Remove the Oil Seals from the Torque Converter Housing
44.

45.

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 68

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Remove the CVT Internal Components

Reduction gear
assembly
46.

Lip seal

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

Final drive
assembly

O-ring
Figure 69

47.

O-ring

Remove the O-ring from the CVT
case.


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

Figure 70

48.

Remove the O-ring from the CVT
case.


O-ring

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

Figure 71

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49.

Remove the O-ring from the input shaft (Figure 72).


50.

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 thrust bearing

Thrust
bearing

Drive
sprocket
Figure 72
51.

Spread the snap ring shown in Figure 73 and Figure 74, and then remove both
sprockets and the chain.

Sprockets
and chain

Snap ring
Figure 74

Figure 73

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52.

Parking rod

Remove the parking rod from the
detent plate as follows:

Detent plate in
“L” position

a. Rotate the detent plate to the “L”
position.
o The detent spring should be
aligned with the leftmost
concave of the detent plate
(Figure 75).

Figure 75

Parking rod
bolts (2)

b. Remove the two (2) parking rod
bolts (Figure 76).

Figure 76

c. Rotate the parking rod vertically to
align the tab on the parking rod
with the slot on the detent plate,
and then separate it from the
detent plate (Figure 77).

Parking
rod
Align tab
with slot

Detent spring

Figure 77

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53.

Reverse
brake tube

Remove the two (2) bolts circled in
green, and then remove the reverse
brake tube from the CVT (Figure 78).


Do not discard the reverse brake
tube and bolts. These will be
reused during assembly.

Reverse brake
tube bolts (2)
Figure 78

Sleeve




Remove the sleeve from the
reverse brake tube.
Remove the O-ring from the
reverse brake tube.
The sleeve and the O-ring are
one-time use parts. Do not reuse.

O-ring

Figure 79

54.

Chain cover
bolts (6)

Remove the six (6) bolts circled in
green, and then remove the chain
cover (Figure 80).


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

Chain cover
Figure 80

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55.

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 81,
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)

56.

Remove the outer race of the roller
bearing from the counter bearing bore
of the CVT case by hand.

Figure 81

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 82

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57.

Inspect type “A” bearing (roller
bearing) as follows:
a. Inspect the bearing outer race and
input shaft for flaking or pitting.
b. 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 83

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

Were any abnormalities found or felt in the bearing (sound, flat spots, flaking)?
NO: Put bearing and shaft aside, and then skip to step 58 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 152 for PCC contact
information.
b. Refer to steps 201-205 on page 109 when replacing the CVT.
c. After CVT replacement, perform ADDITIONAL SERVICE WHEN
REPLACING CONTROL VALVE OR TRANSAXLE ASSEMBLY on page
110.
d. Loosely reassemble the original CVT in the reverse order of disassembly
with the original parts.

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58.

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

59.

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.
CVT case
Take care not to damage the
seal-to-case surface when
removing the seal.
Differential side oil seal
Figure 85

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60.

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

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.
61.

3 mm
punch

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

Manual
shaft

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

Detent spring

62.

Park position

Remove the detent spring bolt circled
in green 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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63.

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

64.

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

Do not discard the bolts. They will
be reused during reassembly.

HINT:


DO NOT remove the manual shaft
lock nut at this step.



DO NOT try to remove the
transmission range switch from the
manual shaft.

Transmission range
switch bolts (2)
Figure 89

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65.

Slide the manual shaft approximately
5.3 inches (135 mm) out of the CVT
case to allow removal of the oil pump
(step 66).

CVT case

5.3
inches

To avoid damage to the seal, 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

66.

Remove the three (3) hex bit screw
fasteners in the locations shown in
Figure 91, and then remove the oil
pump from the CVT case.

Oil pump



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



Do not discard hex bit screw
fasteners. They will be reused
during reassembly.

Oil pump hex bit
screw fasteners (3)
Figure 91

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67.

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

68.

Remove the two (2) oil pump gaskets
from the CVT case.


Oil pump
gasket

Oil pump
gasket

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

Figure 93

69.

Temporarily install the transmission range switch with the two (2) original bolts
removed in step 64 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 72 through 80 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.

70.

Reposition the torque converter
housing onto the CVT.