NTB17-039h
Service Bulletin Details
Public Details for: NTB17-039h
- 2017 - 2016 - 2015 - 2014 - 2013 -
Models from 2017
2017 NISSAN ALTIMA |
2017 NISSAN MAXIMA |
2017 NISSAN MURANO |
2017 NISSAN PATHFINDER |
2017 NISSAN QUEST |
Models from 2016
2016 NISSAN ALTIMA |
2016 NISSAN MAXIMA |
2016 NISSAN MURANO |
2016 NISSAN PATHFINDER |
2016 NISSAN QUEST |
Models from 2014
2014 NISSAN ALTIMA |
2014 NISSAN PATHFINDER |
Models from 2013
2013 NISSAN ALTIMA |
2013 NISSAN PATHFINDER |
Classification: Reference: AT16-020h Date: NTB17-039h October 30, 2019 PATHFINDER, ALTIMA, MAXIMA, MURANO AND QUEST; CVT JUDDER AND DTC P17F0 OR P17F1 STORED This bulletin has been amended. See AMENDMENT HISTORY on the last page. Discard all previous versions of this bulletin. 2013-2017 Altima (L33) 2015-2017 Murano (Z52) 2016-2017 Maxima (A36) APPLIED TRANSMISSION: CVT with V6 engine only APPLIED VEHICLE: 2013-2017 Pathfinder (R52) 2015-2017 Quest (E52) IF YOU CONFIRM The customer reports a transmission judder (shake, shudder, single or multiple bumps or vibration), AND One of these DTCs is stored: P17F0 (CVT_JUDDER (T/M INSPECTION)) P17F1 (CVT_JUDDER (C/U INSPECTION)) NOTE: If a transmission judder (as described above) is not reported, this bulletin does not apply. If either P17F0 or P17F1 are not stored, this bulletin does not apply. If any DTCs are stored other than P17F0 or P17F1, this bulletin does not apply. NTB15-014, Enhanced Diagnostic Logic For CVT Judder, has reprogramming instructions that may apply. ACTION Refer to the Repair Flow Chart on page 2 for CVT repair. CAUTION: Always handle the CVT and component assemblies carefully and with the appropriate lifting tools. IMPORTANT: The purpose of ACTION (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire SERVICE PROCEDURE as it contains information that is essential to successfully completing this repair. Nissan Bulletins are intended for use by qualified technicians, not 'do-it-yourselfers'. Qualified technicians are properly trained individuals who have the equipment, tools, safety instruction, and know-how to do a job properly and safely. NOTE: If you believe that a described condition may apply to a particular vehicle, DO NOT assume that it does. See your Nissan dealer to determine if this applies to your vehicle. 1/113 Repair Flow Chart Customer reports transmission judder (shake, shudder, single or multiple bumps or vibration). DTC P17F0 or P17F1 found stored P17F0 DTC P17F1 DTC No Remove the control valve (valve body). Page 7. This bulletin does not apply Refer to ASIST for further diagnostic information. Perform CVT Chain Inspection. Page 9.* No a. Remove the control valve The CVT chain checks out OK Yes (valve body). Page 7. And then b. Replace the sub-assembly. Page 16. c. Install new valve body. Page 85. a. Replace the subassembly Page 16. And then b. Install new valve body. Page 85. Install new valve body only. Page 85. Check TCM part number and if needed, perform reprogramming. Step 167 on page 93. IMPORTANT: Reprogramming, if needed, must be done before performing additional services. Perform ADDITIONAL SERVICE WHEN REPLACING CONTROL VALVE. Page 99. * DO NOT perform the CONSULT-III plus CVT INSPECTION test. This is no longer accepted for warranty repairs. 2/113 NTB17-039h Table of Contents Required Tools / Material……………………………………………………….… page 4 Essential Tools………………………………………………………………….….. page 4 Weights…………………………………………………………………………...…. page 5 Precautions when Disassembling a CVT Assembly………………………...…. page 6 Control Valve (Valve Body) Removal …………………………...………………. page 7 CVT Chain Inspection……………………………………………………………... page 9 CVT Assembly Removal.................................................................................. page 16 Remove the Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump and Oil Filter……………………………………………………………………………... page 17 Verify Thrust Bearing Type 1 or Type 2…………………………………………. page 25 Clean the CVT Case Surfaces…..……………………………………………….. page 28 Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT Filter Area…………………………………………………………………………………. page 29 New Oil Pump Installation…………………….………………………………….. page 31 Replace the Side Cover – Pulleys and Chain (sub-assembly)……………….. page 33 Remove Side Cover and Install Lubrication Caps.………………..…………… page 48 Type 1 CVT: Clutch Total Endplay Adjustment – Thrust Bearing Selection… page 62 Type 2 CVT: Clutch Total Endplay Adjustment – Bearing Race Selection….. page 67 Clean the Torque Converter Housing, Dummy Cover Passages and Baffle Plates ………………………………………..……………………………………… page 75 CVT Reassembly…………………………………………………………………... page 77 Control Valve (Valve Body) Strainer and Pan Installation……………………... page 85 Install the CVT Assembly…………………………………………………………. page 91 TCM Reprogramming……………………………………………………………… page 92 Troubleshooting…………………………………………………………………… page 105 PARTS INFORMATION…………………………………………………………… page 107 Parts Kits Reference Table………………….................................................... page 109 CLAIMS INFORMATION………………………………………………………….. page 110 Type 1 and Type 2 Additional Reference Images………………..…………….. page 112 3/113 NTB17-039h Required Tools / Materials Cherry picker / engine hoist / lifting arm (never handle replacement CVT sub-assembly by hand) Strap or chain to lift / lower CVT and sub-assembly Petroleum jelly or equivalent Extendable magnet Large clean surface / 1 to 2 work tables Vernier calipers Brake cleaner Rubbing alcohol Plastic scraper Essential Tools Additional Essential Tools are available from Tech•Mate online: www.nissantechmate.com, or by phone: 1-800-662-2001. J-25721-A Slide Hammer Set J-50255 CVT Service Tool Kit J-50818 CVT2 Oil Pump Seal Installer J-51923 J-Hook Case Separator J-50272 Digital Depth Gauge J-50255-UPD Slide Hammer Set J-50271 Gauge Block J-8092 Driver Handle J-52284 Torque Converter Side Seal Installer Figure 1 4/113 J-52283 CVT Case Side Seal Installer NTB17-039h Essential Tools (continued) J-51959 CVT Assembly Guide Pins J-52272 Pulley Bracket Guide Pins Figure 2 CVT Universal Lifting Fixture CVT Side Cover Alignment Aid J-52082 CAUTION: This tool is to only be used to INSTALL side cover J-52082-2 J-52275 Figure 3 Figure 4 Tech Cam J-51951 Lens swab J-51963 (not part of J-51951) Figure 5 Additional Tech Cam J-51951 kits or components are available from Tech•Mate. Weights CVT assembly: 300 lbs. approximately CVT sub-assembly: 65 lbs. approximately 5/113 NTB17-039h GENERAL INFORMATION Precautions when Disassembling a CVT Assembly Transmissions are vulnerable to particles (dust, metal, lint, etc.). When disassembling a CVT, make sure your work environment (shop, workbench, etc.), transmission area (sub-frame, oil pan, harness connector, etc.), and your hands are free of contamination. IMPORTANT: Wash and clean the exterior of the CVT assembly prior to disassembling. CAUTION: Cover all air breather and drive shaft holes to prevent water intrusion. Refrigerating oil seals may help in assembly (axle and T/C seals). Only disassemble those parts which are mentioned in this bulletin. Make sure all parts are clean prior to assembling / installing. Apply rust penetrant to locator / dowel pins on torque converter housing and side cover of CVT and allow to soak as needed (Figure 6). Dowel pin locations Figure 6 Unpack service parts just before installation. To aid with organization, store related parts that have been removed separately. IMPORTANT: The CVT unit “wiring harness connector” will be reused during this procedure. The wiring harness can be disconnected from the valve body at the wiring harness connector and remain in the CVT. Wiring harness connector Figure 7 6/113 NTB17-039h SERVICE PROCEDURE Control Valve (Valve Body) Removal 1. Write down all radio station presets. Presets AM FM 1 FM 2 SAT 1 SAT 2/3 Bass 1 2 Treble 3 Balance 4 Fade 2. Disconnect both battery cables, negative cable first. 3. Was DTC P17F0 found stored? NO: Proceed to step 4. YES: 5 6 Speed Sen. Vol. a. Remove the CVT from the vehicle, place it on a workbench and then remove the valve body. Refer to the Electronic Service Manual (ESM), section TM-Transaxle & Transmission for removal information. NOTE: The number “7” is on the head of all bolts that need to be removed for valve body removal. Do not remove any bolt that does not have the number “7”. CAUTION: For AWD Vehicles use extreme care when moving the axle in and out of the transfer assembly to avoid seal damage. b. Position the CVT on the workbench with the oil pan side down. CAUTION: Do not hit the manual shaft while flipping the CVT; the manual shaft protrudes past the CVT case. Use a plastic / wooden block to support as needed. c. Proceed to step 14 on page 18. 4. Remove the valve body. Before lifting the vehicle place the transmission gear selector in Neutral. Refer to the appropriate ESM, section TM – Transaxle & Transmission, for valve body removal. NOTE: The number “7” is on the head of all bolts that need to be removed for valve body removal. Do not remove any bolt that does not have the number “7”. CAUTION: Never allow any chemicals or fluids other than NS-3 CVT fluid or equivalent to enter the CVT assembly. Never allow any foreign debris, dust, dirt, etc. to enter the CVT assembly. For additional information, see video # 546: “CVT Chain Inspection”. This video is located under the TECH TRAINING GARAGE VIDEOS tab in Virtual Academy. 7/113 NTB17-039h Exploded View Example: Exploded View of Control Valve (valve body) (#7 is on the head of these bolts) Figure 8 1. Transaxle assembly 4. Control valve 7. New-style oil strainer assembly 10. Oil pan 13. Magnet 16. Lip seal 19. O-ring : CVT fluid 2. Terminal cord assembly 5. Bracket 8. Old-style oil strainer assembly 11. Drain plug 14. Spring washer 17. Snap ring 3. CVT fluid temperature sensor bracket 6. O-ring 9. Oil pan gasket 12. Drain plug gasket 15. Manual plate 18. Overflow plug : Always replace after every disassembly. : Nꞏm (kg-m, ft-lb) : Nꞏm (kg-m, in-lb) 8/113 NTB17-039h CVT Chain Inspection 5. Secure the right front tire with a suitable strap. 6. Mark the left front tire with a suitable marking. 7. This will assure all 360° of the chain is inspected. Using borescope J-51951 with mirror attachment, visually inspect the entirety of the two sides of the chain that come in contact with the pulleys: Figure 9 a. First inspect the entirety (360°) of the driver side of the chain that comes in contact with the pulley (see page 11, Figure 13 and Figure 14, and page 12 Figure 15). b. If the inspection result is OK on all 360°, inspect all 360° of the passenger side of the chain. IMPORTANT: Reference the pictures on pages 13-15 for chain image comparison. Be sure to remove the protective film from the mirror before the first use. Clean the camera lens and mirror before each inspection. Use 90% isopropyl alcohol, and a lens swab from the Lens Swab packet J-51963 listed in PARTS INFORMATION. Before inspecting, make sure the camera handle’s AA batteries are fresh and the LCD monitor’s battery is charged. Insert the camera lens behind the pulley between the guide rail and the pulley where shown in Figure 9 (also see pages 10-11, Figure 11-Figure 14). Insert the lens approximately 8-9 inches, and then view the side of the chain that contacts the pulley. Refer to Garage Video #546 if needed for Borescope inspection. Chain Pulley Guide rail ------ ------ Front Driver side Driver side of the chain Passenger side of the chain Figure 10 9/113 NTB17-039h Figure 11 shows where to insert the camera lens on the driver side of the chain. Chain Pulley Guide rail Camera cable ------ ------ ------ Figure 11 Figure 12 shows where to insert the camera lens on the passenger side of the chain. Chain Pulley Guide rail Camera cable ------ ------ ------ Figure 12 10/113 NTB17-039h Figure 13 and Figure 14 shows the routing and location of the camera. NOTE: The CVT’s side cover was removed for easier viewing of camera location. The side cover is not to be removed during boroscope inspection. UP Front of vehicle Camera lens positioned behind plastic guide Camera cable Primary pulley: Camera cable routed past primary pulley Figure 13 For best picture, position camera lens 10 mm away from chain Figure 14 11/113 NTB17-039h 7c. Slowly and carefully turn the left front tire one full turn in the forward rotation to view all of the chain. Holding the borescope with one hand allows for turning the tire with the other hand (see Figure 15). CAUTION: If the tire is rotated in the rearward rotation, the camera lens may get caught between the chain and pulley. Figure 15 d. Is the chain OK on all 360° of both surfaces? Refer to Garage Video #546 if needed (see page 7). YES: Proceed to step 8. NO: If the chain inspection result is NG, proceed to CVT Assembly Removal on page 16. 