Assembly Service Point

Fig 1: Identifying Reverse Brake Piston On Transaxle Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

1. Install the reverse brake piston, while turning it, on the transaxle case.
   Fig 2: Identifying Spring Retainer Assembly And Spring

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.
   CAUTION: When installing the retaining plate, align the tangs at positions A, B, C in the diagram.
   Fig 3: Installing Retaining Plate On Transaxle Case

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Install the retaining plate on the transaxle case.
   Fig 4: Identifying Retaining Plate Tangs

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   CAUTION:

   • Set the spring compressor right on top of the spring of spring retainer assembly.
   • Do not reuse the snap ring.
   • When installing the snap ring, make sure that the joint falls in the area A in the diagram.
   Fig 5: Installing Snap Ring On Transaxle Using Special Tool MB992139

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Using the special tool MB992139, compress the return spring, and install the snap ring on the transaxle case by means of a flat blade screwdriver etc.
   Fig 6: Identifying Joint Falls Area

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   Fig 7: Identifying Reverse Brake Retaining Plate, Drive Plate, Driven Plate And Dish Plate

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case.
   CAUTION:

   • When conducting measurements, measure two or more places, and find the average value.
   • Do not reuse the snap ring.
   • When installing the snap ring, make sure that the joint falls in the area A in the diagram.
   Fig 8: Measuring Clearance Between Snap Ring And Retaining Plate

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   Fig 9: Identifying Joint Falls Area

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Using a flat blade screwdriver etc., install the snap-ring on the transaxle case, and measure clearance between the snap ring and retaining plate. Select the snap ring so as to obtain standard value of the clearance. For selection of the snap ring, refer to "SERVICE SPECIFICATIONS ."

   Standard value: 1.2 - 1.5 mm (0.05 - 0.06 in) 

   (For reverse clutch clearance) 

   CAUTION:

   • Apply Vaseline when installing the needle bearing.
   • Be careful to attach the needle bearing in right direction.
   Fig 10: Installing Needle Bearing On Reverse Brake Piston

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
7. Install the needle bearing on the reverse brake piston. Refer to A in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
   Fig 11: Installing Planet Carrier On Reverse Brake

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Install the planet carrier on the reverse brake.
   CAUTION:

   • Apply Vaseline when installing the needle bearing.
   • Be careful to attach the needle bearing in right direction.
   Fig 12: Installing Needle Bearing On Primary Pulley Side Of Sun Gear

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. Install the needle bearing on the primary pulley side of the sun gear. Refer to B in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
   Fig 13: Installing Sun Gear On Planet Carrier

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
10. Install the sun gear on the planet carrier.
    CAUTION:

    • Apply Vaseline when installing the needle bearing.
    • Be careful to attach the needle bearing in right direction.
    Fig 14: Installing Needle Bearing On Forward Clutch Drum Side Of Sun Gear

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
11. Install the needle bearing on the forward clutch drum side of the sun gear. Refer to C in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
    Fig 15: Installing Forward Clutch Assembly On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
12. Install the forward clutch assembly on the transaxle case.
    CAUTION: When conducting measurements, measure two or more places, and find the average value.
    Fig 16: Identifying Total End Play

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
13. Measure the total end play as follows:
    Fig 17: Measuring Distance M1 From Oil Pump Cover Mounting Surface Of Transaxle Case To Needle Bearing Mounting Surface

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the distance M1 from the oil pump cover mounting surface of the transaxle case to the needle bearing mounting surface of the forward clutch drum.
       Fig 18: Measuring Distance M2 From Edge Of Oil Pump Cover To Mounting Surface On Transaxle Case

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transaxle case.
    3. Calculate the total end play by the following expression. Select the needle bearing so that the total end play meets its standard value.

    Total end play = M1 - M2 - bearing thickness 

    Standard value: 0.25 - 0.55 mm (0.010 - 0.022 in) 

    (For total end play) 

    CAUTION:

    • Apply Vaseline when installing the needle bearing.
    • Be careful to attach the needle bearing in right direction.
    Fig 19: Installing Needle Bearing On Forward Clutch Assembly

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
14. Install the selected needle bearing on the forward clutch assembly. Refer to D in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.
    CAUTION:

    • Do not reuse the seal rings.
    • Apply Vaseline when installing the seal rings.
    Fig 20: Locating Oil Pump Cover Seal Rings

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
15. Install the seal rings on the oil pump cover.
    CAUTION: Do not reuse the bolt.
    Fig 21: Locating Transaxle Case Detent Spring

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16. Install the detent spring on the transaxle case and tighten the bolt to the specified torque.

