Reposition the CVT on the work bench
with the torque converter housing side
facing down (Figure 129).

100. Clean and then zero the Digital Depth
Gauge J-50272.
101. Set the digital gauge to millimeters.

Figure 129
102. Clean the Gauge Block J-50271.

Gauge Block
J-50271

HINT: If Gauge Block J-50271 is not
used, the thickness of the substitute
measuring bar (measurement “X”) will
need to be measured. (Figure 133,
page 64). This can be done either with
a set of calipers or with Digital Depth
Gauge
J-50272.
103. Confirm the sealing surfaces of the
CVT case are clean.
104. Place Gauge Block J-50271 across the
sub-assembly sealing surface as
shown in Figure 130.
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Figure 130

NTB20-035C

105. Measure the average distance (Y) shown in Figure 133 as follows:


Refer to Figure 131, Figure 132 and Figure 133, then proceed to page 65.



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 131

Do not measure
in this area

Figure 132

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

Figure 133

Proceed to the next page.

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NTB20-035C

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

Measure to this slightly
raised machined surface
Figure 135

Figure 134

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 134 and Figure 135.
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 105b →
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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NTB20-035C

New Snap Ring Selection and Installation to the New Sub-assembly

106. Remove the top of the shipping box of
the new sub-assembly.

Top of the
shipping box

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

Figure 136
107. Remove the upper board with foam
spacer assembly.


The packing material may be
different then what is shown in
Figure 137.

Upper board

Figure 137
108. 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 138

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109. Locate the plastic bag that contains
the snap rings (Figure 139).


There are six 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.
Snap ring set
Figure 139

110. 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.



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

New sub-assembly
Figure 140

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

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111. Take the lower board with foam cushion (lower board) out of the shipping box shown
in Figure 142.
HINT: Step 112 is for kits that have a
separate spacer (Figure 141). In later
kits this spacer will be part of the lower
board and step 112 will not be used.

112. Take the spacer (Figure 141) out of the
shipping box and place 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 142.

Spacer

Figure 141

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.

HINT: 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 sub-assembly.
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 142
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113. Remove the sub-assembly from the
plastic bag.

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

The sub-assembly must be level
and oriented as shown in
Figure 143 for proper seating
of the CVT case later in this
procedure.
Lower board
and spacer

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

Figure 143

New sub-assembly

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

Snap ring
Figure 144

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116. 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 65

→



Subtract constant value

→ ─
41.30
------------------------------------



Subtotal

→



Add value for “B1” from data sheet

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



Total calculated depth

→

D ___________

=

___________

= E ___________

E = This will be used to select a snap ring from Table A on page 71.

EXAMPLE:
If D = 41.39 mm
Constant
= 41.30 mm (subtracted)
And B1 = 1.56 mm (added)
____________________
E = 1.65 mm

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117. Select the appropriate Part Number from Table A shown below, based on the
calculated result of “E” in step 116 on page 70.
EXAMPLE: If E = 1.65, and is between or equal to 1.64 to 1.67, choose new snap
ring Part Number “31506 3JX9C”.
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

118. Open the plastic bag (with snap rings) that was removed from the shipping box in step
109 on page 67 and then choose the correct Part Number selected from Table A.
HINT: There are six individually packed snap rings in the plastic bag. See Reference #
5 in the KIT PARTS REFERENCE TABLE.
119. Measure the new snap ring and confirm its thickness is equal to the Snap Ring
Reference in Table A.
120. Install the selected snap ring onto the secondary pulley front bearing of the new subassembly.
HINT: Discard unused snap rings.

Selected snap ring
Figure 145

Figure 146

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NTB20-035C

Install Sub-assembly to CVT Case

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

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

Figure 147
Torque converter
housing
123. 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.
124. Remove the two (2) temporary bolts
and then remove the torque converter
housing from the CVT case.


Figure 148

Discard these bolts.

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NTB20-035C

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

To avoid damage to the CVT:
o Only use the weight of the CVT
case when installing it to the
sub-assembly.

New subassembly

o Do NOT use any other external
force to seat the CVT case to
the sub-assembly.

b. Align the primary pulley front bearing
bore of the CVT case to the primary
pulley front bearing of the subassembly.

Figure 149
Primary pulley
sub-assembly

CVT case

HINT: Figure 150 is shown looking
down into the CVT case while it is
being lowered.
Primary pulley
front bearing bore
Figure 150
c. Align one of two dowel pin holes
found on the CVT case to the subassembly.

CVT case

Dowel pin
New sub-assembly
Figure 151

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NTB20-035C

d. Align the second dowel pin of the
sub-assembly with the hole on the
opposite side of the CVT case and
seat CVT case.

Dowel pin
Figure 152
e. If the CVT case will not seat on the
sub-assembly:
1) Access the counter driven gear
through the top of the CVT case,
and
2) Rotate the counter driven gear on
the primary pulley back and forth.
HINT: This will allow the splines
of the secondary pulley and the
planetary carrier plate to align.
See Figure 154.

Counte
Counter
r driven
driven
gear

Figure 153

Secondary
pulley splines
Figure 154

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NTB20-035C

f. Confirm that the mating surface of the CVT case is seated to the sub-assembly
completely.
o If the CVT case does not sit completely flush with the sub-assembly, DO NOT
apply any vertical force to seat it.
1) If this occurs, first lift the CVT case up slightly and then lower.
2) Repeat until the CVT case and sub-assembly sit flush with each other.

CVT case

No gap

New sub-assembly
Figure 155
g. Rotate the counter driven gear back and forth by hand to confirm its rotation is
smooth.

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NTB20-035C

126. Temporarily install two (2) original bolts hand tight to hold the sub-assembly to the
CVT case.