8. Flush the CVT cooler(s). IMPORTANT: A CVT Cooler flush is required after a valve body or CVT sub-assembly replacement. Refer to bulletin NTB15-013 to perform CVT Cooler flush. 9. Replace the valve body. For valve body replacement, go to page 85, Control Valve (Valve Body) Strainer and Pan Installation. Inspect this side Inspect this side Do not inspect this side Do not inspect this side Figure 16 12/113 NTB17-039h CVT chain Figure 17 Inspect these surfaces Close-up of area to be inspected Figure 18 13/113 NTB17-039h Pictures in Figure 19 and Figure 20 were taken with borescope J-51951. OK OK Writing will show as reversed; this is normal Figure 19 Figure 20 OK Figure 21 OK Figure 22 14/113 NTB17-039h Pictures in Figure 23 and Figure 24 were taken with borescope J-51951. NG NG Scuff marks caused by slippage Figure 23 Figure 24 NG Figure 25 NG Figure 26 NG Figure 27 15/113 NTB17-039h CVT Assembly Removal Overview of Sub-assembly Repair 1. Precautions When Disassembling a CVT Assembly 2. Remove the CVT 3. Apply rust penetrant to dowel pins 4. Remove Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump, Oil Filter 5. Confirm Thrust Bearing Type 6. Clean the CVT Case Surfaces 7. Clean Oil Passages in CVT Case, Oil Pump Cover, and CVT Filter Area 8. Install New Oil Pump 9. Temporarily Install Dummy cover, Torque Converter Housing and Filter Cover 10. Check Pulley Movement Characteristics 11. Install Sub-assembly – Pulley, Chain and Side Cover 12. Remove Side Cover and Install Lubrication Caps 13. Apply Sealant, Install Side Cover and Bracket Bolts 14. Confirm Parking Rod Operation 15. Check New Pulley Movement Characteristics 16. Torque Bracket Bolts 17. Adjust Total Thrust Bearing End-play 18. Clean Torque Converter Housing, Dummy Cover and Baffle Plates 19. CVT Reassembly 20. Install Valve Body, Strainer, and Pan 21. Install CVT Assembly 16/113 NTB17-039h Remove the CVT 10. Temporarily install the oil pan gasket and oil pan with four oil pan bolts to corners of the oil pan, hand tight (Figure 28). NOTE: A new valve body will be installed later in this procedure. Figure 28 11. Remove the CVT from the vehicle. Refer to the ESM, section TM-Transaxle & Transmission for removal information. AWD Vehicles CAUTION: Use extreme care when moving the axle in and out of the transfer assembly. To avoid seal damage or deformation, properly support and guide the axle. 17/113 NTB17-039h 12. Place the CVT on a workbench with the oil pan side down. Use wood or plastic blocks to keep the CVT steady. CAUTION: Do not deform the oil pan. 13. Remove the torque converter. Figure 29 14. Drain CVT fluid out of the torque converter. Torque converter Figure 30 Primary speed sensor 15. Remove the primary speed sensor. IMPORTANT: The speed sensor will be reused. Figure 31 18/113 NTB17-039h Remove the Converter Housing, Oil Seals, Oil Pump Cover, Oil Pump and Oil Filter 16. Remove all 24 converter housing mounting bolts (see Figure 32). NOTE: These bolts will be replaced with new ones and will not be reused. Dowel Pin Apply rust remover to the dowel pins if needed. Figure 32 17. Separate and then remove the converter housing from the CVT case. Use Slide Hammer J-25721-A and Slide Hammer Bolt J-50255-UPD with J-Hook J-51923 at the cut out areas similar to the one shown in Figure 33 and Figure 34. Work around the CVT at specified areas, repeatedly until case halves separate. CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from the CVT case. J-25721-A ----- J-50255-UPD ----- J-51923 One of three cutout areas Figure 34 Figure 33 19/113 NTB17-039h 18. Note the location of the pin shown in Figure 35. CAUTION: This pin can slip out during movement of the CVT while converter housing is removed. Figure 35 19. O-ring Remove the O-ring from the input shaft. This O-ring will be replaced with a new one. Figure 36 20. Carefully remove the reduction gear assembly (Figure 37). 21. Carefully remove the differential assembly (Figure 38). Reduction gear assembly Differential assembly Figure 37 Figure 38 20/113 NTB17-039h 22. Remove the following oil seals using suitable tools: CAUTION: Be careful not to damage any of the seal bore surfaces. a. CVT case differential side oil seal (drive shaft seal). See Figure 39. Figure 39 b. Torque converter seal (Figure 40). Figure 40 c. Converter Housing differential side right hand oil seal (drive shaft seal). See Figure 41. NOTE: All wheel drive transfer case O-ring will be replaced later in this procedure. Figure 41 21/113 NTB17-039h Baffle plate nuts 23. Remove the two (2) nuts from baffle plate A, and then remove baffle plate A (see Figure 42). Figure 42 24. Baffle plate A Remove the oil pump chain, driven and drive sprockets as one assembly (Figure 43). Spread the snap ring to remove the sprocket (Figure 44). IMPORTANT: The drive sprocket has a specific top and bottom. Keep the sprockets and chain together after removal. Drive sprocket Driven sprocket Oil pump chain Snap ring Figure 44 Figure 43 22/113 NTB17-039h Thrust washer 25. Remove the following: a. “Pump cover” (dummy cover) thrust washer (Figure 45). This thrust washer will be reused. Dummy cover Figure 45 Snap ring b. Oil pump snap ring (Figure 46). Lightly push the ends of the snap ring together, rotate one side upwards while pulling the snap ring towards the pump opening. This snap ring will be reused, do not discard. Figure 46 c. Oil pump bracket (Figure 47). Oil pump bracket Retained by two bolts. Figure 47 23/113 NTB17-039h 26. Remove the four (4) bolts from baffle plate B, and then remove baffle plate B (Figure 48). Baffle plate B Figure 48 27. 28. Remove the two (2) bolts from baffle plate C, and then remove baffle plate C (Figure 49). Baffle plate C Remove the five (5) dummy cover bolts, and then remove the dummy cover. See Figure 50. NOTE: These bolts will be reused. Figure 49 IMPORTANT: Lift the dummy cover from the sides ONLY. Do NOT lift from the input shaft (Figure 50); this can lift the clutch pack out. Confirm that the input shaft O-ring has been removed. If not removed it can cause the clutch pack to lift out. Do NOT remove the lathe cut seals (white seals, Figure 51 from the dummy cover. These seals will be reused. Dummy cover Dummy cover Do not lift here Lathe cut seals (white seals) Figure 51 Figure 50 24/113 NTB17-039h IMPORTANT: Depending on the model year and make of the vehicle there will be one of two different dummy covers and corresponding clutch packs; Type 1 (Thrust Bearing) and Type 2 (Thrust Bearing with Bearing Race) – See Figure 53 and Figure 54. MY13-14 Pathfinder, MY13-17 Altima, and MY16-17 Maxima use Type 1 (Thrust Bearing). MY15-17 Pathfinder, MY15-17 Murano and MY15-17 Quest use Type 2 (Thrust Bearing with Bearing Race). Please see page 112 for Type 1 and Type 2 Additional Reference Images. Type 1 29. For Type 1 remove the thrust bearing from the clutch assembly (Figure 52) and then proceed to step 31. For Type 2, proceed to step 30. This bearing will not be re-used. Thrust bearing Secondary speed sensor Figure 52 30. For Type 2, remove the thrust bearing from clutch assembly (Figure 53) and bearing race from the dummy cover (Figure 54). 31. These will be re-used later. Wipe any metallic debris off of the face of the secondary speed sensor (Figure 52). NOTE: The position of the secondary speed sensor is the same for Type 1 or Type 2. Thrust bearing Thrust bearing race Figure 54 Figure 53 25/113 NTB17-039h Oil pan gasket surface Top of CVT 32. Remove the oil pump as follows: a. Remove the fitting bolt located above the corner of the oil pan gasket surface (Figure 55). Fitting bolt Figure 55 b. Remove the three oil pump Allen™-head bolts, and remove the oil pump (Figure 56). NOTE: o Do NOT discard the Allenhead bolts. Bolts will be reused. o New oil pump will be installed at later steps. Figure 56 33. Remove CVT fluid filter as follows: a. Remove the four (4) bolts and then remove the CVT fluid filter cover (Figure 57). NOTE: Bolts will be reused. CVT fluid filter cover Figure 57 26/113 NTB17-039h Fluid filter b. Remove the CVT fluid filter with grommet seal and O-ring seal (Figure 58). Discard the oil filter and seal. They will be replaced. O-ring seal Figure 58 Grommet Grommet is fitted to the bottom end of the filter and is included with replacement filter (Figure 59). Figure 59 27/113 NTB17-039h Clean the CVT Case Surfaces 34. Thoroughly clean the mating surfaces of the CVT case and Torque Converter Housing. A plastic scraper can be used. CAUTION: DO NOT use sanding discs, similar abrasive tools, or metal blades. 35. Use brake spray or equivalent solvent and lint-free towels only. Make sure brake spray or solvents used are compatible with local regulations. Avoid debris entering into the inside of the CVT. Make sure rust and debris have been cleaned off of dowel pins and receiving holes (Figure 60). Clean the dowel pins and dowel pin receiving holes of any rust or debris with emery cloth (Figure 60). NOTE: Use small wire brush or similar tool at the inside surface of dowel pin holes. DO NOT SCRAPE CVT CASE mating surfaces. Clean dowel pin receiving holes Clean dowel pin Figure 60 28/113 NTB17-039h Clean the Oil Passages in the CVT Case, Oil Pump Cover, and CVT Filter Area In the following steps: Brake cleaner and compressed air will be used to clean out oil passages in the CVT assembly. Make sure the brake cleaner or solvents are compatible with local regulations. WARNING: Wear eye / face protection when using compressed air and cleaning fluids. CAUTION: Regulate air pressure up to a maximum of 75 PSI. 36. Clean within this area Clean the area where the CVT fluid filter fits (Figure 61). 37. Do not use water-based (aqueous) cleaners. Make sure the old filter grommet seal is removed. Clean the fluid passages to and from the filter (Figure 61). Fluid passages Figure 61 38. Clean filter cover (Figure 62). Figure 62 29/113 NTB17-039h 39. Spray brake clean in all oil passages of the CVT case where shown in Figure 63 and Figure 64. 40. Remove lip seal if not already removed. 