    Tightening torque: 6.9 N.m (61 in-lb) 

    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    Fig 22: Locating Plug O-Ring

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
17. Install the O-ring on the plug.
    Fig 23: Locating Converter Housing Plug (F1CJA)

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18. Install the plug on the converter housing to the specified torque.

    Tightening torque: 7.5 N.m (66 in-lb) 

    CAUTION: Do not bend the pipe when attaching it.
    Fig 24: Locating Converter Housing Plug (W1CJA)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 25: Installing Pipe On Converter Housing

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
19. Install the pipe on the converter housing.
    Fig 26: Locating Clip And Bolt

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20. Install the clip and tighten the bolt to the specified torque.

    Tightening torque: 5.9 N.m (52 in-lb) 

    CAUTION:

    • Do not reuse the outer race.
    • Replace the outer race together with the inner race.
    Fig 27: Installing Differential Bearing Outer Race Of Differential Side Bearing On Converter Housing (F1CJA)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 28: Installing Differential Bearing Outer Race Of Differential Side Bearing On Converter Housing (W1CJA)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
21. Using the special tools MB990779 and MB990780 < F1CJA > or MB991168 and MB991702 < W1CJA >, Install the differential bearing outer race of differential side bearing on the converter housing.
    CAUTION:

    • When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
    • When conducting measurements, measure two or more places, and find the average value.
    Fig 29: Identifying Differential Assembly Preload

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
22. Measure the preload A of the differential assembly as follows:
    Fig 30: Measuring Distance M3 From Edge Of Transaxle Case To Mounting Surface Of Adjusting Shim

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the distance M3 from the edge of transaxle case to the mounting surface of adjusting shim.
       Fig 31: Measuring Distance M4 From Differential Case To Edge Of Converter Housing

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing.
       Fig 32: Measuring Distance M5 From Differential Case To Outer Race Of Differential Side Bearing

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. Install the outer race on differential side bearing, and measure the distance M5 from the differential case to the outer race of differential side bearing.
    4. Using the following expression, calculate the distance M6 from the edge of converter housing to the outer race of differential side bearing.

       M6 = M4 - M5 

    5. Using the following expression, calculate thickness of the adjusting shim.

    Thickness of adjusting shim = M3 - M6 + preload 

    Standard value: 0.17 - 0.23 mm (0.007 - 0.009 in) 

    (For differential preload) 

    CAUTION: Do not reuse the adjusting shim.
    Fig 33: Installing Adjusting Shim On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
23. Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ."
    CAUTION:

    • Do not reuse the outer race.
    • Replace the outer race together with the inner race.
    Fig 34: Installing Outer Race Of Differential Side Bearing On Transaxle Case Using Special Tool MB990780

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
24. Using the special tool MB990780, install the outer race of differential side bearing on the transaxle case.
    CAUTION:

    • Do not reuse the outer race.
    • Replace the outer race together with the inner race.
    Fig 35: Installing Outer Race Of Reduction Gear Bearing On Converter Housing Using Special Tools MB990932 And MB990938

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
25. Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the converter housing.
    CAUTION:

    • When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
    • When conducting measurements, measure two or more places, and find the average value.
    Fig 36: Identifying Reduction Gear Assembly Preload

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
26. Measure the preload A of the reduction gear assembly in the following way.
    Fig 37: Measuring Distance M7 From Edge Of Transaxle Case To Mounting Surface Of Adjusting Shim

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the distance M7 from the edge of transaxle case to the mounting surface of adjusting shim.
       Fig 38: Measuring Distance M8 From Edge Of Reduction Gear Assembly To Edge Of Converter Housing

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install the reduction gear assembly on the converter housing, and measure the distance M8 from the edge of reduction gear assembly to the edge of converter housing.
       Fig 39: Measuring Distance M9 From Edge Of Reduction Gear Assembly To Outer Race Of Reduction Gear Bearing

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. Install the outer race of reduction gear side bearing on the bearing, and measure the distance M9 from the edge of reduction gear assembly to the outer race of reduction gear bearing.
    4. Using the following expression, calculate the difference M10 from the outer race of reduction gear bearing to the edge of converter housing.

