 87 and then remove the
detent spring from the CVT case.


Do not discard the bolt. It will be
reused during reassembly.

Figure 87

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67.

Remove the manual shaft retaining pin
(straight pin) from the CVT case by
grasping and pulling vertically by
hand.


Retaining pin

Do not discard the pin. It will be
reused during reassembly.
Manual shaft

Figure 88

68.

Remove the two (2) bolts shown in
Figure 89 for the transmission range
switch.


Do not discard the bolts. They will
be reused during reassembly.
HINT:
o DO NOT remove the manual
shaft lock nut at this step.
o DO NOT try to remove the
transmission range switch from
the manual shaft.
Transmission range
switch

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Figure 89

NTB20-035C

69.

CVT case

5.3 inches

Slide the manual shaft approximately
5.3 inches (135 mm) out of the CVT
case to allow removal of the oil pump
(step 70).
Do not remove the manual shaft
completely from the CVT case. If the
retaining pin slot contacts the seal,
damage may occur.

Manual shaft
Figure 90

70.

Remove the three (3) Allen® bolts
shown in Figure 91 and then remove
the oil pump from the CVT case.


This oil pump will not be reused, it
will be replaced with a new one.



Do not discard Allen® bolts. They
will be reused during reassembly.

Oil pump

3 Allen® bolts
Figure 91

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71.

Remove the snap ring from the
original oil pump.
HINT: DO NOT discard the removed
snap ring. This snap ring will be
reused.

Snap-ring

Figure 92

72.

Remove the oil pump gasket from the
CVT case.


Oil pump
gasket

The oil pump gasket is a one-time
use part. Do not reuse.

Figure 93