73.

Temporarily install the transmission range switch with the two (2) original bolts
removed in step 68 on page 47, finger tight.


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

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Remove the Sub-assembly
IMPORTANT: Steps 74 through 81 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.
74.

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 94
75.

Remove the two (2) pulley bearing
retainer bolts shown in Figure 95.


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

Figure 95
76.

Remove the eleven (11) side cover
bolts shown in Figure 96.


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

Figure 96

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77.

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 shown in Figure 97.



The mating surfaces will be cleaned at a later step.



This step will help with sub-assembly removal at a later step.
o To avoid damage to the CVT, do not use the speed sensor bore for slide
hammer tool location.
o Do not pry the surfaces apart as internal CVT damage may result.

Side cover

Figure 97
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78.

Align the primary pulley bearing
retainer bolt holes with the bolt hole on
the case as shown in Figure 98.
HINT: This helps alignment of the
bearing retainer bolt threads after
reinstalling the original side cover.

Figure 98

79.

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

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

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

Figure 99

80.

Place the original side cover onto the
CVT case.


Side cover

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

Figure 100

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81.

Install the two (2) original pulley bearing retainer bolts (Figure 101) 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).

82.

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

Pulley bearing
retainer bolts

Side cover

Side cover
bolts
Figure 101

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83.

Reposition the CVT with the side
cover facing down.

Side cover
Figure 102
84.

Remove the two (2) side cover bolts
which were temporarily installed to
hold the side cover to the CVT in step
82 on page 53.
HINT: Only one (1) bolt is shown in
Figure 103 and is for reference only.

Side cover
bolt
Figure 103

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 104.

Figure 104

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86.

Place the CVT case on the work
bench with the torque converter side
facing down.

Figure 105

87.

Remove the lubrication tube bolt
shown in Figure 106 and then remove
the lubrication tube from the CVT
case.


Lubrication tube

Do not discard the bolt or
lubrication tube. These will be
reused during reassembly.

To prevent drivability concerns,
ensure that the lubrication tube is
not bent during sub-assembly
installation.

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Lubrication
tube bolt
Figure 106

NTB20-035C

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.

88.

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 107
89.

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 108

Torque converter
housing sealing
surface

Figure 109
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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.

90.

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.

Make sure the surface of the work
bench has been cleaned to avoid
contamination of components.

Figure 110

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91.

Spray brake cleaner into each oil passage of the CVT case, where shown in Figure
111 and Figure 112 with yellow 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.

92.

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 111

Figure 112
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93.

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 113
94.

Clean the input shaft bearing bore area (Figure 114 and Figure 115).
Input shaft
bearing bore

Figure 114

95.

Figure 115

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 116.
 Apply compressed air in the same
passages to remove the remaining
cleaner and debris.

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Fluid discharge
Figure 116

NTB20-035C

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.



To avoid the risk of minor personal
injury, do not face the passage
indicated in red of Figure 117 when
Fluid discharge
cleaning passages as brake
cleaner will exit the passage.
Figure 117

97.

Clean the passages of the oil pump
cover as follows:

Input shaft

Oil pump cover

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.

Figure 118

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 119

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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
yellow shown in Figure 121.
e. Apply compressed air in the same
passages to remove the remaining
cleaner and debris.
Figure 120

To avoid the risk of minor personal injury, do not face the passage indicated in white
in Figure 121 and Figure 122 while cleaning.
Oil pump cover

Oil pump cover

Fluid discharge

Fluid discharge
Figure 122

Figure 121

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

Washer

Figure 123

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g. Install the original thrust bearing in the correct orientation as shown in Figure 124
and Figure 125.


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.

Oil pump cover
Thrust bearing

Figure 125

Figure 124

h. Insert the input shaft into the oil pump cover (Figure 126 and Figure 127).
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 126.
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

Input shaft

Oil pump
cover

Thrust bearing

Figure 127

Figure 126

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Measuring the CVT Sub-assembly Case Depth

98.

Torque converter
housing

Temporarily install the torque
converter housing to the CVT case
with two (2) bolts at opposite corners,
hand tight (Figure 128).


Use the original bolts to secure.

Figure 128
99.