41. Apply compressed air in the same passages. NOTE: Do not stand in front of the passages while using compressed air. Do not spray brake clean directly into clutch pack. Lip seal Figure 63 Apply cleaner, and then 75 PSI maximum air pressure in these passages. Air pressure comes out these passages. Figure 64 30/113 NTB17-039h New Oil Pump Installation 42. Install the new oil pump using three (3) original Allen-head bolts (Figure 65). NOTE: Finger tighten the Allen-head bolts at this time. IMPORTANT: A Parts Kits Reference Table is provided on page 109. Use the check off column on the left to ensure the correct new part is installed at each step. Attach this to the repair order. Figure 65 Fitting bolt 43. Place a new O-ring on the fitting bolt, and coat with CVT fluid (Figure 66). O-ring Figure 66 44. Fitting bolt Install the fitting bolt finger tight (Figure 67). Figure 67 31/113 NTB17-039h 45. Torque the three (3) Allen head bolts and fitting bolt. Allen head bolt torque: 17.6 – 20.6 N•m (1.79 – 2.1 kg-m, 13.0 – 15.2 ft-lb) Fitting bolt torque: 26.0 – 30.0 N•m (2.65 – 3.06 kg-m, 19.2 – 22.1 ft-lb) 46. Install the original snap ring (Figure 68). Snap ring Figure 68 47. Install the CVT fluid filter and components (Figure 69 and Figure 70). Install a new filter with grommet (one part). Install a new O-ring. Confirm that all components and areas where components fit are thoroughly clean. Apply CVT fluid to the grommet seal and O-ring before installing. Install the filter cover. Bolt torque 4.2 N•m (0.43 kg-m, 37.2 in-lb.) Fluid filter O-ring seal CVT fluid filter cover Figure 70 Figure 69 32/113 NTB17-039h Replace the Side Cover – Pulleys and Chain (sub-assembly) 48. Temporarily install the dummy cover with 3 bolts, finger tight (Figure 71). IMPORTANT: Do not install any thrust bearing to the clutch assembly bore at this time. If the cover does not seat flush see TROUBLESHOOTING The Dummy Cover Will Not Sit Flush on page 105. Bolts Dummy cover Figure 71 49. Temporarily install the converter housing onto the CVT case with three bolts finger tight (Figure 72). IMPORTANT: When fitting the CVT case surfaces, DO NOT use the bolts to draw in the case halves. Make sure the case surfaces are flush, and have no gaps prior to installing the bolts. Bolts Converter housing Figure 72 33/113 NTB17-039h 50. Flip the CVT case so that the converter housing faces down and side-cover faces up. Lifting fixture J-51595 can be used for this step. This tool is not shown in Required Tools / Materials. Manual shaft CAUTION: Do not hit the manual shaft (Figure 73) while flipping the CVT; the manual shaft protrudes past the CVT case. Use a plastic / wooden block to support as needed. 51. Figure 73 Note the location of the terminal connector harness. Do not pinch the terminal connector harness between the CVT case and work bench or supporting blocks. Rotate the primary pulley by hand to check the pulleys rotational characteristics. Rotate the primary pulley by hand IMPORTANT: Remember the pulley’s rotational characteristics. This will be used as a reference after the new side cover-pulleys and belt subassembly (sub-assembly) have been installed. Figure 74 This will be used as a reference later in the procedure to determine if the sub-assembly installation is successful or not. WARNING: Do not place fingers between the pulley and the CVT case. Do not place fingers under pulley Figure 75 34/113 NTB17-039h NOTE: When working with sub-assembly install, uninstall, and bracket attachment, it is critical that CVT and sub-assembly are level. If not level, the pulleys and bearings can sit slightly at an angle and will hinder installation. 52. Remove the nineteen (19) side cover bolts (Figure 76). Loosen the bolts with hand tools only. These bolts will be replaced with new ones and will not be reused. Figure 76 53. Remove the six (6) pulley bracket bolts. These bolts will be reinstalled to the original pulley and belt subassembly. Figure 77 35/113 NTB17-039h 54. Attach universal Lifting Fixture J-52082 with spacers J-52082-2 to the side cover as shown in Figure 78. NOTE: Install and tighten by hand only. a. Loosen all of the wing-nut bolts on the Lifting Fixture. b. Confirm that three (3) spacers (# J-52082-2) are present between the longer legs and triangle bracket as shown in Figure 78. c. Install the Lifting Fixture to the CVT case at the six (6) bolt holes shown in Figure 77 on page 35. d. Tighten the two (2) joints to the triangle brackets. e. Tighten the wing-nut bolts on the Lifting Fixture finger tight. CAUTION: Do not cross-thread the bolts when attaching to the CVT side cover. (3) Spacers (# J-52082-2) Triangle bracket Lifting Fixture J-52082 Longer legs 55. Triangle bracket joint Figure 78 Install the two CVT Assembly Guide Pins (J-51959 - Guide Pins) as shown in Figure 79 and Figure 80. The Guide Pins must be located next to the dowel pins. Guide Pin Guide Pin Guide Pin Dowel Pin Pins Dowel Pin Figure 79 Figure 80 36/113 NTB17-039h 56. Raise the Lifting Fixture so that the CVT assembly weight is mostly supported by the Lifting Fixture and just slightly raised off of the work surface (using Tool #: J-52082). 57. Loosen the side cover with a slide hammer at the three points shown in Figure 81. Rotate between the 3 locations on the side cover until the CVT case separates from the sub-assembly; this can take more than one rotation to loosen the sealant. CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from the CVT case. NOTE: Apply rust penetrant to the two dowel pins as needed. The following Figure is for reference only and does not show the lifting device attached. Tool location marks Dowel pin Dowel pin 58. Figure 81 Raise the lifting fixture to remove the “side cover with pulleys and chain subassembly” (sub-assembly) from the CVT case (Figure 82) and set aside. CAUTION: Make sure the primary speed sensor is removed from the sub-assembly. 59. Sub-assembly The speed sensor will be reused. DO NOT discard the speed sensor. This sub-assembly will not be reused. Remove the lifting fixture from the subassembly and replace all six (6) original bolts. 37/113 Figure 82 CVT case NTB17-039h 60. Thoroughly clean the mating surfaces of the CVT case (Figure 83) that the subassembly was just separated from (a plastic scraper can be used). Clean off the dowel pins. Confirm that the dowel pins have remained in the CVT case. If not, remove them from the sub-assembly and relocate back to the CVT case. Reinstall the guide pins if they were removed during case cleaning. CAUTION: DO NOT use sanding discs, similar abrasive tools, or metal blades. Use brake cleaner or equivalent solvent and lint-free towels only. Make sure brake spray or solvents used are compatible with local regulations Avoid debris entering into the inside of the CVT. Make sure rust and debris have been cleaned off of the dowel pins and receiving holes. 61. Remove the O-ring from the CVT case (Figure 84). This O-ring will not be reused. Mating surfaces O-ring Figure 84 Figure 83 62. Remove the thrust bearing from the planetary carrier plate (Figure 85). The thrust bearing will be reused. DO NOT discard. CAUTION: If not found on the planetary carrier plate, the thrust bearing may still be attached to the primary pulley. Thrust bearing Figure 85 38/113 NTB17-039h Shift select lever 63. Rotate the shift select lever counter clockwise to the “L” range position (Figure 86), so that the parking rod is at its lowest position (Figure 87). Figure 86 Parking rod Figure 87 64. 65. Remove the six (6) bolts from the new sub-assembly and then remove their O-rings. These bolts will be reused. These O-rings will not be reused. Lifting Fixture Attach Lifting Fixture to the new subassembly, and then raise subassembly out of shipping box. CAUTION: Do not cross thread side cover holes when installing the Lifting Fixture. Always start bolts by hand. 39/113 Sub-assembly Figure 88 NTB17-039h 66. Install the original thrust bearing onto the primary pulley of the new sub-assembly (Figure 89). CAUTION: The thrust bearing has two different sides. Reference Figure 89 for correct bearing orientation. Apply a thin layer of petroleum jelly or equivalent to the original thrust bearing to hold it in place on the primary pulley. The thrust bearing must sit flush with primary pulley surface (Figure 89). Reuse the thrust bearing which was removed from the planetary carrier plate. Primary pulley Thrust bearing Primary pulley bearing surface Figure 89 40/113 NTB17-039h 67. Coat the primary pulley bearing, secondary pulley gear teeth and the secondary bearing with CVT fluid prior to installation (Figure 90). IMPORTANT: Do NOT apply sealant to the case at this time. The sub-assembly will be sealed later in this procedure. The following Figures are for reference only and may or may not have the sealant in place, or have the old sealant removed. Clean the surfaces and apply sealant when and where instructed. Coat these surfaces with CVT fluid Figure 90 68. Position the new sub-assembly over the CVT case and then lower it just far enough to allow the Guide Pins to be inserted into their appropriate sub-assembly holes (the Guide Pins are different lengths). IMPORTANT: Do NOT allow the output gear to contact the lubrication tubes when the side cover is positioned over the guide pins. NOTE: Guide pin locations are shown in Figure 79 on page 36. Output Gear Lubrication Tube Lubrication Tube Figure 91 41/113 NTB17-039h IMPORTANT: Before continuing, it is recommended that you review and understand the instructions on pages 42 to 47. Confirm dowel pins are clean – this will ease installation. The sub-assembly will lower into the CVT case without applying extra vertical force. IF THE SUB-ASSEMBLY DOES NOT LOWER COMPLETELY, INTERFERENCE IS PRESENT. ! PHYSICAL Key Technique: Raise the sub-assembly to remove weight from the interference, adjust as necessary, and then lower again. Use the “gap size” between the sub-assembly and the CVT case to determine the cause of interference. At any given gap, only 1 item will be the cause of interference 50 mm - Page 43 40 mm - Page 44 CASE GAP = ? 18 mm - Page 45 5 mm Page 46 Figure 92 Case gap Figure 93 42/113 NTB17-039h 69. Carefully lower the Lifting Fixture to install the sub-assembly into the CVT case as follows: While visually looking down into the bore (Figure 95) to confirm that the output gear is clearing the CVT case bearing bore, a. Level the sub-assembly by placing hands on top to guide it into the CVT case. b. Lower the sub-assembly until a gap of 40 mm (1.6 inch) is present to the CVT case (Figure 98 on page 44) and then proceed to step 70. If the sub-assembly will not lower any farther than 50 mm (2 inches) the output gear has not cleared the bearing bore (Figure 95). Sub-assembly will not lower past 50 mm (2 inches)? Interference is present between the output gear and bearing bore and are highlighted with yellow in Figure 94 and Figure 95. Sub-assembly 50 mm (2 inches) gap Output gear Bearing bore Output gear Figure 94 Bearing bore CVT case Figure 95 43/113 NTB17-039h 70. Install the parking rod into the parking pawl of the CVT sub-assembly as follows: IMPORTANT: Perform step 70 while the sub-assembly has a 40 mm gap (1.6 inch) to the CVT case (Figure 98). a. Rotate the shift select lever clockwise on the side of the CVT to adjust the park rod to the highest position. b. Use a magnet, or similar tool, to align the parking rod in the CVT case ( Figure 97) with the opening in the parking pawl ( in in Figure 96) in the side cover. NOTE: If the parking rod is not located correctly it may keep the case from lowering. If the parking rod is not located correctly, the shift select lever will not rotate through all detents (P-R-N-D-L) once the sub-assembly is completely installed. Side cover Parking pawl Parking rod CVT case Figure 97 Figure 96 Sub-assembly 40 mm (1.6 inch) gap CVT case Figure 98 44/113 NTB17-039h 71. Continue to slowly lower the sub-assembly into the CVT case. If the primary and the secondary pulley bearings do not align properly with their bores (Figure 99) or are at an angle, a gap of 18 mm (0.7 inch) may be present. Possible areas of interference are highlighted with orange and tan in Figure 99. As needed, level the sub-assembly as it is lowered into the CVT case to help the primary and the secondary pulley bearings align in their bores. MINOR LEVELING ADJUSTMENTS with limited weight on the sub-assembly will help the installation. Vertical force is not needed. Once the sub-assembly is LEVEL the primary and the secondary pulley bearings will smoothly align while lowering. Sub-assembly will not lower past 18 mm (0.7 inch)? If this occurs Do NOT force sub-assembly into case. a. Raise the sub-assembly slightly. b. Level the sub-assembly (visually check the gap between case and subassembly side cover and confirm that it is even all around). c. Gently lower the sub-assembly. d. Gently shake the sub-assembly horizontally, lower, raise and repeat as needed to help align. e. Lower to 6 mm (0.25 inch) to clear the dowel pins. Sub-assembly Primary pulley bearing Secondary pulley bearing 18 mm (0.7 inch) gap Bearing bore Bearing bore Figure 99 45/113 NTB17-039h IMPORTANT: In the following steps the case halves must sit flush against each other without a gap before installing the bolts. The bolts CANNOT be used to draw the cases together. DO NOT APPLY VERTICAL FORCE. 