Disassembly Service Point

CAUTION: Do not disassemble parts other than specified in this manual.

Remove the transfer from the transaxle. < W1CJA >
Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.
Remove the harness bracket from the transaxle.
Remove the oil filler tube and oil level gage from the transaxle.
Remove the control cable bracket and breather hose from the transaxle.
Remove the torque converter from the transaxle.

Fig 1: Removing Torque Converter From Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the plug from the transaxle case.

Fig 2: Identifying Transaxle Case Plug
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Remove the O-ring from the plug.

Fig 3: Locating Plug O-Ring
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Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.

Fig 4: Locating Secondary Pulley Speed Sensor
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Remove the primary pulley speed sensor from the transaxle case, and detach the O-ring from the sensor.

Fig 5: Locating Primary Pulley Speed Sensor
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Remove the shift lever from the manual shaft.

Fig 6: Locating Shift Lever
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Remove the inhibitor switch from the transaxle.

Fig 7: Identifying Inhibitor Switch
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CAUTION: Be careful not to cause damage to the terminal body.
Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.

Fig 8: Identifying Snap Ring And Terminal Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the CVT fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Fig 9: Identifying CVT Fluid Cooler
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the CVT fluid cooler filter from the transaxle case.

Fig 10: Removing CVT Fluid Cooler Filter From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the fastening bolts of converter housing.

BOLT SYMBOL REFERENCE

Bolt symbol	A	B
Bolt length mm	30	35
Quantity	18	5

Fig 11: Identifying Converter Housing Bolts

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CAUTION: Be careful because adjusting shim of the drive sprocket may depart.

Remove the converter housing by tapping with a plastic hammer etc.

Fig 12: Removing Converter Housing
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Using the special tools MB990590 and MB992039, remove the outer race of reduction gear bearing from the converter housing.
Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.
Standard value

ø61.949-61.979 mm (f2.4389-2.4401 in)

Fig 13: Removing Outer Race Of Reduction Gear Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB990590 and MB992039, remove the outer race of differential side bearing from the converter housing.
Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.
Standard value
- F1CJA: ø67.949-67.979 mm (ø2.6752-2.6763 in)
- W1CJA: ø84.941-84.976 mm (ø3.3441-3.3455 in)
  
  Fig 14: Removing Outer Race Of Differential Side Bearing From Converter Housing
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION: When removing the oil seal, be careful not to cause damage to the converter housing.
Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.

Fig 15: Removing Converter Housing Oil Seal From Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the clip.

Fig 16: Locating Clip
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CAUTION: When removing the pipe, be careful not to bend it.
Remove the pipe from the converter housing.

Fig 17: Removing Pipe From Converter Housing
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Remove the plug from the converter housing.

Fig 18: Locating Plug (F1CJA)
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Fig 19: Locating Plug (W1CJA)
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Remove the O-ring from the plug.

Fig 20: Locating Plug O-Ring
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Remove the O-ring from the input shaft.

Fig 21: Locating Input Shaft O-Ring
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Remove the adjusting shim from the drive sprocket.

Fig 22: Locating Drive Sprocket Adjusting Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the baffle plate.

Fig 23: Locating Baffle Plate
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Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Fig 24: Identifying Snap Ring
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Fig 25: Removing Driven Sprocket, Oil Pump Chain And Drive Sprocket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the thrust washer from the oil pump cover.

Fig 26: Locating Thrust Washer
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Remove the snap ring from the oil pump.

Fig 27: Locating Snap Ring
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Remove the reduction gear assembly from the transaxle case.

Fig 28: Identifying Reduction Gear Assembly
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Remove the differential assembly from the transaxle case.

Fig 29: Identifying Differential Assembly (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 30: Identifying Differential Assembly (W1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket.

Fig 31: Locating Bracket
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Remove the baffle plate.

Fig 32: Locating Baffle Plate
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Remove the baffle plate.

Fig 33: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump cover from the transaxle case.

