m. Gently push the ring seal onto the
second groove.

n. Remove the Second Groove Seal
Tool.

Figure 189

o Confirm that both of the Ring Seals are not protruding in any direction.
HINT: If the reduction gear shaft is not going to be immediately installed, the
Split Ring Seal Cover (#J-52595-4) can be slid over both ring seals to prevent
damage.

In the following step use extreme care when installing the final drive and reduction gear
assembly to avoid damage to components/seals.


The machine cut seals are VERY delicate and will damage easily if forced.



The reduction gear assembly should seat without any additional force.



If the reduction gear assembly does not seat, remove it and confirm that the
machine cut seals are in place and centered in their grooves.

156. Confirm that the thrust bearing is in
place in the bottom of the reduction
gear assembly bore.

Thrust bearing

Reduction gear
assembly bore
Figure 190

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157. Install the final drive and reduction
gear assembly together into the CVT
case.


If the reduction gear assembly
does not seat, remove it and
confirm that machine cut seals are
in place and centered in their
grooves.

158. Rotate the final drive by hand to
confirm that it rotates freely.

Final drive
Figure 191

Install the Torque Converter Housing
159. Place the original thrust washer on the
torque converter housing.


Thrust washer

Torque converter
housing

Apply petroleum jelly to the mating
surface side of the washer to hold
the washer on the converter
housing.

HINT: Both sides of the thrust washer
are the same, orientation is not critical.

Figure 192

160. Remove any remaining CVT fluid on the sealing surfaces of the torque converter
housing and the CVT case.
HINT: Brake cleaner is acceptable to remove remaining CVT fluid.

To prevent possible CVT damage, prevent any debris from entering into the torque
converter housing or the CVT case.

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161. Apply sealant to the CVT case side of the torque converter housing to CVT case
mating surface.


Sealant: Loctite 5460 (See the PARTS INFORMATION on page 140 of this
bulletin)



Sealant bead diameter: 2.0 mm



Sealant color: Pink

IMPORTANT:
o Confirm that the mating surfaces are clean before applying sealant.
o Make sure that the starting point and the ending point of the sealant is
between two bolt holes. Overlap both ends of the bead by 3 – 5 mm.
o If the Guide Pins were removed to clean the case surfaces, reinstall them
now.
Be careful not to contact or contaminate the sealant. If the sealant has been
disturbed or contaminated in any way before case assembly, remove the sealant
completely and re-apply to prevent possible leaks.

Overlap
3-5 mm

Figure 193

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HINT: If the torque converter housing does not fully seat, the CVT may not be in Drive.
162. Install the torque converter housing onto the CVT case with nineteen (19) new bolts
and torque to the following pattern shown in Figure 194.


Use new bolts.
o See Reference # 9 in the KIT PARTS REFERENCE TABLE.
o Bolt torque: 27.1 N•m (2.8 kg-m, 20 ft-lb)

IMPORTANT: Tighten the bolts in specific order shown below.


The bolts not visible in Figure 194 are indicated with a dotted green circle.

1
5
3

17

18

11

10
16
9

15

12
8
7

19
6

14

13

4
2
Figure 194

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Install the Control Valve and Oil Pan

163. Rotate the CVT assembly so that the
torque converter housing side is facing
down.

Terminal
assembly

164. Make sure that the terminal assembly
is attached to the bracket of the new
control valve (Figure 195).

O-ring

HINT:



Bracket

Apply CVT Fluid to the O-ring of the
terminal connector.
See Reference # 1 in the KIT
PARTS REFERENCE.
Figure 195

165. Install the new control valve assembly
into the CVT case.


Insert the terminal assembly
through the hole of the CVT case,
and then push the new control
valve horizontally with even
pressure to seat the control valve
completely.

HINT: A clicking sound may be heard
as the new control valve is seated to
the CVT case.
Figure 196
166. First tighten all eleven (11) original
control valve bolts circled in yellow
finger tight by hand, and then tighten
to the specified bolt torque below.

Control valve bolts

These bolts are easily stripped. Use
care to not over-torque as this can
damage the CVT.


87 mm (3.4 inch) long bolt.
11 pieces
o Bolt torque:
7.9 N•m, (0.80 kg-m, 70 in-lb)
Manual valve

HINT: The manual valve may slide
down and interfere with CVT case.

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Figure 197

NTB20-035C

167. Install the original manual plate to the
manual shaft with the original spring
washer and lock nut.


Use an adjustable wrench on the
transmission range switch side of
the manual rod to keep the shaft
from rotating while tightening.



Nut torque:
21.7 N•m (2.2 kg-m, 16 ft-lb)
Nut and washer

Manual plate

Figure 198
168. Confirm that the new O-ring is on the
new oil strainer.


Apply CVT Fluid to the O-ring
before installation.

HINT:



O-ring

The new oil strainer comes with a
new O-ring.
See Reference # 3 in the KIT
PARTS REFERENCE TABLE.