72. Once the dowel pins are cleared, ease the sub-assembly down onto the CVT case until the case halves are flush. Confirm the dowel pins are clean and aligned and are not catching on the subassembly case cover. WARNING: Be careful not to get fingers caught between the CVT case and subassembly when seating. Sub-assembly will not lower past 5 mm (0.2 inch)? If the sub-assembly will not lower past 5 mm (0.2 inch), the primary pulley splines are interfering with the planetary carrier splines. If this occurs Do NOT force sub-assembly into case. a. Raise the sub-assembly slightly to separate the primary pulley and the planetary carrier splines to remove interference. b. Slightly rotate the primary pulley back and forth slowly, through the bottom of the CVT, and then lower the sub-assembly. c. Repeat as needed. Sub-assembly Primary pulley 5 mm (0.2 inch) gap Rotate pulley in green highlighted area only CVT case Touch side of primary pulley to align splines Primary pulley splines Planetary carrier splines Do not place fingers below primary pulley Figure 100 46/113 NTB17-039h Shift select lever 73. Rotate the select lever to “N” range. This helps keep the sub-assembly level. Figure 101 Lifting Fixture 74. Remove the Lifting Fixture from the side cover. Loosen the wing nuts. Unthread the tool from the pulley brackets. Figure 102 47/113 NTB17-039h Remove Side Cover and Install Lubrication Caps IMPORTANT: In the following steps, use only a slide hammer and hands to separate the side cover. In the following steps, if the side cover does not easily lift off by hand it is still seated on the pulley bearings and must first be completely separated. Do NOT use tool J-52275 at this time. 75. Install two Pulley Bracket Guide Pins (J-52272). 76. The bracket guide pins will be used as a height marker of the pulleys to ensure they remain seated in the case as the side cover is removed. Pulley Bracket Guide Pins (J-52272) Use slide hammer (J-25721-A) with Jhook case separator (J-51923) and evenly separate the side cover from the belt and pulley assembly. Alternate between the three hooking locations on the side cover until the side cover separates from the pulleys (see page 37 Figure 81). As the side cover is raised up, the exposed height of the pulley guide pins will shorten. This is an indicator that the pulleys are remaining seated in the CVT case. Slide hammer (J-25721-A) with J-hook case separator (J-51923) Figure 103 Raise evenly; lift by hand. Make sure the side cover is completely separated from the pulley bearings. Once the side cover is separated from pulley bearings, it will rock freely and can be easily lifted by hand. IMPORTANT: Use only a slide hammer and hands to separate the side cover from the pulleys. 77. Figure 104 Lift off the side cover by hand. NOTE: The side cover weighs 9 lbs. 48/113 NTB17-039h 78. Install two (2) new lubrication caps (see Parts Information) shown in Figure 105 onto the tubes of the CVT case shown in Figure 106 as follows: a. Insert the lubrication caps through the slots in each chain guide. b. Face the larger side of the “wedge shaped index guide” away from the pulleys. c. Gently push each lubrication cap down into the square cut seat of the CVT case tubes. NOTE: Slightly rotating the lubrication caps will help in aligning them into the square cut seats. IMPORTANT: Confirm that the caps are installed in the correct orientation. Lubrication cap Lubrication cap Lubrication cap Wedge shaped index Chain guide Figure 105 Figure 106 shows the pulleys and chain removed to illustrate how the lubrication caps attach to the CVT case tubes and is for reference only. Lubrication cap Wedge shaped index Square cut seat CVT case tube Figure 106 49/113 NTB17-039h Guide pins 79. Confirm two Pulley Bracket Guide Pins (J-52272) are in place. One guide pin to each pulley bracket. The guide pins can be installed into any of the three bolt holes. Figure 107 80. Rotate each bracket to align with holes in the case as shown in Figure 108. Align these holes Pulley Bracket Guide Pins go here Figure 108 O-ring 81. Install a new O-ring. Apply CVT fluid to the O-ring before installation. Press down completely into the machined groove. NOTE: Do not re-use the old O-ring. Figure 109 50/113 NTB17-039h 82. Shim Confirm that the shim and the lathe cut seal, on the underside of the side cover, stay in place. The shim is located in the secondary pulley bearing bore. The lathe cut seal is located in the center of the same bearing bore. NOTE: Apply petroleum jelly or equivalent as needed to keep the shim and lathe cut seal in place while lowering the side cover to the CVT. Lathe cut seal Figure 110 Install Side Cover Side Cover Alignment Aid (#J-52275) 83. Install the Side Cover Alignment Aid (#J-52275), with two (2) bolts hand tight. NOTE: The Alignment Aid will assist with level installation and help keep integrity of sealant until the case halves are flush against one another. 84. Lift side cover with suitable lifting tool and confirm that the underside case mating surface is clean. Figure 111 51/113 NTB17-039h 85. Apply one continuous 2.0 mm diameter bead of sealant along the center of the CVT case side mating surface (Figure 112). Sealant: Loctite 5460 (See the Parts Information section of this bulletin.) Color: Pink IMPORTANT: Confirm that the mating surfaces are clean before applying sealant. 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. If the Guide Pins were removed to clean the case surfaces, reinstall them now. CAUTION: 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. Figure 112 52/113 NTB17-039h Manual lever 86. Rotate the manual lever clockwise to the “P” range to set the parking rod at the highest position. Figure 113 87. Install the CVT Assembly Guide Pins (#J-51959). IN THE FOLLOWING STEPS IF THE SIDE COVER DOES NOT LOWER COMPLETELY, PHYSICAL INTERFERENCE IS PRESENT. NOTE: Before installing side cover read steps 88-91. 88. Install the side cover to the CVT case. a. Route each of the 4 guide pins from under the side cover through their respective bolt holes. Figure 114 Not shown with sealant and is for reference only. b. Lower the side cover until the parking rod can be aligned with parking pawl and then proceed to step 89 on the next page. See Figure 116 on page 54. IMPORTANT: Keep the side cover as level as possible during installation. To assist with proper pulley positioning, confirm the CVT is on a flat surface. Do not use excessive vertical force to install. 53/113 Figure 115 NTB17-039h 89. Install the parking rod into the parking pawl of the CVT side cover as follows: IMPORTANT: Perform step 89 while the side cover has a 38 mm gap (1.5 inch) to the CVT case (Figure 118). a. Rotate the shift select lever clockwise on the side of the CVT to adjust the park rod to the highest position. b. Use a magnet, or similar tool, to align the park rod in the CVT case ( in in Figure 116) in the side Figure 117) with the opening in the parking pawl ( cover. NOTE: If the parking rod is not located correctly it may keep the side cover from lowering. If the parking rod is not located correctly, the shift select lever will not rotate through all detents (P-R-N-D-L) once the side cover is completely installed. Side cover Not shown with sealant and is for reference only. Parking pawl Parking rod CVT case Figure 117 Figure 116 Not shown with sealant and is for reference only. Side cover 38 mm (1.5 inch) gap CVT case Figure 118 54/113 NTB17-039h Apply pressure to these locations 90. Using your hand, press down on the side cover over each of the pulley bearings to level and seat the side cover. IMPORTANT: The side cover will not be fully seated at this step. Figure 119 Side Cover Alignment Aid (# J-52275) 91. Rotate the manual lever to the “N” position. 92. Remove the Side Cover Alignment Aid (# J-52275) shown in Figure 119. NOTE: Figure 120 shown with Side Cover Alignment Aid removed. 93. Figure 120 Continue to lower the side cover until it is flush with the CVT case. Use a plastic hammer or rubber mallet, if the side cover is caught, and gently tap evenly around the top of the side cover to help seat. IMPORTANT: Side cover must be completely seated. Bolts cannot be used to draw case halves together. Do NOT use metal hammers or mallets. If it is necessary to unseat the side cover assembly, use a slide hammer and then restart from step 83 on page 51. Do NOT pry with a screw driver. 55/113 NTB17-039h 94. Remove the two (2) CVT Assembly Guide Pins (# J-51959). 95. Leave the Pulley Bracket Guide Pins in place. Install the sub-assembly side cover with nineteen (19) new side cover bolts to the CVT case (Figure 121). CAUTION: Do not reuse the original side cover bolts. Torque the first eight (8) bolts marked as in the sequence numbered in Figure 121 below, and then torque the rest of the bolts in a clockwise manner. Bolt torque: 45 N•m (4.6 kg-m, 33 ft-lb) 19 pieces. Some bolts are hidden 4 8 2 6 Torque un-numbered bolts in clockwise pattern 3 1 5 7 Figure 121 96. Install six (6) new O-rings from Parts Information to the six (6) new pulley bearing retainer bolts that were removed from the new sub-assembly on page 39, step 64. 56/113 NTB17-039h 97. Install the new pulley bearing retainer bolts to secure the pulleys and side cover. a. Install four (4) bolts first, hand tight. b. Remove two (2) guide pins from the pulley bracket. c. Install the last two (2) bolts with Orings, hand tight. Figure 122 98. Confirm the parking rod operates correctly as follows: a. Rotate the shift select lever counter- clockwise and confirm that all detents for each of the P-R-N-D-L are felt. Shift select lever b. Rotate the lever clockwise to return the rod back to the P position. c. Are all of the detents felt? YES: Proceed to step 99. NO: If the lever does not rotate or if all detents are not felt: Figure 123 1) Remove the sub-assembly side cover and then remove sealant. 2) Restart from step 83 on page 51. 