Disassembly Service Point

1. Remove the transfer from the transaxle. <W1CJC>
2. Remove the front and rear roll stopper bracket from the transaxle.
3. Remove the radiator hose bracket, harness bracket, corrugate clamp bracket and air breather bracket from the transaxle.
4. Remove the oil filler tube and dipstick from the transaxle.
5. Remove the control cable bracket and breather hose from the transaxle.
6. Remove the oil cooler feed hose, oil cooler return hose, oil cooler pipe assembly, oil cooler tube assembly <Vehicles with air-cooled oil cooler assembly>, eye bolt and gasket from the transaxle.
7. Remove the drain plug and drain plug gasket from the oil pan.
8. Remove the torque converter from the transaxle.
   Fig 1: Torque Converter Of Transaxle

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   CAUTION: When removing the O-ring, be careful not to cause damage to the input shaft.
9. Remove the O-ring from the input shaft.
   Fig 2: Locating O-Ring Of Input Shaft

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
10. Remove the plug from the transaxle case, and detach the O-ring from the plug.
    Fig 3: Locating Plug Of Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
11. Remove the turbine speed sensor from the converter housing, and detach the O-ring from the sensor.
    Fig 4: Locating Turbine Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
12. Remove the primary pulley speed sensor from the side cover, and detach the O-ring from the sensor.
    Fig 5: Locating Primary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
13. Remove the secondary pulley speed sensor from the transaxle case, and detach the O-ring from the sensor.
    Fig 6: Locating Secondary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
14. Remove the manual control lever from the manual shaft.
    Fig 7: Locating Manual Control Lever Of Manual Shaft

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
15. Remove the transmission range switch from the transaxle case.
    Fig 8: Locating Transmission Range Switch

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

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
17. Remove the filter cover from the transaxle case.
    Fig 10: Locating Filter Cover

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
18. Remove the O-ring and CVT fluid filter from the transaxle case.
    Fig 11: O-Ring And CVT Fluid Filter Of 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.
19. Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.
    Fig 12: Removing Side Oil Seal From Transaxle Case Using Flat Blade Screwdriver

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When removing the side oil seal, be careful not to cause damage to the converter housing.
20. Using a flat blade screwdriver etc., remove the side oil seal from the converter housing. <F1CJC>
    Fig 13: Removing Side Oil Seal From Converter Housing Using Flat Blade Screwdriver

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When removing the converter housing oil seal, be careful not to cause damage to the converter housing and input shaft.
21. Remove the converter housing oil seal from the converter housing.
    Fig 14: Locating Converter Housing Oil Seal

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful not to cause damage to the terminal body.
22. Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.
    Fig 15: Snap Ring And Terminal Body

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
23. Remove the oil pan from the transaxle case.
24. Remove the magnet from the oil pan.
    Fig 16: Locating Magnet Of Oil Pan

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
25. Remove the oil pan gasket from the transaxle case.
    Fig 17: Locating Oil Pan Gasket Of Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
26. Remove the oil strainer.

    Bolt symbol	A	B
    Shank length mm (inch)	44 (1.7)	12 (0.5)
    Quantity	1	2

27. Remove the O-ring from the oil strainer.
    Fig 18: Oil Strainer Bolts

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
28. Remove the bracket from the valve body assembly.
    Fig 19: Locating Valve Body Assembly Bracket

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
29. Remove the manual valve lever.
    Fig 20: Locating Manual Valve Lever

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
30. Remove the valve body assembly from the transaxle case in the following way.
    1. Remove mounting bolts of the valve body assembly.