Figure 199

169. Install the new oil strainer to the control
valve with the three (3) original bolts.


12 mm (0.5 inch) long bolt,
three (3) pieces
3 Bolts

o Bolt torque:
7.9 N•m (0.80 kg-m, 70 in-lb)

Oil strainer
Figure 200

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170. Remove the magnets from the CVT oil pan.
HINT: The CVT oil pan may come with two (2) or three (3) magnets.

171. Clean the magnets.

172. Clean the CVT oil pan.

173. Reinstall the magnets to the CVT oil pan in their original positions.

174. Install the CVT oil pan with a new oil
pan gasket using the original bolts.
o Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)
HINT: See Reference # 2 in the KIT
PARTS REFERENCE TABLE.

Figure 201

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Seal the Sub-assembly Cover

175. Confirm the torque converter housing
side is facing down.

Side cover

176. Remove the two temporary side
cover bolts.

Figure 202

177. Remove the two pulley bearing
retainer bolts.


Pulley bearing
retainer bolts

These bolts will be reused later in
this procedure.

Figure 203
178. Remove the side cover.


Use a slide hammer (J-25721-A) if
needed.



There are three slide hammer tool
locations on the side cover.

HINT: Figure 204 shown with side
cover removed.

Figure 204

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179. Install the original lubrication tube into
the CVT case.


Place the fluid jet nozzle under the
CVT belt and then insert the
lubrication tube into the CVT case.
Lubrication
tube

To avoid damage to the CVT belt, take
care not to contact the CVT belt with
any tools during tube installation.
Figure 205

Lubrication
tube bolt

180. Install the original lubrication tube bolt.


16 mm (0.6 inch) long bolt.
o Bolt torque:
6.8 N•m (0.70 kg-m, 60 in-lb)

Lubrication
tube
Figure 206

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181. Apply sealant to the side cover sealing surface of the CVT case.


Sealant bead diameter: 2.0 mm

Sealant:
 Loctite 5460 (See the PARTS INFORMATION on page 140 of this bulletin)
 Color: Pink
IMPORTANT:
o Confirm that the mating surfaces are clean before applying sealant.
o Make sure that the starting point and the ending point of the sealant is between
two bolt holes. Overlap both ends of the bead by 3 – 5 mm.

Be careful not to contact or contaminate the sealant. If the sealant has been
disturbed or contaminated in any way before side cover assembly is installed,
remove the sealant completely and reapply to prevent possible leaks.

Overlap
3 mm to 5 mm

Figure 207

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Assembly Guide
Pins, Pulley Bracket
(Guide Pin J-52272)

182. Screw in Guide Pin (J-52272) to either
one of the two female bolt threads of
the pulley bearing retainer.


Case
bolt hole

Place the guide pin next to the
case bolt hole as shown in
Figure 208.

Figure 208
183. Install the side cover.
184. Install eleven (11) new side cover
bolts, and then torque all of the side
cover bolts to the specified torque in
the sequence shown in Figure 209.


32.8 mm (1.3 inch) long bolt,
eleven (11) pieces

1

3

5

9

10
Side cover

8
11

o Bolt torque:
27.1 N•m (2.8 kg-m, 20 ft-lb)
7
HINT: See Reference # 6 in the KIT
PARTS REFERENCE TABLE.

6

2

4

Figure 209

185. Remove the O-rings that came on the
new bearing retainer bolts and replace
them with new O-rings from PARTS
INFORMATION on page 140.
HINT: See Reference # 8 in the KIT
PARTS REFERENCE TABLE.
186. Screw in one (1) original pulley bearing
retainer bolt, hand tight.
Pulley retainer bolts

Side
cover

Figure 210

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187. Remove the Guide Pin (J-52272) and
then install the other pulley bearing
retainer bolt, hand tight.

Guide Pin

188. Torque the two pulley bearing retainer
bolts to specified torque.


Bolt torque:
28.8 N•m (2.90 kg-m, 21 ft-lb)

Figure 211

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Install and Adjust the Transmission Range Switch
189. Rotate the manual lever to the “N”
position (two clicks counterclockwise
from the left hard stop).

Manual
lever

Guide hole

190. Remove the lock nut, washer and
manual lever from the manual shaft.


They will be reused.

191. Adjust the transmission range switch
position as follows:
a. Install the alignment pin (#J-523062) into the Transmission Range
Switch Alignment Bracket (#J52306-1) as shown in Figure 213.
b. Attach the combined alignment tool
onto the manual shaft as shown in
Figure 214 with part number facing
out.
HINT: The combined alignment tool
will only insert into the transmission
range switch while in Neutral.
o Transmission range switch may
need to be rotated to allow pin
to align.
o Alignment pin will insert into
guide hole in the transmission
range switch (Figure 212).

Lock nut,
washer
Figure 212

Alignment Pin
(#J-52306-2)
Transmission Range Switch
Alignment Bracket (#J-52306-1)

Figure 213