57/113 NTB17-039h 99. Confirm the rotational smoothness of the primary pulley as follows: a. With a clean hand, access the primary pulley from the bottom of the CVT to rotate. b. Rotate the primary pulley by hand and confirm that the characteristic is the same as previously checked at step 51 (page 34), prior to removing the original subassembly. Figure 124 c. Is the rotational characteristic “the same” (OK) or “worse than before the sub-assembly was replaced” (NG)? OK: The rotational characteristic is the same or better; proceed to step 100. NG: 1) Remove the 19 case bolts and 6 pulley bracket bolts. Refer to page 35 steps 52 and 53. 2) Install the two Pulley Bracket Guide Pins (J-52272). Refer to page 48 step 75. 3) Remove the side cover. 4) Remove the two (2) lubricating caps. 5) Remove the silicone from the sealing surfaces. 6) Reinstall the side cover and then remove the Pulley Bracket Guide Pins. 7) Restart sub-assembly installation from Step 54 on Page 36. 8) Follow procedure through to page 58 step 99 and check rotational characteristics. 100. Torque all six (6) bolts. Bolt torque: 28 N•m (2.8 kg-m, 20 ft-lbs). Figure 125 58/113 NTB17-039h 101. Install the CVT case side axle seal (Figure 126). Use Seal Installer J-52283 and Driver Handle J-8092. Apply a light coat of CVT fluid to the seal lip surfaces. J-8092 CVT case J-52283 Figure 126 102. Place the CVT on the work bench with the side cover facing down on the bench. Bolts 103. Remove the converter housing which was temporarily installed with three bolts. Converter housing Figure 127 104. Unbolt the three (3) bolts holding the dummy cover and then remove the dummy cover. Bolts Dummy cover Figure 26F 59/113 NTB17-039h Digital Gauge “Zero” Procedure IMPORTANT: The Depth Gauge MUST be set to “zero” before performing measurements in the following service procedure. Measurement tools: Gauge Block (straight bar) Depth Gauge (Digital Vernier scale) with a datum level (accuracy: 0.01 mm) Depth Gauge Bottom out “ZERO” switch ON/OFF switch Inch/mm switch Lay flat Datum level Gauge Block Figure 128 60/113 NTB17-039h Depth Gauge Calibration To calibrate the Digital Depth Gauge J-50272: a. Turn the Depth Gauge ON and set it to “mm” measurement. b. Place the Depth Gauge’s datum level flush on top of the Gauge Block. c. Carefully slide the depth marker down until it bottoms out on the Gauge Block. d. With the depth marker bottomed out, press the “ZERO” switch. The Depth Gauge’s display should now read 0.00 mm. NOTE: Push (extend) the depth marker to the gauge block to correctly zero. Do not use the gauge block to push (retract) the depth marker up to the datum point. Depth marker Datum level flush with Gauge Block Figure 129 61/113 NTB17-039h Pages 62-66 are for Type 1 Thrust Bearing ONLY. Proceed to page 67 if working with Type 2 Thrust Bearing (with bearing race). Type 1 CVT: Clutch Total Endplay Adjustment – Thrust Bearing Selection IMPORTANT: The clutch total endplay (Figure 130) must always be adjusted when a new sub-assembly is installed. The Type 1 CVT uses the thrust bearing thickness between the clutch drum of clutch assembly and the dummy cover to adjust the total endplay. Thrust Bearing Selection There are eight (8) thicknesses of thrust bearings available for total endplay adjustment. For additional information, see video # 547: “CVT Belt and Pulley Replacement” and fast forward to minute marker 13:10. This video is located under the TECH TRAINING GARAGE VIDEOS tab in Virtual Academy. Dummy cover CVT case Total endplay Clutch drum Thrust bearing Figure 130 105. Clean and then zero the Digital Depth Gauge (part #: J-50272). See pages 60-61. Set Digital Depth Gauge to millimeters. 106. Clean Gauge Block J-50271. 107. Confirm that the CVT case and the dummy cover mating surfaces are clean. 62/113 NTB17-039h CVT case Oil pump 108. Calculate the “average clutch assembly bore depth” (D) shown in Figure 131 as follows: Gauge Block IMPORTANT: Measurements are required from two opposite ends to obtain the average. Clutch drum of clutch assembly Figure 131 Clutch assembly bore a. Position the Gauge Block over the clutch assembly bore on the surface where the dummy cover seats (Figure 132). IMPORTANT: This surface is lower than the CVT case to torque converter housing surface. Gauge Block Figure 132 b. Confirm the Gauge Block is not sitting on the clutch assembly or against the input shaft. Dummy cover seat Dummy cover seat NOTE: The clutch assembly should sit 1-3 mm lower than the dummy cover seat (Figure 133). If the clutch assembly is sitting higher than the dummy cover surface, see TROUBLESHOOTING The Dummy Cover Will Not Sit Flush on page 105. 63/113 Clutch assembly Figure 133 NTB17-039h c. Position the Depth Gauge on the Depth Gauge Gauge Block (Figure 134). Datum level NOTE: Make sure the Depth Gauge’s datum level is flush with the top of the Gauge Block. d. Carefully slide the gauge down until it bottoms out on the bottom of the clutch assembly bore. Write this measurement as D1 (use millimeters). Clutch assembly bore Gauge Block NOTE: Do not measure from the clutch assembly bore shown in red (Figure 135). Figure 134 Do not measure from this raised step (highlighted in red). Measure here; D2 Measure here; D1 Figure 135 e. Measure this same distance on the opposite side (180 degrees) of the clutch assembly bore and write it as D2. f. Using the formula below, calculate the average and write down the calculated value as D. (D1 + D2) D = --------------------------- Write the measurement for “D” here _____ mm 2 64/113 NTB17-039h 109. Measure the average (H) dummy cover height (Figure 137) as follows: Clean surfaces Clean here a. Clean the dummy cover surfaces that contact the CVT case and thrust bearing (Figure 136). CAUTION: Use brake cleaner (or equivalent) and a lint-free towel only. Make sure the brake spray or solvents used are compatible with local regulations. b. Place the dummy cover upside Clean here down on a work bench, and place the Gauge Block onto the thrust bearing surface (Figure 137). Figure 136 c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy cover (Figure 137). NOTE: Make sure the Depth Gauge’s datum level is flush with the top of the Gauge Block. d. Carefully slide the Depth Gauge down until it contacts the dummy cover surface that mates with the CVT case. Write this measurement as H1 (use millimeters). e. Measure this same distance on the opposite side of the dummy cover and write as H2 (Figure 137). Gauge Block Measure opposite sides Figure 137 f. Using the formula below, calculate the average and then write down the calculated value as H. (H1 + H2)(H1 + H2) H= H = --------------Write the measurement for “H” here _____ mm 2 110. Choose the thrust bearing to adjust Clutch Total Endplay (A) as follows: a. Calculate A (Total Endplay): Total Endplay A = D – H (This will be the thrust bearing thickness). Fill in the measurements below for “D” and “H” from pages 64 and 65 to calculate for “A”. D measurement ______ mm – H measurement ______ mm = A - - - - - - - - - - - - - - - - ______ mm 65/113 Please print this page and attach it to the repair order. NTB17-039h b. Choose the appropriate bearing from Table A below, based on A (eight different thicknesses of thrust bearings are available). Example: If A = 4.3 mm, it falls between the lower and upper clearances for bearing thickness 3.93 mm. Refer to PARTS INFORMATION for Thrust Bearing part numbers by thickness. c. Measure and confirm that the selected thrust bearing is the correct thickness before installing (Figure 138). Table A PART #: 314071XZ0B 1XZ0C 1XZ0D 1XZ0E 1XZ1A 1XZ1B 1XZ1C 1XZ1D A=D-H BEARING CLEARANCE (A) THICKNESS 3.87 - 4.06 MM 4.07 - 4.22 mm 4.23 - 4.42 mm 4.43 - 4.57 mm 4.58 - 4.77 mm 4.78 - 4.93 mm 4.94 - 5.08 mm 5.09 - 5.29 mm 3.57 3.75 3.93 4.1 4.28 4.46 4.61 4.79 Figure 138 111. Install the thrust bearing flush to the clutch assembly bore as shown in Figure 139. Install thrust bearing in area shown in green so that it is centered by the four tabs. CAUTION: The thrust bearing has two sides. See image below for appropriate orientation. Four Alignment tabs. (One not shown). Silver surface faces UP Black surface faces DOWN Thrust bearing This gap should face down Correct installation Incorrect installation Figure 139 66/113 NTB17-039h Pages 67-74 are for Type 2 Thrust Bearing (with bearing race) ONLY. Proceed to page 62 if working with Type 1 Thrust Bearing. Type 2 CVT: Clutch Total Endplay Adjustment – Bearing Race Selection IMPORTANT: The clutch total endplay (Figure 130) must always be adjusted when a new sub-assembly is installed. The Type 2 CVT uses the thrust bearing race thickness between the clutch drum of clutch assembly and the oil pump cover (dummy cover) to adjust the total endplay. Thrust Bearing Race Selection There are seven (7) thicknesses of thrust bearing races available for total endplay adjustment. CVT case Bearing race Dummy cover Thrust bearing Clutch drum Figure 140 112. Clean and then zero the Digital Depth Gauge (part #: J-50272). See pages 60-61. Set Digital Depth Gauge to millimeters. 113. Clean Gauge Block J-50271. 114. Confirm that the CVT case and the dummy cover mating surfaces are clean. CAUTION: Do NOT use sanding discs or similar abrasive tools. Use brake spray or equivalent solvent and lint-free towels only. Make sure the brake spray or solvents used are compatible with local regulations. 67/113 NTB17-039h 115. Calculate the “average clutch assembly surface depth” (D) as follows: IMPORTANT: Measurements are required from two opposite ends to obtain the average. Figure 141 Gauge Block a. Position the Gauge Block over the clutch assembly on the surface that the dummy cover seats. IMPORTANT: This surface is lower than the CVT case to torque converter housing. Figure 142 b. Confirm the Gauge Block is not sitting on the clutch assembly or against the input shaft. Input shaft NOTE: The top surface of the clutch assembly must be 1-3 mm below the CVT case surface, where the dummy cover seats. If the clutch assembly is sitting higher than the dummy cover surface, see TROUBLESHOOTING The Dummy Cover Will Not Sit Flush on page 105. 