       Bolt symbol	A	B	C
       Shank length mm (inch)	54 (2.1)	44 (1.7)	54 (2.1)
       Quantity	8	1	2

       Fig 21: Valve Body Assembly Mounting Bolts Loosening Sequence

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Remove the valve body assembly from the transaxle case.
       NOTE: Tilt the valve body assembly, and after removing from the manual shaft side, remove the terminal body from the transaxle case.
       Fig 22: Removing Valve Body Assembly From Transaxle Case

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
31. Remove the valve body harness from the valve body assembly.
    Fig 23: Locating Valve Body Harness

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
32. Remove the lip seal from the transaxle case.
    Fig 24: Locating Lip Seal Of Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

REASSEMBLY SERVICE POINT 

1. Install the lip seal on the transaxle case.
   Fig 25: Locating Lip Seal Of Transaxle Case

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Install the valve body assembly on the transaxle case as follows.
   1. Install the valve body harness on the valve body assembly.
      CAUTION:

      • Push in the valve body harness until the detent contacts the transaxle case 
      • Be careful not to cause damage to the terminal body. 
      Fig 26: Locating Valve Body Harness

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   2. Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the diagram.
      Fig 27: Aligning Detent Of Terminal Body With Transaxle Case

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 28: Installing Terminal Body On Transaxle Case

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   3. Slide the valve body assembly from the bottom, and install it on the transaxle case.
      Fig 29: Sliding Valve Body Assembly

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   4. Install the fastening bolts of valve body assembly, and tighten to the specified torque of 7.9 N.m (70 in-lb).

      Bolt symbol	A	B	C
      Shank length mm (inch)	54 (2.1)	44 (1.7)	54 (2.1)
      Quantity	8	1	2

   Fig 30: Valve Body Assembly Fastening Bolts Tightening Sequence

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Install the manual valve lever, and tighten the fastening nuts to the specified torque of 22.1 N.m (16 ft-lb).
   Fig 31: Locating Manual Valve Lever

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Install the bracket on the valve body assembly, and tighten the fastening bolts to the specified torque of 7.9 N.m (70 in-lb).
   Fig 32: Locating Valve Body Assembly Bracket

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   CAUTION:

   • Do not re-use the O-ring.
   • Apply transmission fluid when installing the O-ring.
5. Install the O-ring on the oil strainer.
   Fig 33: Installing O-Ring On Oil Strainer

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
6. Install the oil strainer, and tighten the fastening bolts to the specified torque of 7.9 N.m (70 in-lb).

   Bolt symbol	A	B
   Shank length mm (inch)	44 (1.7)	12 (0.5)
   Quantity	1	2

   Fig 34: 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.
7. Install the oil pan gasket on the transaxle case.
   Fig 35: Locating Oil Pan Gasket On Transaxle Case

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
8. Install the magnet on the oil pan.
   Fig 36: Locating Magnet On Oil Pan

   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.
9. Tighten each oil pan mounting bolt to the specified torque of 5.9 N.m (52 in-lb) in the order of number shown.
   Fig 37: Oil Pan Mounting Bolts Tightening Sequence

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   CAUTION: Do not re-use the snap ring.
10. Install the snap ring on the terminal body.
    Fig 38: Snap Ring And Terminal Body

    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.
11. Using the special tools, install the converter housing oil seal on the converter housing.
    • Oil seal installer (MB992141)
    • Handle (MB992075)
    Fig 39: Installing Converter Housing Oil Seal On Converter Housing Using Special Tools

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    Depth from the case edge A: 

    Within -1.0 ± 0.5 mm (-0.04 ± 0.02 inch) [recessed]. 

    Fig 40: Checking Case Edge Depth

    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.
12. Using the special tool, install the side oil seal on the transaxle case.
    • Oil seal installer (MB992140)
    • Handle (MB992075)
    Fig 41: Installing Side Oil Seal On Transaxle Case Using Special Tool

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    Depth from the case edge A: 

    Within -1.8 ± 0.5 mm (-0.07 ± 0.02 inch) [recessed] 

    Fig 42: Checking Case Edge Depth

    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.
13. Using the special tools, install the side oil seal on the converter housing. <F1CJC>
    • Oil seal installer (MB992206)
    • Handle (MB992075)
    Fig 43: Installing Side Oil Seal On Converter Housing Using Special Tools

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    Depth from the case edge A: 

    Within -6.3 ± 0.5 mm (-0.25 ± 0.02 inch) [recessed] 

    Fig 44: Checking Case Edge Depth

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
14. Install the O-ring and CVT fluid filter on the transaxle case.
    Fig 45: O-Ring And CVT Fluid Filter Of Transaxle Case