       M10 = M8 - M9 

    5. Using the following expression, calculate the thickness of adjusting shim.

    Thickness of adjusting shim = M7 - M10 + preload 

    Standard value: 0.11 - 0.17 mm (0.004 - 0.006 in) 

    (For reduction gear preload) 

    CAUTION: Do not reuse the adjusting shim.
    Fig 40: Installing Adjusting Shim On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
27. Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ."
    CAUTION:

    • Do not reuse the outer race.
    • Replace the outer race together with the inner race.
    Fig 41: Installing Outer Race Of Reduction Gear Bearing On Transaxle Case Using Special Tools MB990932 And MB990938

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
28. Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the transaxle case.
    CAUTION:

    • Do not reuse the lip seal.
    • Apply transmission fluid when installing the lip seal.
    Fig 42: Locating Transaxle Case Lip Seal

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
29. Install the lip seal on the transaxle case.
    CAUTION:

    • Do not reuse the O-rings.
    • Apply transmission fluid when installing the O-rings.
    Fig 43: Installing O-Rings On Oil Pump Fastening Bolts

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
30. Install the O-rings on the oil pump fastening bolts.
    Fig 44: Locating Transaxle Case Oil Pump Mounting Bolts

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
31. Install the oil pump on the transaxle case and tighten the bolt to the specified torque. (One fastening bolt is installed at the backside from the transaxle case side. Only this bolt should be tightened to the specified torque of 28 N.m [21 ft-lb].)

    Tightening torque: 19 N.m (14 ft-lb) 

    CAUTION: Do not reuse the snap ring.
    Fig 45: Locating Oil Pump Snap Ring

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
32. Install the snap ring on the oil pump.
    CAUTION:

    • Do not reuse the lip seal.
    • Apply transmission fluid or Vaseline when installing the lip seal.
    Fig 46: Locating Transaxle Case Lip Seal

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
33. Install the lip seal on the transaxle case.
    Fig 47: Identifying Control Valve Body Harness

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
34. Install the valve body harness on the control valve.
35. Install the control valve assembly on the transaxle case as follows:
    Fig 48: Inserting Pins Into Linkage Stopper Holes Of Control Valve Assembly

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Insert pins etc. (ø3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.
    2. Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the illustration.
       Fig 49: Aligning Detent Of Terminal Body With Transaxle Case

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
       CAUTION: Align the notch of pulley ratio linkage with the prong of pulley sensor.
       Fig 50: Installing Control Valve Assembly

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. Slide the control valve assembly from the bottom, and install it on the transaxle case.
       CAUTION: Apply transmission fluid when attaching the bush.
       Fig 51: Identifying Protrusion

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
       Fig 52: Installing Bush On Control Valve Assembly

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    4. Install the bush on the control valve assembly.
       Fig 53: Identifying Control Valve Assembly Fastening Bolts

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    5. Install the fastening bolts of control valve assembly and tighten the bolt to the specified torque.

       Tightening torque: 7.9 N.m (70 in-lb) 

       CONTROL VALVE ASSEMBLY BOLTS IDENTIFICATION
       
       

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

       Fig 54: Locating Manual Lever

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
36. Install the manual lever and tighten the bolt to the specified torque.

    Tightening torque: 22.1 N.m (16 ft-lb) 

    Fig 55: Locating Control Valve Assembly Bracket

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
37. Install the bracket on the control valve assembly and tighten the bolt to the specified torque.

    Tightening torque: 7.9 N.m (70 in-lb) 

    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    Fig 56: Installing O-Ring On Oil Strainer

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
38. Install the O-ring on the oil strainer.
    Fig 57: Identifying Oil Strainer Bolts

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
39. Install the oil strainer and tighten the bolt to the specified torque.

    Tightening torque: 7.9 N.m (70 in-lb) 

    OIL STRAINER BOLTS IDENTIFICATION
    
    

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

    CAUTION:

    • Do not reuse the oil pan gasket.
    • Remove any moisture, oil, and used gasket from the mounting surface of oil pan gasket.
    • When installing the oil pan gasket, align the dowel pins of transaxle case with dowel pin holes A of the oil pan gasket.
    Fig 58: Installing Oil Pan Gasket On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
40. Install the oil pan gasket on the transaxle case.
41. Install the magnet on the oil pan.
    CAUTION: When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
    Fig 59: Identifying Dowel Pin Holes

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
42. Install the oil pan on the transaxle case and tighten the bolts to the specified torque.