68/113 Clutch assembly Figure 143 NTB17-039h c. Position the Depth Gauge on the Gauge Block. NOTE: Make sure the depth gauge’s datum level is flush on top of the Gauge Block. d. Carefully slide the gauge down until it bottoms out on the upper surface of the clutch drum where thrust bearing seats, where shown in Figure 144. Write this measurement as D1 (use millimeters). Measure 180 degrees apart Figure 144 e. Measure this same distance on the opposite side (180 degrees) of the clutch assembly surface and write it as D2. f. Using the formula below, calculate the average and write down the calculated value as D. (D1 + D2) D = --------------------------- Write the measurement for “D” here _____ mm 2 69/113 NTB17-039h Clean here 116. Measure the average (H) dummy cover height where case seats as follows; Clean surfaces a. Clean the dummy cover surface that contact the CVT case and depth gauge. CAUTION: Use brake spray (or equivalent) and lint-free towel only. Make sure the brake spry or solvents used are compatible with local regulations. b. Place the dummy cover upside down on a workbench, and place the Gauge Block onto the top surface. Clean here Figure 145 c. Position the Depth Gauge on the Gauge Block over an outer end of the dummy cover. NOTE: Make sure the Depth Gauge’s datum level is flush with the top of the Gauge Block. d. Carefully slide the Depth Gauge down until it contacts the dummy cover surface that mates with the CVT case. Write this measurement as H1 (use millimeters). e. Measure this same distance on the opposite side of the dummy cover and write it as H2. Measure opposite sides Figure 146 f. Using the formula below, calculate the average and then write down the calculated value as H. (H1 + H2) H = --------------2 Write the measurement for “H” here _____ mm 70/113 NTB17-039h 117. Measure the average (J) dummy cover height where thrust race seats as follows: a. Carefully slide the Depth Gauge down until it contacts the dummy cover surface that mates with the thrust race. Write this measurement as J1 (use millimeters). b. Measure this same distance on the opposite side (180 degrees) of the dummy cover and then write as J2. Measure 180 degrees apart Figure 8GG c. Using the formula below, calculate the average and then write down the calculated value as J. (J1 + J2) J = --------------2 Write the measurement for “J” here _____ mm 118. Calculate gap G. Gap G = J – H Fill in the measurements below for “J” and “H” to calculate for “G”. J measurement ______ mm – H measurement ______ mm = G ------------------- ______ mm 71/113 NTB17-039h 119. Measure the thickness of the thrust bearing ONLY (without original race) as follows: a. Place the thrust bearing roller side down on the Gauge Block (Figure 147). IMPORTANT: Roller side of thrust bearing must face down and be flat on the Gauge Block to accurately measure thickness. b. Measure at two different positions of the thrust bearing that are 180 degrees apart. c. Add the two measurements, and then divide by two. Write down the calculated value as E. (E1 + E2) E = --------------2 Write the measurement for “E” here _____ mm Roller side Gauge Block Thrust bearing Figure 147 120. Choose the thrust bearing race to adjust Clutch Total Endplay (C) as follows: a. Calculate C (clearance). Total Clearance C = D – T + G – E NOTE: “T “ is the Thickness of the Gauge Block (J-50271: 20mm). Fill in the measurements below for “D”, “G” and “E” from pages 69-72 to calculate for “C”. D measurement – T measurement + G measurement – E measurement = C---------------- ______ mm _ 20 __ mm ______ mm ______ mm ______ mm Please print this page and attach it to the repair order. EXAMPLE: If D = 23.81, G = 0.41, E = 2.57 C = D – 20 + G – E = 23.81 - 20 + 0.41 - 2.57 C = 1.65 72/113 NTB17-039h b. Choose an appropriate thrust bearing race from Table B below based on C (seven different thrust bearing “race thicknesses” are available). Example: If C = 1.65 mm, it falls between the lower and upper clearances for race thickness 1.2 mm. c. Measure and confirm that the selected thrust bearing race is the correct thickness before installing (Figure 148). IMPORTANT: Do not measure from the thrust bearing race lip (Figure 149). Table B 3WX0A CLEARANCE (C) C=D–T+G–E 0.90 – 1.08 mm RACE THICKNESS 0.6 mm 3WX0B 3WX0C 3WX0D 1.09 – 1.29 mm 1.30 – 1.50 mm 1.51 – 1.70 mm 0.8 mm 1.0 mm 1.2 mm 3WX1A 3WX1B 3WX1C 1.71 – 1.90 mm 1.91 – 2.10 mm 2.11 – 2.30 mm 1.4 mm 1.6 mm 1.8 mm PART #: 31435- Incorrect Correct Thrust bearing race lip Do not measure from thrust bearing race lip Thrust bearing race Figure 148 Figure 149 73/113 NTB17-039h 121. Install the thrust bearing onto the clutch drum. IMPORTANT: The thrust bearing has two sides. The needle bearing side is the upper side. The race side mates with the clutch drum surface. Thrust bearing Figure 150 122. Install the bearing race onto the dummy cover. Apply petroleum jelly or equivalent to the thrust race to hold in place on the dummy cover. Thrust bearing race Figure 151 74/113 NTB17-039h Clean the Torque Converter Housing, Dummy Cover Passages and Baffle Plates IMPORTANT: Remove as much of the CVT and cleaning fluids as possible, and clean the related parts in the following steps. 123. Remove the baffle plate and lubrication tube as follows: Baffle plate and bolts a. Remove the three bolts, and then remove the baffle plate from the converter housing (Figure 152). Figure 152 b. Remove the bolt and then remove Lubrication tube, tube bracket, and and bracket bolt the lubrication tube and its bracket (Figure 153). Figure 153 124. Clean all baffle plates. 75/113 NTB17-039h 125. Clean the oil passages of the converter housing, lubrication tube and dummy cover with brake cleaner (or equivalent) where shown in Figure 154 and Figure 155 below. NOTE: Do not stand in front of the passages shown while using compressed air. Air pressure comes out these passages Apply cleaner, and then 75 PSI air pressure to these passages Apply cleaner, and then 75 PSI air pressure to this passage Figure 154 Air pressure comes out here Apply 75 PSI maximum air pressure in these passages Figure 155 126. Install the lubrication tube and bracket, and then the baffle plate with three bolts (Figure 156). Bolt torque: 5.9 N•m (0.6 kg-m, 52 in-lb.) Baffle plate and bolts Lubrication tube and bracket Figure 156 76/113 NTB17-039h CVT Reassembly 127. Install a new torque converter seal with Seal Installer J-50818 (Figure 157). Place the torque converter housing flat during installation. Apply a light coat of CVT fluid to the seal lip surfaces. The torque converter housing seal will be 0.5 mm (0.020 inches) below the bore’s surface when the seal installer bottoms out. J-50818 Figure 157 J-52284 128. Is this vehicle an all-wheel drive (AWD)? YES: Proceed to step 129. NO: Install the torque converter housing side axle seal (Figure 158). Use Seal Installer J-52284 and Driver Handle J-8092. Apply a light coat of CVT fluid to the seal lip surfaces. Proceed to step 129. J-8092 Converter housing Figure 158 77/113 NTB17-039h 129. Apply petroleum jelly or equivalent to the dummy cover’s lathe cut seals (Figure 159) before installing the dummy cover to the CVT case. IMPORTANT: Confirm that the lathe cut seals (white seals) are in their appropriate slots. Carefully reposition seals as necessary. Lathe cut seals must be in correct the positions during final assembly to prevent drivability issues. This area must remain clear Figure 159 Dummy cover lathe cut seals (white seals) 130. Confirm that the input shaft’s lathe cut seals are in the correct locations. Input shaft IMPORTANT: Lathe cut seals (white seals) must be in their appropriate slots. This area must Carefully reposition seals as remain clear necessary. Input shaft lathe cut seals (white seals) correctly located in slots Lathe cut seals must be in the correct positions during final assembly to prevent drivability issues. Figure 160 131. Install the dummy cover first, then baffle plate C, and then the related bolts finger tight (Figure 161). IMPORTANT: Visually check that the dummy cover is fully seated on the CVT case. If it is not, refer to TROUBLESHOOTING pages 105106. Do not force the dummy cover into place. Make sure the dummy cover is fully seated before installing the bolts. Do not torque these bolts at this time. 78/113 Dummy cover, baffle plate C, and bolts Figure 161 NTB17-039h 132. Install baffle plate B and “L” bracket with the related bolts finger tight (Figure 162). Baffle plate B and bolts 133. Torque the bolts from steps 131 and 132 in the following order: 2 a. Baffle plate B bolts: 5.9 N•m (0.6 kg- m, 52.2 in-lb.) 1 b. “L” bracket bolts: 25.5 N-m (2.6 kgm, 19 ft- lb). Torque 11 and then 2 . c. Dummy cover and baffle plate C bolts torque: 19.0 N•m (1.9 kg-m, 14 ft-lb.) “L” bracket and bolts Figure 162 Thrust washer 134. Install the thrust washer onto the dummy cover (Figure 163). Use petroleum jelly or equivalent to hold the thrust washer in place. Make sure the tabs fit into the holes. Tabs Figure 163 79/113 NTB17-039h Drive sprocket Chain Driven sprocket 135. Install the drive sprocket, driven sprocket, and chain as an assembly (Figure 164). Make sure the raised edge (wider edge) on the drive sprocket is facing up (Figure 165). Figure 164 Raised edge Figure 165 a. Expand the snap ring with a suitable tool, and then push down on the driven sprocket until it bottoms out (Figure 166). Snap ring ends Driven sprocket b. Release the snap ring and then pull up on the driven sprocket until the snap ring locks into its groove. NOTE: A click sound is heard when the snap ring locks in place. Figure 166 80/113 NTB17-039h Baffle plate A nuts 136. Install baffle plate A with two nuts (Figure 167). Nut torque: 5.9 N•m (0.6 kg-m, 52.2 in-lb.) Figure 167 O-ring 137. Install a new O-ring on the input shaft (Figure 168). Apply CVT fluid to the O-ring and O-ring groove before installing. Figure 168 138. Install the differential assembly and the reduction gear assembly into the CVT case (Figure 169). Thoroughly clean each assembly before installing. Oil the bearings and gear teeth with CVT fluid before installing. Reduction gear assembly Differential assembly Figure 169 81/113 NTB17-039h 139. Confirm the pin (Figure 170) is located in the CVT case prior to installation of the converter housing. Pin NOTE: If necessary apply petroleum jelly or equivalent to keep it in place. Figure 170 82/113 NTB17-039h 140. Apply one continuous 2.0 mm (0.8 inches) diameter bead (Figure 171) of pink colored Loctite 5460 Sealant (see the Parts Information section of this bulletin). Before sealant application, make sure the mating surfaces are clean from oil, dirt, old sealant, etc. (Figure 171). IMPORTANT: Have the converter housing ready for installation prior to applying the sealant. NOTE: Start applying sealant where shown, making sure that the starting point and the ending point are about the middle between the bolt holes. Overlap both ends of the bead by 3-5 mm (0.12-0.20 inches). Make sure to apply sealant around the center bolt hole. Also apply sealant around this bolt hole Figure 171 83/113 NTB17-039h 141. Install the torque converter housing onto the CVT case (see Figure 172 for torque sequence): Install new bolts (24). a. Torque the first six (6) bolts with symbol below). in numbered sequence (see b. Torque the remaining bolts with symbol below). in numbered sequence (see All bolts are 30 mm (1.2 inches) in length. Bolt torque: 45.0 N•m (4.6 kg-m, 33.2 ft-lb.) IMPORTANT: Make sure to torque the bolts in the sequence shown (Figure 172). 23 22 21 7 20 19 24 8 9 18 17 10 16 11 15 14 13 12 Figure 172 142. Clean off the excess sealant. 84/113 NTB17-039h Control Valve (Valve Body) Strainer and Pan Installation IMPORTANT: Installation steps in this bulletin may contain different style parts than what were originally installed in the CVT. Pay careful attention, REASSEMBLY MAY NOT BE IDENTICAL TO DISASSEMBLY. Confirm that the QR label, control valve and CD part numbers all match before installing the control valve (refer to NTB12-103). For additional information, see video # 547: “CVT Belt and Pulley Replacement” and fast forward to minute marker 19:52. This video is located under the TECH TRAINING GARAGE VIDEOS tab in Virtual Academy. CAUTION: Handle the valve body carefully. NOTE: If an oil strainer bracket was removed, discard it. An oil strainer bracket (Figure 173) will not be used with the new oil strainer. Oil strainer bracket Figure 173 143. Install a new lip seal (Figure 174). Do NOT reuse the old lip seal. Apply a small amount of petroleum jelly or equivalent to the lip seal to keep it in place on the CVT. Lip seal Figure 174 85/113 NTB17-039h 144. Install the Control Valve with eleven (11) mounting bolts (Figure 175). IMPORTANT: Leave four (4) holes blank at this step. 25 mm bolts bolt CAUTION: Make sure the wiring harness does not get pinched (see Figure 176 and Figure 177 for correct routing). 