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
15. Install the filter cover on the transaxle case, and tighten the fastening bolts to the specified torque of 5.1 N.m (45 in-lb).
    Fig 46: Locating Filter Cover

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
16. Install the CVT fluid cooler on the transaxle case, and tighten the fastening bolts to the specified torque of 4.2 N.m (37 in-lb).
    Fig 47: Locating CVT Fluid Cooler

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the transmission range switch.
17. Install the transmission range switch on the transaxle case as follows:
    1. Install the transmission range switch on the transaxle case.
       Fig 48: Locating Transmission Range Switch

       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 of 17.2 N.m (13 ft-lb).
    3. Set the manual shaft at N position.
       Fig 49: Locating Manual Control Lever Of Manual Shaft

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    4. Insert pins etc. [ 5 mm (0.2 inch)] in adjusting holes in both transmission range switch and shift lever, and after alignment, tighten the fastening bolts to the specified torque of 5.9 N.m (52 in-lb).
    Fig 50: Shift Lever, Inhibitor Switch, Adjusting Holes And Fastening Bolts

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
18. Install the O-ring on the secondary pulley speed sensor.
    Fig 51: Installing O-Ring On Secondary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
19. Install the secondary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque of 5.9 N.m (52 in-lb).
    Fig 52: Locating Secondary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
20. Install the O-ring on the primary pulley speed sensor.
    Fig 53: Installing O-Ring On Primary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
21. Install the primary pulley speed sensor on the side cover, and tighten the fastening bolts to the specified torque of 5.9 N.m (52 in-lb).
    Fig 54: Locating Primary Pulley Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
22. Install the O-ring on the turbine speed sensor.
    Fig 55: Installing O-Ring On Turbine Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
23. Install the turbine speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque of 5.9 N.m (52 in-lb).
    Fig 56: Locating Turbine Speed Sensor

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
24. Install the O-ring on the plug.
    Fig 57: Installing O-Ring On Plug

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
25. Fasten the plug on the transaxle case to the specified torque of 7.5 N.m (66 in-lb).
    Fig 58: Locating Plug Of 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.
26. Install the O-ring on the input shaft.
    Fig 59: Locating O-Ring Of Input Shaft

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When conducting measurements, measure two or more places, and find the average value.
27. Install the torque converter on the transaxle, and measure the size (A) to check if it meets the standard value.

    Standard size (A): 13 mm (0.5 inch) 

    Fig 60: Measuring Torque Converter Standard Size

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the drain plug gasket.
28. Install the drain plug and drain plug gasket on the transaxle case, and tighten to the specified torque of 34.3 N.m (25 ft-lb).
    CAUTION: Do not re-use the gasket.
29. Install the oil cooler feed hose, oil cooler return hose, oil cooler pipe assembly, oil cooler tube assembly <Vehicles with air-cooled oil cooler assembly>, eye bolt and gasket on the transaxle, and tighten to the specified torque.
    • Eye bolt: 44 ± 5 N.m (32 ± 3 ft-lb)
    • Oil cooler tube assembly mounting bolt: 9.5 ± 3.5 N.m (84 ± 30 in-lb)
30. Install the control cable bracket and breather hose on the transaxle, and tighten the fastening bolts to the specified torque of 25 ± 4 N.m (18 ± 2 ft-lb).
31. Install the oil filler tube and dipstick on the transaxle, and tighten the fastening bolts to the specified torque of 8.5 ± 3.5 N.m (75 ± 31 in-lb).
32. Install the radiator hose bracket, harness bracket, corrugate clamp bracket and air breather bracket on the transaxle, and tighten the fastening bolts to the specified torque of 25 ± 4 N.m (18 ± 2 ft-lb).
33. Install the front and rear roll stopper bracket on the transaxle, and tighten the fastening bolts to the specified torque of 90 ± 10 N.m (66 ± 7 ft-lb).
34. Install the transfer on the transaxle, and tighten the fastening bolts to the specified torque of 69 ± 9 N.m (51 ± 6 ft-lb). <W1CJC>