    Tightening torque: 7.9 N.m (70 in-lb) 

    CAUTION: Do not reuse the drain plug gasket.
43. Install the drain plug and drain plug gasket on the transaxle case and tighten the bolt to the specified torque.

    Tightening torque: 34.3 N.m (25 ft-lb) 

    Fig 60: Locating Transaxle Case Oil Pump Cover

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
44. Install the oil pump cover on the transaxle case, and fix the fastening bolts temporarily.
    Fig 61: Locating Baffle Plate

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
45. Install the baffle plate, and fix the fastening bolts temporarily.
    Fig 62: Locating Oil Guide

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
46. Install the oil guide and tighten the bolt to the specified torque.

    Tightening torque: 5.9 N.m (52 in-lb) 

    Fig 63: Locating Bracket

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
47. Install the bracket, and tighten the fastening bolts of the bracket to the bolts to the specified torque.

    Tightening torque: 26 N.m (19 ft-lb) 

48. Tighten the fastening bolts of the oil pump cover and baffle plate to the bolts to the specified torque.

    Tightening torque: 19 N.m (14 ft-lb) 

    CAUTION:

    • Make sure the tang of thrust washer is aligned with the mounting hole of oil pump cover.
    • Apply Vaseline when installing the thrust washer.
    Fig 64: Locating Oil Pump Cover Thrust Washer

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
49. Install the thrust washer on the oil pump cover.
    CAUTION: Pull the driven sprocket up softly to make sure it is securely attached.
    Fig 65: Identifying Oil Pump Chain Driven Sprocket Snap Ring

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 66: Expanding Oil Pump Chain Driven Sprocket And Drive Sprocket Snap Ring

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
50. Expand the snap ring, and install the driven sprocket, oil pump chain, and drive sprocket.
    Fig 67: Locating Chain Cover

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
51. Install the chain cover, and tighten the fastening nuts to the specified torque.

    Tightening torque: 5.9 N.m (52 in-lb) 

    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    Fig 68: Locating Input Shaft O-Ring

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
52. Install the O-ring on the input shaft.
    Fig 69: Identifying Transaxle Case Differential Assembly (F1CJA)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
53. Install the differential assembly on the transaxle case.
    Fig 70: Identifying Transaxle Case Differential Assembly (W1CJA)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 71: Identifying Transaxle Case Reduction Gear Assembly

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
54. Install the reduction gear assembly on the transaxle case.
    CAUTION:

    • Do not reuse the converter housing oil seal.
    • Apply transmission fluid when installing the converter housing oil seal.
    Fig 72: Installing Converter Housing Oil Seal On Converter Housing Using Special Tools MB992141 And MB992075

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
55. Using the special tools MB992141 and MB992075, install the converter housing oil seal on the converter housing.

    Depth from the case edge: within - 1.0 ± 0.5 mm (recessed) 

    CAUTION:

    • Do not reuse the converter housing side oil seal.
    • Apply transmission fluid when installing the converter housing side oil seal.
    Fig 73: Installing Converter Housing Side Oil Seal On Converter Housing Using Special Tools MB992206 And MB992075

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
56. Using the special tools MB992206 and MB992075, install the converter housing side oil seal on the converter housing.
    CAUTION:

    • Remove any moisture, oil and oil sealant from the application surface.
    • Make sure the starting point and the ending point are about the middle between the bolts.
    Fig 74: Identifying Converter Housing Mounting Surface Of Transaxle Case Sealant Specifications (1 Of 2)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 75: Identifying Converter Housing Mounting Surface Of Transaxle Case Sealant Specifications (2 Of 2)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
57. Apply the sealant on the converter housing mounting surface of the transaxle case in the following way.

    Specified sealant: Loctite 509 

    SEALANT APPLICATION SPECIFICATIONS
    
    

    L1	9 mm (0.35 in)
    L2	5 mm (0.20 in)
    L3	ø1.5 mm (0.059 in)
    L4	R8.5 mm (0.334 in)
    L5	R5 - 8 mm (0.20 - 0.31 in)
    L6	3 - 5 mm (0.12 - 0.20 in)
    L7	ø17 mm (0.67 in)
    L8	3.5 mm (0.137 in)

    Fig 76: Identifying Converter Housing Bolts

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
58. Install the converter housing on the transaxle case, and tighten the fastening bolts to the specified torque.