54 mm (2.125 inches) long bolt 7 pieces 44 mm (1.73 inch) long bolt 2 pieces 25 mm long (1 inch) long bolt 2 pieces 44 mm bolts ; ; Figure 175 ; CAUTION: The two 25 mm bolts are installed WITHOUT the strainer bracket. Bolt torque: 7.9 N•m (0.81 kg-m, 70 in-lb.) Correctly routed Incorrectly routed Figure 176 Figure 177 86/113 NTB17-039h 145. Replace the metal bracket of the fluid temperature sensor as follows: NOTE: The new bracket will be oriented the same way the old bracket was. a. Cut the old plastic zip tie with an appropriate tool to remove the fluid temperature sensor’s metal bracket from the terminal harness assembly (Figure 178 and Figure 179). CAUTION: Cut the plastic zip tie over the metal bracket to avoid damage to the fluid temperature sensor. b. Discard the removed metal bracket and plastic zip tie. c. Use the new plastic zip tie from the Parts Information to attach the fluid temperature sensor of the terminal connector harness to the fluid temperature sensor’s new metal bracket. IMPORTANT: Locate the plastic zip tie at the center notch of three notches on the fluid temperature sensor (Figure 179). Tighten the plastic zip tie so that it is oriented as shown in Figure 179. d. Cut off the plastic zip tie excess. Fluid temperature sensor Fluid temperature sensor Plastic zip tie located at corner Figure 178 Plastic zip tie in center notch Fluid temperature sensor’s metal bracket 87/113 Figure 179 NTB17-039h 146. Connect the electrical harness connector (Figure 180). Harness connector Figure 180 147. Install the CVT fluid temperature sensor bracket to the valve body with one (1) bolt (Figure 181). NOTE: Leave one (1) bolt hole blank as it will be used to secure the oil strainer at a later step. 1 bolt 54 mm (2.125 inches) long bolt. Bolt torque: 7.9 N•m (0.81 kg-m, 70 in-lb.) Figure 181 148. Install the new oil strainer with its new O-ring seal with two (2) bolts (Figure 182). NOTE: The replacement strainer maybe a different shape than the original. 54 mm (2.125 inches) long bolt 2 pieces. 54 mm bolts ; Bolt torque: 7.9 N•m (0.81 kg-m, 70 in-lb.) Figure 182 88/113 NTB17-039h 149. Install the manual plate, lock washer, and nut (Figure 183). NOTE: Make sure the manual plate fits into the slot of the manual valve before applying torque to the nut. Manual plate Slot and manual plate end Lock washer Reuse the existing manual plate, lock washer, and nut. Nut Nut torque: 22.1 N•m (2.3 kg-m, 16 ft-lb.) 150. Clean the original oil pan and magnets with a suitable cleaner. Visible debris should not be present at re-assembly. Manual valve Figure 183 151. Reassemble the original magnets to the pan. NOTE: Return the magnets to their original locations. 152. Install a new oil pan gasket to the pan. 153. Install the oil pan bolts (see Figure 184). Reuse the existing pan bolts. Oil pan bolts torque: 7.9 N•m (0.81 kg-m, 70 in-lb.) Figure 184 154. Install a new drain washer to the drain plug on the oil pan. 155. Install the primary speed sensor to the CVT assembly. (Perform only if installing CVT assembly.) IMPORTANT: Install a new O-ring to the speed sensor before installation. DO NOT reuse the old O-ring. Bolt torque: 5.9 N•m (0.6 kg-m, 52 in-lb.) 89/113 NTB17-039h 156. Install the torque converter to the CVT assembly (perform only if installing the CVT assembly). Verify the torque converter is installed at the proper depth (see Figure 185). A = 14.4 mm Converter housing Measure here Converter front A Straight edge laid on mating surface of converter housing Figure 185 157. Attach the QR label (Figure 186) with the new calibration data onto the transmission range switch (inhibitor switch Figure 187). A QR Label and CD-R are included with the new valve body. Confirm that the QR label and the CD-R part numbers are the same (Figure 186). CD-R Inhibitor switch QR Label QR Label Figure 186 Figure 187 158. If only the valve body (control valve) was replaced, skip to step 160 on the next page. 90/113 NTB17-039h Install the CVT Assembly 159. Install the CVT assembly into the vehicle. NOTE: Refer to the Electronic Service Manual (ESM), section TM – Transaxle & Transmission, for CVT installation. And then, External O-ring to the transfer case 2WD vehicles skip to step 160 below: Vehicles with all-wheel drive, install the transfer case as follows: Transfer case a. Replace only the external O-ring to the transfer case and then install the transfer case to the CVT. Apply CVT fluid to the O-ring. NOTE: Refer to the ESM, section DLN – Driveline, for the transfer case assembly installation. Figure 188 Use extreme caution when installing the axle to the transfer assembly to avoid seal damage or deformation. Properly support and guide the axle. b. Proceed to step 160. 160. Flush the CVT cooler. IMPORTANT: A CVT Cooler flush is required. Refer to bulletin NTB15-013 to perform CVT Cooler flush. 161. Connect both battery cables, negative cable last. 162. Reset/reinitialize systems as needed. Refer to the ESM, section PG – Power Supply & Ground Elements, for a listing of systems that require reset/initialization after reconnecting the 12V battery. Look in the PG section index for ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL. This list often includes items such as radio, power windows, clock, sunroof, etc. 91/113 NTB17-039h TCM Reprogramming A. IMPORTANT: Before starting, make sure: ASIST on the CONSULT PC has been synchronized (updated) to the current date. All CONSULT-III plus (C-III plus) software updates (if any) have been installed. NOTE: Most instructions for reprogramming with C-III plus are displayed on the CONSULT PC screen. If you are not familiar with the reprogramming procedure, click here. This will link you to the "CONSULT- III plus (C-III plus) Reprogramming" general procedure. CAUTION: Connect a battery maintainer or smart charger to the vehicle battery, set to “power supply” mode. If the vehicle battery voltage drops below 12.0V or rises above 15.5V during reprogramming, the TCM may be damaged. Be sure to turn OFF all vehicle electrical loads. If a vehicle electrical load remains ON, the TCM may be damaged. Be sure to connect the AC Adapter. If the CONSULT PC battery voltage drops during reprogramming, the process will be interrupted and the TCM may be damaged. Turn OFF all external Bluetooth® devices (e.g., cell phones, printers, etc.) within range of the CONSULT PC and the VI. If Bluetooth® signal waves are within range of the CONSULT PC during reprogramming, reprogramming may be interrupted and the TCM may be damaged. 92/113 NTB17-039h 163. Connect the CONSULT PC to the vehicle to begin the reprogramming procedure. 164. Start C-III plus. 165. Wait for the plus VI to be recognized. The serial number will display when the plus VI is recognized. 166. Select Re/programming, Configuration. Plus VI is recognized Figure 189 167. Follow the on-screen instructions and navigate the C-III plus to the screen shown in Figure 190. 168. When you get to the screen shown in Figure 190, confirm reprogramming applies as follows. A. Find the TCM Part Number and write it on the repair order. NOTE: This is the current TCM Part Number (P/N). TRANSMISSION Current TCM P/N 31036 Figure 190 B. 93/113 NTB17-039h B. Compare the P/N you wrote down to the numbers in the Current TCM Part Number column in Table C below. If there is a match, continue with the reprogramming procedure; step 169. If there is not a match, reprogramming is not needed; skip to step 178 on page 99, Perform ADDITIONAL SERVICE WHEN REPLACING CONTROL VALVE. Table C Model Model Year 2013 Altima 2014 2015 2016/2017 2015 Murano 2016/2017 2013 Pathfinder 2014 2015 2016 2017 Maxima Quest 2016 2017 2015 2016 2017 Current TCM Part Number Before Reprogramming: 31036 3NT0A, 3TA6A 3TA6B 3TA9E 3TM0A, 3TM1A, 3TM2A, 3TM3A 3TM0D, 3TM1D 3TM0E, 3TM1E 9HM2A, 9HM5A, 9HM5B, 9HM5C, 9HM5D 9HP0A, 9HP0B, 9HP0C, 9HP4C 3TF0A, 3TF0B 9HS9A 5AA0A, 5AA1A, 5AA2A, 5AA9A 5AA9B, 5AA0D, 5AA0E 5AG0A, 5AG9A, 5AG0B, 5AG9B 5AG0C 3KA2A, 3KA4A, 3KA5A, 3KA6A 3KA4B, 3KA5B, 3KA6B 3KA4C, 3KA6C 3KA4D, 3KA4E 3KD2A, 3KD4A, 3KD5A 3KD4B, 3KD5B 3KD4C, 3KD4D, 3KD4E 9PA3A, 9PA7A, 9PA9A 9PA3B, 9PA7B 9PA3C, 9PA7C 9PA3D, 9PA5D, 9PA7D 9PA5E 9PB0A, 9PB3A, 9PB9A 9PB0B, 9PB0C, 9PB0E 9PF0A, 9PF1A 9PF1B, 9PF9A 9PK0B, 9PK0C, 9PK9A 4RA0A, 4RA0B, 4RA0C, 4RA0D 4RA1A, 4RA1B 9DD0A, 9DD0B, 9DD0C, 9DD9A, 9DD9B 4AY0A, 4AY0B, 4AY6A 6AX0A, 6AX0B, 6AX9A 6AX2A, 6AX2B 169. Follow the on-screen instructions to navigate C-III plus and reprogram the TCM. 94/113 NTB17-039h NOTE: In some cases, more than one new P/N for reprogramming is available. If more than one new P/N is available, the screen in Figure 191 displays. Select and use the reprogramming option that does not have the message “Caution! Use ONLY with NTBXX-XXX”. If you get this screen and it is blank (no reprogramming listed), it means there is no reprogramming available for this vehicle. Close C-III plus and refer back to ASIST for further diagnosis. TRANSMISSION Figure 191 Before reprogramming will start, you will be required to enter your User Name and Password. The CONSULT PC must be connected to the Internet (Wi-Fi or cable). If you do not know your User Name and Password, contact your Service Manager. Figure 192 95/113 NTB17-039h 170. When the screen in Figure 193 displays, reprogramming is complete. NOTE: If the screen in Figure 193 does not display (indicating that reprogramming did not complete), refer to the information on the next page. 171. Disconnect the battery charger from the vehicle. 172. Select Next. Figure 193 NOTE: In the next step (page 98) you will perform Erase All DTCs. DTC erase is required before C-III plus will provide the final reprogramming confirmation report. 96/113 NTB17-039h TCM Recovery: Do not disconnect plus VI or shut down C-III plus if reprogramming does not complete. If reprogramming does not complete and the “!?” icon displays as shown in Figure 194: Check battery voltage (12.0–15.5 V). Ignition is ON, engine OFF. External Bluetooth® devices are OFF. All electrical loads are OFF. Select retry and follow the on screen instructions. “Retry” may not go through on first attempt and can be selected more than once. Figure 194 If reprogramming does not complete and the “X” icon displays as shown in Figure 195: Check battery voltage (12.0 – 15.5 V). CONSULT A/C adapter is plugged in. Ignition is ON, engine OFF. Transmission is in Park. All C-III plus / VI cables are securely connected. All C-III plus updates are installed. Figure 195 Select Home, and restart the reprogram procedure from the beginning. 97/113 NTB17-039h 173. Follow the on-screen instructions to Erase All DTCs. 174. When the entire reprogramming process is complete, the screen in Figure 196 will display. 175. Verify the before and after part numbers are different. 176. Print a copy of this screen (Figure 196) and attach it to the repair order for warranty documentation. 177. Select Confirm. 31036 - _ _ _ _ _ 31036 - _ _ _ _ _ TRANSMISSION Figure 196 98/113 NTB17-039h 178. Perform ADDITIONAL SERVICE WHEN REPLACING CONTROL VALVE. Refer to TM – Transaxle & Transmission / RE0F10E / BASIC INSPECTION, and perform ADDITIONAL SERVICE WHEN REPLACING CONTROL VALVE. IMPORTANT: Check off these additional services as they are completed and attach this to the repair order when finished. 179. Verify the CVT operates normally and no abnormal noises are heard during a test drive. CHECK OFF ADDITIONAL SERVICE PROCEDURE PRINT CURRENT CALIBRATION DATA CHECK THE SERIAL NUMBER WRITE THE DATA PRINT NEW CALIBRATION DATA FWD CLUTCH POINT LEARNING (Using procedure starting below) PERFORM SELECT LEARNING (DRIVE/REVERSE LEARNING) ERASE CVT FLUID DEGRADATION LEVEL DATA FWD CLUTCH POINT LEARNING (using CONSULT-III plus) 180. Apply the vehicle’s parking brake. 181. Start the engine and warm up to operating temperature (50-100o C [122-212o F]). 