Assembly Service Point

CAUTION: When the outer races of reduction gear bearing and differential side bearing are removed, measure the mounting bore diameters of outer race in the converter housing and transaxle case, and replace the housing case or the CVT assembly if the standard value is not satisfied. The standard values are listed in "SERVICE SPECIFICATIONS."

CAUTION:

Do not re-use the reverse brake piston.
Apply transmission fluid when installing the reverse brake piston.

Install the reverse brake piston, while turning it, on the transaxle case.

Fig 1: Identifying Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.

Fig 2: Identifying Spring Portion Of Spring Retainer Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When installing the retaining plate, align the tangs at positions A, B, C in the diagram.
Install the retaining plate on the transaxle case.

Fig 3: Installing Retaining Plate On 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 re-use the snap ring.
- When installing the snap ring, make sure that the joint falls in the area A in the diagram.
Fig 4: Identifying Transaxle Snap Ring Position
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 5: Installing Snap Ring On Transaxle Case Using Special Tool MB992139
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 6: Identifying Snap Ring Installation Area
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case.

Fig 7: Identifying Reverse Brake Retaining Plate And Dish Plate On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- When conducting measurements, measure two or more places, and find the average value.
- Do not re-use the snap ring.
- When installing the snap ring, make sure that the joint falls in the area A in the diagram.
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)

Fig 8: Installing Snap-Ring On Transaxle Case Using Flat Blade Screwdriver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 9: Identifying Snap-Ring Installation Position On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
Install the needle bearing on the reverse brake piston. Refer to A in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.

Fig 10: Installing Needle Bearing On Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planet carrier on the reverse brake.

Fig 11: Installing Planet Carrier On Reverse Brake
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
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 12: Installing Needle Bearing On Primary Pulley
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the sun gear on the planet carrier.

Fig 13: Installing Sun Gear On Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline when installing the needle bearing.
- Be careful to attach the needle bearing in right direction.
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 14: Installing Needle Bearing On Forward Clutch Drum Side Of Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the forward clutch assembly on the transaxle case.

Fig 15: Installing Forward Clutch Assembly On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When conducting measurements, measure two or more places, and find the average value.
Measure the total end play as follows:

Fig 16: Identifying Total End Play
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 17: Measuring Distance M1 From Oil Pump Cover Mounting Surface Of Transaxle Case To Needle Bearing Mounting Surface Of Forward Clutch Drum
  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)
  
  Fig 18: Measuring Distance M2 From Edge Of Oil Pump Cover To Mounting Surface On Transaxle Case
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  CAUTION:
  - Apply Vaseline when installing the needle bearing.
  - Be careful to attach the needle bearing in right direction.
Install the selected needle bearing on the forward clutch assembly. Refer to D in the "IDENTIFICATION OF NEEDLE BEARINGS " for right direction.

Fig 19: Locating Seal Rings On Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the seal rings.
- Apply Vaseline when installing the seal rings.
Install the seal rings on the oil pump cover.

Fig 20: Locating Detent Spring On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not re-use the bolt.
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)

Fig 21: Installing O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the plug.

Fig 22: Installing O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the plug on the converter housing to the specified torque.
Tightening torque: 7.5 N.m (66 in-lb)

Fig 23: Locating Plug On Converter Housing (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 24: Locating Plug On Converter Housing (W1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not bend the pipe when attaching it.
Install the pipe on the converter housing.

Fig 25: Installing Pipe On Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the clip and tighten the bolt to the specified torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 26: Locating Transaxle Clip
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
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.

Fig 27: Installing Differential Bearing Outer Race Of Differential Side Bearing On Converter Housing Using Special Tools MB990779 And MB990780 (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 28: Installing Differential Bearing Outer Race Of Differential Side Bearing On Converter Housing Using Special Tools MB990779 And MB990780 (W1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
Measure the preload A of the differential assembly as follows:

Fig 29: Identifying Preload A Of Differential Assembly
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 30: Measuring Distance M3 From Edge Of Transaxle Case To Mounting Surface Of Adjusting Shim
  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 31: Measuring Distance M4 From Differential Case To Edge Of Converter Housing
  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.
  
  Fig 32: Measuring Distance M5 From Differential Case To Outer Race Of Differential Side Bearing
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  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 re-use the adjusting shim.
Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ".

Fig 33: Installing Shim On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
Using the special tool MB990780, install the outer race of differential side bearing on the transaxle case.

Fig 34: Installing Outer Race Of Differential Side Bearing On Transaxle Case Using Special Tool MB990780
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the converter housing.

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.
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.
Measure the preload A of the reduction gear assembly in the following way.

Fig 36: Identifying Preload A Of Reduction Gear Assembly
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 37: Measuring Distance M7 From Edge Of Transaxle Case To Mounting Surface Of Adjusting Shim
  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 38: Measuring Distance M8 From Edge Of Reduction Gear Assembly To Edge Of Converter Housing
  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.
  
  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.
  
  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 re-use the adjusting shim.
Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ".

Fig 40: Installing Adjusting Shim On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the outer race.
- Replace the outer race together with the inner race.
Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the transaxle case.

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.
CAUTION:
- Do not re-use the lip seal.
- Apply transmission fluid when installing the lip seal.
Install the lip seal on the transaxle case.

Fig 42: Locating Lip Seal On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the O-rings.
- Apply transmission fluid when installing the O-rings.
Install the O-rings on the oil pump fastening bolts.

Fig 43: Installing O-Rings On Oil Pump Fastening Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)

Fig 44: Locating Oil Pump On Transaxle Case Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not re-use the snap ring.
Install the snap ring on the oil pump.

Fig 45: Locating Oil Pump Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the lip seal.
- Apply transmission fluid or Vaseline when installing the lip seal.
Install the lip seal on the transaxle case.