    Tightening torque: 45 N.m (33 ft-lb) 

    CONVERTER HOUSING BOLTS IDENTIFICATION
    
    

    Bolt symbol	A	B
    Shank length mm (in)	30 (1.18)	35 (1.38)
    Quantity	18	5

    CAUTION: Do not reuse the snap ring.
    Fig 77: Identifying Terminal Body Snap Ring

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
59. Install the snap ring on the terminal body.
    CAUTION:

    • Do not reuse the side oil seal.
    • Apply transmission fluid when installing the side oil seal.
    Fig 78: Installing Side Oil Seal On Transaxle Case Using Special Tool MB992140 And MB992075

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
60. Using the special tool MB992140 and MB992075, install the side oil seal on the transaxle case.

    Depth from the case edge: within - 1.8 ± 0.5 mm (recessed) 

    CAUTION: Do not reuse the inhibitor switch.
61. Install the inhibitor switch on the transaxle case as follows:
    Fig 79: Identifying Inhibitor Switch On Transaxle

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Install the inhibitor switch on the transaxle case.
       Fig 80: Locating Manual Shaft Shift Lever

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install the shift lever on the manual shaft, and tighten the fastening nuts to the specified torque.

       Tightening torque: 17.2 N.m (13 ft-lb) 

    3. Set the manual shaft at N position.
       Fig 81: Identifying Installing Bolt And Adjustment Hole

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    4. Insert pins etc. (f5 mm) in adjusting holes in both inhibitor switch and shift lever, and after alignment, tighten the fastening bolts to the specified torque.

    Tightening torque: 5.5 N.m (49 in-lb) 

    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    Fig 82: Installing Oil Ring On Primary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
62. Install the oil ring on the primary pulley speed sensor.
    Fig 83: Identifying Primary Pulley Speed Sensor On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
63. Install the primary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque.

    Tightening torque: 5.9 N.m (52 in-lb) 

    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    Fig 84: Installing O-Ring On Secondary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
64. Install the O-ring on the secondary pulley speed sensor.
    Fig 85: Locating Secondary Pulley Speed Sensor On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
65. Install the secondary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque.

    Tightening torque: 5.9 N.m (52 in-lb) 

    CAUTION:

    • Apply transmission fluid or Vaseline when installing the transmission fluid cooler filter.
    • Do-not reuse the transmission fluid cooler filter.
    Fig 86: Installing Transmission Fluid Filter On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
66. Install the transmission fluid filter on the transaxle case.
    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • When installing O-ring, make sure that projection of the O-ring is put into the groove on the filter.
    Fig 87: Installing O-Ring On Transmission Fluid Filter

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
67. Install the O-ring on the transmission fluid filter.
    Fig 88: Locating Transmission Fluid Cooler On Transaxle Case (Without Fluid Cooler Hose)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 89: Locating Transmission Fluid Cooler On Transaxle Case (With Fluid Cooler Hose)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
68. Install the transmission fluid cooler on the transaxle case, and tighten the fastening bolts to the specified torque.

    Tightening torque: 4.2 N.m (37 in-lb) 

    CAUTION:

    • Do not reuse the O-ring.
    • Apply transmission fluid when installing the O-ring.
    Fig 90: Locating O-Ring On Plug

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
69. Install the O-ring on the plug.
    Fig 91: Identifying Plug On Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
70. Fasten the plug on the transaxle case and tighten the bolt to the specified torque.

    Tightening torque: 7.5 N.m (66 in-lb) 

    CAUTION: When conducting measurements, measure two or more places, and find the average value.
    Fig 92: Measuring Size Between Convertor Housing And Transaxle

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
71. Install the converter on the transaxle, and measure the size A to check if it meets the standard value.

    Standard value: 15.9 mm (0.63 in) 

72. Install the oil filler tube and oil level gage on the transaxle. Refer to the following or the exploded view for the tightening torque.

    Tightening torque: 8.5 ± 3.5 N.m (75 ± 31 in-lb) 

73. Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque.

    Tightening torque: 25 ± 4 N.m (18 ± 2 ft-lb) 

74. Install the harness bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.

    Tightening torque: 25 ± 4 N.m (18 ± 2 ft-lb) 

75. Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.

    Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb) 

76. Install the transfer on the transaxle. Refer to the following or the exploded view for the tightening torque.

Tightening torque: 68 ± 9 N.m (50 ± 7 ft-lb)