Disassembly Service Point

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

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: Identifying 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 manual control lever from the manual shaft.

Fig 6: Locating Manual Control 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: Pressing Terminal Body Into Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Fig 9: Identifying Transmission Fluid Cooler
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Remove the transmission fluid filter from the transaxle case.

Fig 10: Removing Transmission Fluid Filter
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Remove the fastening bolts of converter housing.

BOLT SYMBOL SPECIFICATION

Bolt symbol	A	B
Shank length mm (in)	30 (1.18)	35 (1.38)
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: Tapping 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 (2.4389 - 2.4401 in)

Fig 13: Measuring Mounting Bore Diameter Of Reduction Gear Bearing Outer Race Converter Housing Side
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:

ø67.949 - 67.979 mm (2.6752 - 2.6763 in)

Fig 14: Measuring Mounting Bore Diameter Of Differential Side Bearing Outer Race Converter Housing Side
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: Locating Converter Housing Pipe
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Remove the plug from the converter housing.

Fig 18: Locating Converter Housing Plug
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Remove the O-ring from the plug.

Fig 19: Identifying Plug O-Ring
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Remove the O-ring from the input shaft.

Fig 20: Locating Input Shaft O-Ring
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Remove the chain cover.

Fig 21: Locating Chain Cover
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Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Fig 22: Identifying Snap Ring
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Fig 23: Identifying Oil Pump Chain And Drive Sprocket
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Remove the thrust washer from the oil pump cover.

Fig 24: Locating Oil Pump Cover Thrust Washer
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Remove the snap ring from the oil pump.

Fig 25: Locating Oil Pump Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear assembly from the transaxle case.

Fig 26: Identifying Reduction Gear Assembly
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Remove the differential assembly from the transaxle case.

Fig 27: Identifying Differential Assembly
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Remove the bracket.

Fig 28: Locating Bracket Bolts
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Remove the oil guide.

Fig 29: Locating Oil Guide
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Remove the baffle plate.

Fig 30: Locating Baffle Plate
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Remove the oil pump cover from the transaxle case.

Fig 31: Locating Oil Pump Cover
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Remove the seal rings from the oil pump cover.

Fig 32: Locating Seal Rings
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Remove the needle bearing from the forward clutch assembly.

Fig 33: Locating 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 34: Locating Oil Pan Bolts
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Remove the oil pan gasket from the transaxle case.

Fig 35: Locating Oil Pan Gasket
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Remove the oil strainer

BOLT SYMBOL SPECIFICATION

Bolt symbol	A	B	C
Shank length mm (in)	12 (0.47)	44 (1.73)	12 (0.47)
Quantity	1	1	1

Fig 36: Locating Oil Strainer Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the O-ring from the oil strainer.

Fig 37: Identifying Oil Strainer O-Ring
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Remove the bracket from the control valve assembly.

Fig 38: Locating Bracket Bolts
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Remove the manual valve lever.

Fig 39: Locating Manual Valve Lever
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Remove the control valve assembly from the transaxle case as follows:

Insert pins etc. (ø3 mm (0.12 in) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.

Fig 40: Identifying Pulley Ratio Linkage And Pins
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove fastening bolts of the control valve assembly.

BOLT SYMBOL SPECIFICATION

Bolt symbol	A	B
Shank length mm (in)	54 (2.13)	44 (1.73)
Quantity	10	1

Fig 41: Locating 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 42: Removing Control Valve Assembly From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the bush from the control valve.

Fig 43: Removing Bush From Control Valve
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Remove the lip seal from the transaxle case.

Fig 44: Locating Lip Seal
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Remove the valve body harness from the control valve.

Fig 45: 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 46: Locating Oil Pump Bolts
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Remove the O-ring from the oil pump fastening bolt.

Fig 47: Identifying Oil Pump Fastening Bolt O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 48: Locating Lip Seal
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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 (2.6752 - 2.6763 in)

Fig 49: Measuring Mounting Bore Diameter Of Differential Side Bearing Outer Race Transaxle Case Side
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 50: 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 (2.4389 - 2.4401 in)

Fig 51: Measuring Mounting Bore Diameter Of Reduction Gear Bearing Outer Race Transaxle Case Side
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 52: 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 53: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring from the transaxle case.

Fig 54: Locating Detent Spring
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Remove the forward clutch assembly from the transaxle case.

Fig 55: 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 56: 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 57: Removing Sun Gear
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Remove the needle bearing on primary pulley side from the sun gear.

Fig 58: Removing Needle Bearing
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Remove the planet carrier from the transaxle case.

Fig 59: Removing Planet Carrier
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Remove the needle bearing from the planet carrier.

Fig 60: Removing Needle Bearing
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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 61: Removing Reverse Brake Retaining Plate, Drive Plate, Driven Plate, And Dish Plate From Transaxle Case
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 62: 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 illustration, and remove the reverse brake piston from the transaxle case.

Fig 63: Locating Oil Hole
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 64: Identifying Reverse Brake Piston
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