Fig 46: Locating Lip Seal On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body harness on the control valve.

Fig 47: Identifying Valve Body Harness On Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the control valve assembly on the transaxle case as follows:

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

Fig 48: Installing Control Valve Assembly On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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: Installing Terminal Body On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Align the notch of pulley ratio linkage with the prong of pulley sensor.
Slide the control valve assembly from the bottom, and install it on the transaxle case.
CAUTION: Apply transmission fluid when attaching the bush.

Fig 50: Sliding Control Valve Assembly From Bottom
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 51: Identifying Control Valve Assembly Protrusion
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the bush on the control valve assembly.

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

Install the fastening bolts of control valve assembly and tighten the bolt to the specified torque.

TIGHTENING TORQUE SPECIFICATIONS

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

Fig 53: Identifying Fastening Bolts Of Control Valve Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the manual lever and tighten the bolt to the specified torque.
Tightening torque: 22.1 N.m (16 ft-lb)

Fig 54: Locating Manual Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)

Fig 55: Locating Bracket On Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the oil strainer.

Fig 56: Installing O-Ring On Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the oil strainer and tighten the bolt to the specified torque.

TIGHTENING TORQUE SPECIFICATIONS

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

Fig 57: Identifying Oil Strainer Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION:

Do not re-use 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.

Install the oil pan gasket on the transaxle case.
Install the magnet on the oil pan.

Fig 58: Installing Oil Pan Gasket On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
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)

Fig 59: Identifying Oil Pan Gasket On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not re-use the drain plug gasket.
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)
Install the oil pump cover on the transaxle case, and fix the fastening bolts temporarily.

Fig 60: Locating Oil Pump Cover On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the baffle plate, and fix the fastening bolts temporarily.

Fig 61: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil guide and tighten the bolt to the specified torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 62: Locating Oil Guide
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)
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)

Fig 63: Locating Oil Pump Cover On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
Install the thrust washer on the oil pump cover.

Fig 64: Locating Thrust Washer On Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Pull the driven sprocket up softly to make sure it is securely attached.
Expand the snap ring, and install the driven sprocket, oil pump chain, and drive sprocket.

Fig 65: Identifying Driven Sprocket Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 66: Installing Oil Pump Chain And Drive Sprocket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the chain cover, and tighten the fastening nuts to the specified torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 67: Locating Chain Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the input shaft.

Fig 68: Locating O-Ring From Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential assembly on the transaxle case.

Fig 69: Identifying Differential Assembly On Transaxle Case (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 71: Identifying Reduction Gear Assembly On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the converter housing oil seal.
- Apply transmission fluid when installing the converter housing oil seal.
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)

Fig 72: Identifying Converter Housing Oil Seal With Special Tools MB992141 And MB992075
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the converter housing side oil seal.
- Apply transmission fluid when installing the converter housing side oil seal.
Using the special tools MB992206 and MB992075, install the converter housing side oil seal on the converter housing.

Fig 73: Identifying Converter Housing Oil Seal With Special Tools MB992206 And MB992075
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.

Apply the sealant on the converter housing mounting surface of the transaxle case in the following way.

Fig 74: Identifying Sealant On Converter Housing Mounting Surface Of Transaxle Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SPECIFIED SEALANT THICKNESS CHART

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 75: Identifying Sealant Thickness Of Converter Housing Mounting Surface

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the converter housing on the transaxle case, and tighten the fastening bolts to the specified torque.

TIGHTENING TORQUE SPECIFICATIONS

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

Fig 76: Identifying Converter Housing On Transaxle Case Fastening Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not re-use the snap ring.

Install the snap ring on the terminal body.

Fig 77: Locating Snap Ring On Terminal Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the side oil seal.
- Apply transmission fluid when installing the side oil seal.
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)

Fig 78: Installing Side Oil Seal On Transaxle Case Using Special Tool MB992140 And MB992075
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not re-use the transmission range switch.
Install the transmission range switch on the transaxle case as follows:
1. Install the transmission range switch on the transaxle case.
  
  Fig 79: Identifying Transmission Range Switch On Transaxle Case
  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 80: Locating Shift Lever On Manual Shaft
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Insert pins etc. (ø5 mm) in adjusting holes in both transmission range switch and shift lever, and after alignment, tighten the fastening bolts to the specified torque.
  Tightening torque: 5.5 N.m (49 in-lb)
  
  Fig 81: Identifying Adjusting Holes On Both Transmission Range Switch And Shift Lever
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  CAUTION:
  - Do not re-use the O-ring.
  - Apply transmission fluid when installing the O-ring.
Install the oil ring on the primary pulley speed sensor.

Fig 82: Installing Oil Ring On Primary Pulley Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)

Fig 83: Installing Primary Pulley Speed Sensor On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the secondary pulley speed sensor.

Fig 84: Installing O-Ring On Secondary Pulley Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)

Fig 85: Locating Secondary Pulley Speed Sensor On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply transmission fluid or Vaseline when installing the transmission fluid cooler filter.
- Do-not re-use the transmission fluid cooler filter.
Install the transmission fluid filter on the transaxle case.

Fig 86: Installing Transmission Fluid Filter On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not re-use 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.
Install the O-ring on the transmission fluid filter.

Fig 87: Installing O-Ring On Transmission Fluid Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)

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.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the plug.

Fig 90: Installing O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fasten the plug on the transaxle case and tighten the bolt to the specified torque.
Tightening torque: 7.5 N.m (66 in-lb)

Fig 91: Identifying Plug On Transaxle Case Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When conducting measurements, measure two or more places, and find the average value.
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)
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)
Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque:

Fig 92: Checking Converter On Transaxle Position
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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