Fig 34: Locating Oil Pump Cover
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Remove the seal rings from the oil pump cover.

Fig 35: Locating Seal Rings
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Remove the needle bearing from the forward clutch assembly.

Fig 36: Removing Needle Bearing From Forward Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pan from the transaxle case.
Remove the magnet from the oil pan.

Fig 37: Identifying Oil Pan
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pan gasket from the transaxle case.

Fig 38: Removing Oil Pan Gasket From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the oil strainer

BOLT SYMBOL REFERENCE

Bolt symbol	A	B	C
Bolt length mm	12	44	12
Quantity	1	1	1

Fig 39: Identifying Oil Strainer Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the O-ring from the oil strainer.

Fig 40: Removing O-Ring From Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket from the control valve assembly.

Fig 41: Locating Control Valve Bracket
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Remove the manual lever.

Fig 42: Locating Manual Lever
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Remove the control valve assembly from the transaxle case as follows:

Insert pins etc. (f3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.

Fig 43: Identifying Pulley Ratio Linkage And Pin
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove fastening bolts of the control valve assembly.

BOLT SYMBOL REFERENCE

Bolt symbol	A	B
Bolt length mm	54	44
Quantity	10	1

Fig 44: Identifying Control Valve Assembly Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the control valve assembly from the transaxle case.
NOTE: Tilt the control valve assembly, and after removing from the manual shaft side, remove the terminal body from the transaxle case.

Fig 45: Removing Control Valve Assembly From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the bush from the control valve.

Fig 46: Removing Bush From Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 47: Locating Lip Seal
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Remove the valve body harness from the control valve.

Fig 48: Identifying Valve Body Harness
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Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side).

Fig 49: Locating Oil Pump Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the oil pump fastening bolt.

Fig 50: Removing O-Ring From Oil Pump Fastening Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 51: Locating Lip Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB990590 and MB992039, remove outer race of the differential side bearing from the transaxle case.
Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the transaxle case side; if the standard value is not satisfied, then replace the CVT assembly.
Standard value

ø67.949-67.979 mm (ø2.6752-2.6763 in)

Fig 52: Removing Outer Race Of Differential Side Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 53: Removing Adjusting Shim From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB990590 and MB992039, remove outer race of the reduction gear bearing from the transaxle case.
Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the transaxle case side; if the standard value is not satisfied, then replace the CVT assembly.
Standard value

ø61.949-61.979 mm (ø2.4389-2.4401 in)

Fig 54: Removing Outer Race Of Reduction Gear Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 55: Removing Adjusting Shim From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When removing the side oil seal, be careful not to cause damage to the transaxle case.
Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.

Fig 56: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring from the transaxle case.

Fig 57: Locating Detent Spring
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Remove the forward clutch assembly from the transaxle case.

Fig 58: Removing Forward Clutch Assembly From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on forward clutch drum side from the sun gear.

Fig 59: Removing Needle Bearing On Forward Clutch Drum Side From Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sun gear from the planet carrier.

Fig 60: Removing Sun Gear From Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on primary pulley side from the sun gear.

Fig 61: Removing Needle Bearing On Primary Pulley Side From Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planet carrier from the transaxle case.

Fig 62: Removing Planet Carrier From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the planet carrier.

Fig 63: Removing Needle Bearing From Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Check if there is damage, deformation, burn marks or permanent sets of the dish plate, driven plate, snap ring, and drive plate. Replace any defective part.
Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case.

Fig 64: Removing Reverse Brake Retaining Plate, Drive Plate, Driven Plate And Dish Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Set the spring compressor right on top of the spring of spring retainer assembly.
- Do not remove the return spring from the spring retainer assembly.
Using the special tool MB992139, compress the return spring, and remove the snap ring from the transaxle case.
Remove the retaining plate and return spring assembly.

Fig 65: Compressing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.
Feed the air in the oil hole shown in the diagram, and remove the reverse brake piston from the transaxle case.

Fig 66: Identifying Oil Hole
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 67: Identifying Reverse Brake Piston
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