182. Connect the CONSULT PC to the vehicle. 183. Start CONSULT-III plus (C-III plus). 99/113 NTB17-039h 184. Wait for the plus VI to be recognized. The serial number will display when the plus VI is recognized. 185. Select Diagnosis (One System). Figure 197 186. Select Work Support under TRANSMISSION. Figure 198 100/113 NTB17-039h IMPORTANT: The following FWD CLUTCH POINT LEARNING will be performed twice. Once in drive (D) and once in reverse (R). 187. Select FWD CLUTCH POINT LEARNING and then Start. Figure 199 188. With the engine still running and at idle, depress the brake pedal and shift the CVT into neutral (N). Confirm that all of the required conditions indicated in Figure 200 are being met. 189. Select Start. Required conditions Figure 200 101/113 NTB17-039h 190. While maintaining all conditions shown in Figure 200 and the “Current status” indicates “EXECUTING”, shift the CVT into D and then wait until the “Current status” indicates “COMPLETED”. NOTE: This may take up to three (3) minutes to complete. Figure 201 191. When the screen in Figure 202 is displayed, select End. 192. Turn the engine OFF and then back ON. Figure 202 102/113 NTB17-039h 193. Select FWD CLUTCH POINT LEARNING and then Start. Figure 203 194. With the engine still running and at idle, depress the brake pedal and shift the CVT into neutral (N). Confirm that all of the conditions indicated in Figure 204 are being met. 195. Select Start. Required conditions Figure 204 103/113 NTB17-039h 196. While maintaining all conditions shown in Figure 204 and the Current status indicates EXECUTING, shift the CVT into R and then wait until the Current status indicates COMPLETED. NOTE: This may take up to 3 minutes to complete. Figure 205 197. When the screen in Figure 206 is displayed, select End. Figure 206 104/113 NTB17-039h TROUBLESHOOTING The Dummy Cover Will Not Sit Flush Clutch pack seated correctly If the dummy cover does not sit flush, the clutch pack may not be fully seated. Figure 207 shows clutch pack fully seated. Clutch pack is not fully seated if it is not below the surface that the dummy cover bolts to. Use instructions below to fully seat clutch pack. Surface dummy cover seats on NOTE: Always handle the clutch pack by the input shaft. Figure 207 Dummy cover 198. Remove the dummy cover. Figure 208 O-ring removed Clutch pack 199. Pull up the clutch pack by the input shaft to remove the entire clutch pack. Make sure the O-ring is not installed at this time, or it could be damaged during reassembly. Input shaft Figure 209 105/113 NTB17-039h Clutch pack Clutch pack layers 200. Using an appropriate tool, gently align the layers of the clutch pack. Bottom of the clutch pack shown in Figure 210. Appropriate tool Align layers Figure 210 201. Reinsert the entire clutch pack while holding the input shaft. 202. Gently jiggle the input shaft until the clutch pack seats below case lip. Input shaft 203. If the clutch pack does not seat, rotate back and forth from the input shaft and jiggle. Clutch pack 204. If the clutch pack still does not seat, repeat from step 199. Figure 211 106/113 NTB17-039h PARTS INFORMATION REPAIR DESCRIPTION PART # QUANTITY See Table D below 3170E-29X9C 1 1 Sub-assembly Repair KIT-PULLEY CONTROL VALVE KIT (5) SEAL-O RING (Transfer case to CVT AWD only) SEAL-O RING Loctite 5460 Sealant (1) (4) 33118-4BA0A 1 22180-9NB0A 999MP-LT5460P 2 (2) (3) Control Valve Replacement CONTROL VALVE KIT (5) 3170E-29X9C 1 11026-JA00A 16439-7S01D 1 2 Applies to all repairs WASHER-DRAIN CLAMP SEAL-O RING (External Oil Cooler O-ring for Pathfinder only) Transmission Cooler Cleaner Nissan NS-3 CVT Fluid (1) (4) Lens Swab packet (6) 22180-9NB0A 2 999MP-AM006P 999MP-NS300P J-51963 As needed As needed As needed (1) (2) (3) (4) (5) (6) Nissan NS-3 CVT Fluid and Loctite 5460 Sealant can be ordered through the Nissan Maintenance Advantage program: Phone: 877-NIS-NMA1 (877-647-6621) or Website: Order via link on dealer portal www.NNAnet.com and click on the “Maintenance Advantage” link. One container of Loctite 5460 Sealant is good for approximately 5 repairs. Sealant is not included in the kits. Bill out Loctite 5460 Sealant (or equivalent) under expense code 008. Do not include the Loctite 5460 Sealant part number on the claim. For warranty repairs, Nissan NS-3 CVT Fluid and Loctite 5460 Sealant must be used. For customer pay repairs, Nissan NS-3 CVT and Loctite 5460 Sealant Fluid or their equivalents are recommended. Includes QR label, CD-R, and control valve assembly. Shop supplies. Table D DESCRIPTION MODEL Pathfinder KIT-PULLEY MODEL YEAR PART NUMBER 2013-2014 31214-29X7C 2015-2017 31214-29X9B Altima (6 Cylinder) 2013-2014 31214-29X7A 2015-2017 31214-29X8A Maxima 2016-2017 31214-29X8B Murano and Quest 2015-2017 31214-29X9A 107/113 NTB17-039h PARTS INFORMATION CONTINUED THRUST BEARING (TYPE 1) DESCRIPTION PART #: 314071XZ0B 1XZ0C 1XZ0D 1XZ0E THRUST BEARING 1XZ1A 1XZ1B 1XZ1C 1XZ1D BEARING THICKNESS 3.57 3.75 3.93 4.1 4.28 4.46 4.61 4.79 BEARING RACE (TYPE 2) DESCRIPTION PART #: 314353WX0A 3WX0B 3WX0C RACE – BRG 3WX0D 3WX1A 3WX1B 3WX1C BEARING THICKNESS 0.6 mm 0.8 mm 1.0 mm 1.2 mm 1.4 mm 1.6 mm 1.8 mm 108/113 QTY 1 of each is included in the Kit. Select 1 for installation. QTY 1 of each is included in the Kit. Select 1 for installation. NTB17-039h PARTS KITS REFERENCE TABLE (Parts are listed in order of installation) IMPORTANT: Check off parts as they are used and attach this to the repair order when finished. CHECK OFF DESCRIPTION PART # PUMP ASSY-OIL 31340-3WX0A SEAL-O RING (Pump fitting bolt) 31526-28X0C SEAL-O RING (Filter cover) 31526-3VX0A FILTER ASSY-OIL GOVENOR (CVT fluid filter) 31726-28X0A MY13-14 Pathfinder 31209 29X8C MY13-14 Altima 31209 29X8A PULLEY ASSYCVT MY15-17 Altima, Murano & Quest 31209 29X9A (Sub-assembly) MY16-17 Maxima & 31209 29X9B MY15-17 Pathfinder CAP-GUIDE, CHAIN (Lubrication cap) 31268-3WXOA SEAL-O RING 31526-28X0A (O-ring between CVT case and side cover) Loctite 5460 Sealant 999MP-LT5460P BOLT (For sub-assembly side cover) 31377-1XZOB SEAL-O RING (Pulley retainer bolts) 31526-28X0C SEALOIL-DIFFER 38342-3WX0C (Differential side oil seal; CVT case side) See page 62 THRUST BEARING (Type 1) See page 67 RACE-BRG (TYPE 2) SEAL ASSY-OIL (Torque converter) 31375-1XF00 SEAL OIL-DIFFER 38342-3WX0D (Torque converter side, front wheel drive only) SEAL-O RING (Input shaft) 31526-80X01 Loctite 5460 Sealant 999MP-LT5460P BOLT (Torque converter housing) 31377-1XZOB SEAL-LIP (Between CVT and control valve) 31528-1XZ0A VALVE ASSY-CONTROL (Valve body) 31705-29X0C BAND (Zip tie for bracket) 24224-3VX0B BRACKET (Temperature sensor bracket) 31069-3VX0D STRAINER ASSY-OIL, AUTO TRANS 31728-29X0D GSKT-OIL PAN 31397-1XF0D WASHER-DRAIN (For drain plug) 11026-JA00A QUANTITY 1 1 (of 7) 1 1 1 2 1 As needed 19 (of 43) 6 (of 7) 1 1 1 1 1 1 As needed 24 (of 43) 1 1 1 1 1 1 1 SEAL-O RING (Speed Sensor) 31526-1XG0C 1 SEAL-O RING 31526-3VX0B 1 (CVT filler plug at converter housing) Nissan NS-3 CVT Fluid 999MP-NS300P As needed SEAL-O RING (Transfer case to CVT. AWD only) 33118-4BA0A 1 SEAL-O RING 22180-9NB0A 2 (External Oil Cooler O-ring for Pathfinder only) Complete CVT Flush Procedure Perform ADDITIONAL SERVICE WHEN REPLACING CONTROL VALVE (page 99) 109/113 NTB17-039h CLAIMS INFORMATION IF DTC P17F1 is stored and Sub-Assembly is replaced Submit a Primary Part (PP) type line claim using the following claims coding: OPERATION PFP OP CODE SYM DIAG FRT JD01AA CVT R&R (2) JD023A Inspect CVT Chain, Chain = NG (Includes JX36AA 1.1 control valve R&I) Replace CVT Sub-assembly MY13-14 (1) ZE 32 Pathfinder, MY16-17 Maxima or JX45AA 3.2 MY13-17 Altima V6 Replace CVT Sub-assembly MY15-17 Pathfinder or MY15-17 Murano or JX53AA 3.4 MY15-17 Quest Reprogram TCM JE99AA (2) (1) Reference the Parts Information Table (Table D on page 107) and use the applicable Belt and Pulley Assembly Part Number as the Primary Failed Part. (2) Reference the current Nissan Warranty Flat Rate Manual and use the indicated Flat Rate Time. NOTE: FRT allows adequate time to access DTC codes. No other diagnostic procedures subsequently required. Do NOT claim any diagnostic OP Codes with this claim. EXPENSE CODE EXPENSE CODE 008 DESCRIPTION Sealant MAX AMOUNT $12.46 OR IF DTC P17F0 is stored and Sub-Assembly is replaced Submit a Primary Part (PP) type line claim using the following claims coding: OPERATION PFP OP CODE SYM DIAG FRT JD01AA CVT R&R (2) JD023A Replace CVT Sub-assembly (Includes control valve R&I) MY13-14 Pathfinder, MY16-17 JX50AA 4.0 Maxima, or MY13-17 Altima V6 (1) ZE 32 Replace CVT Sub-assembly (Includes control valve R&I) MY15-17 Pathfinder or JX54AA 4.2 MY15-17 Murano or MY15-17 Quest Reprogram TCM JE99AA (2) (1) Reference the Parts Information Table (Table D on page 107) and use the applicable Belt and Pulley Assembly Part Number as the Primary Failed Part. (2) Reference the current Nissan Warranty Flat Rate Manual and use the indicated Flat Rate Time. NOTE: FRT allows adequate time to access DTC codes. No other diagnostic procedures subsequently required. Do not claim any diagnostic OP codes with this claim. Proceed to the next page for additional claims information. 110/113 NTB17-039h CLAIMS INFORMATION continued. EXPENSE CODE EXPENSE CODE 008 DESCRIPTION Sealant MAX AMOUNT $12.46 OR If DTC P17F1 is stored and Control Valve is replaced (chain inspection shows no signs of chain slip, OK): Submit a Primary Part (PP) type line claim using the following claims coding: (1) (2) OPERATION PFP OP CODE SYM DIAG FRT Inspect CVT Chain, Chain = OK JX37AA 0.3 (1) ZE 32 Replace Valve Body JD48AA (2) Reprogram TCM JE99AA (2) Reference the Parts Information Table and use the applicable Control Valve Kit part number (3170E-29X9C) as the Primary Failed Part. Reference the current Nissan Warranty Flat Rate Manual and use the indicated Flat Rate Time. NOTE: FRT allows adequate time to access DTC codes. No other diagnostic procedures subsequently required. Do NOT claim any diagnostic OP Codes with this claim. 111/113 NTB17-039h Type 1 and Type 2 Additional Reference Images TYPE 1 2013-2014 Pathfinder 2016-2017 Maxima 2013-2017 Altima (6 Cylinder Only) TYPE 2 2015-2017 Pathfinder 2015-2017 Murano 2015-2017 Quest Type 1 Type 2 Type 1 Type 2 Type 1 Type 2 Type 1 Type 2 112/113 NTB17-039h REMINDER! Attach the following to the repair order: Total EndPlay (A) calculation (page 65) Total EndPlay (C) calculation (Page 72) C-III plus screen showing the TCM part number before and after the reprogramming (Step 176 on page 98) C-III plus screen showing the current calibration data (Step 178 on page 99) C-III plus screen showing the new calibration data (Step 178 on page 99) Parts Kit Reference Table (Page 109) AMENDMENT HISTORY PUBLISHED DATE REFERENCE DESCRIPTION April 27, 2017 NTB17-039 Original bulletin published May 2, 2017 NTB17-039a Amended to change information on page 1 June 29, 2017 NTB17-039b Minor changes made to the PARTS INFORMATION and PARTS KITS REFERENCE TABLE, with related changes throughout the bulletin October 12, 2017 NTB17-039c Added models, model year and additional service procedure information October 26, 2017 NTB17-039d Thrust bearing quantity information clarified in PARTS INFORMATION March 5, 2018 NTB17-039e Added Quest to APPLIED VEHICLES and information related to Quest on pages 25, 100, 102, 103 and 105 March 14, 2018 NTB17-039f CLAIMS INFORMATION added October 8, 2019 NTB17-039g TCM reprogramming added October 30, 2019 NTB17-039h CLAIMS INFORMATION on page 111 and step reference on page 90 revised. 113/113 NTB17-039h