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 reuse 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 Reverse Brake Piston
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: Aligning Spring Portion Of Spring Retainer Assembly With Reverse Brake Piston Projections
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: Identifying Retaining Plate On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 4: Identifying Aligning Positions Of 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.
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: Compressing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 6: [Identifying Joint Falls 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 Retaining Plate, Drive Plate, Driven Plate And Dish Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
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 brake end play)

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.
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 Side Of Sun Gear
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 Between Oil Pump Cover And Forward Clutch Drum Needle Bearing Mounting Surface
  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 Between Edge Of Oil Pump Cover To Transaxle Case Mounting Surface
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: Installing Needle Bearing On Forward Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the seal rings.
- Apply Vaseline when installing the seal rings.
Install the seal rings on the oil pump cover.

Fig 20: Locating Oil Pump Cover Seal Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse 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: Locating Detent Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the plug.

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

Fig 23: Locating Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 24: 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: 6.9 N.m (61 in-lb)

Fig 25: Locating Clip
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the outer race.
- Replace the outer race together with the inner race.
Using the special tools MB991168 and MB991702, Install the differential bearing outer race.

Fig 26: Installing Differential Bearing Outer Race Using Special Tools MB991168 And MB991702
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 27: Identifying Preload 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 28: Measuring Distance Between 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 29: Measuring Distance Between 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 30: Measuring Distance Between 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 - 0.29 mm (0.007 - 0.011 in)
  
  (For differential preload)
CAUTION: Do not reuse the adjusting shim.
Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ".

Fig 31: Installing Selected Shim On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse 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 32: Installing Outer Race Of Differential Side Bearing On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse 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 33: Installing Outer Race Of Reduction Gear Bearing On Converter Housing
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 34: Identifying Preload 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 35: Measuring Distance Between 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 36: Measuring Distance Between 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 37: Measuring Distance Between Edge Of Reduction Gear Assembly To Reduction Gear Bearing Outer Race
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Thickness of adjusting shim = M7 - M10 + preload
  
  Standard value: 0.13 - 0.19 mm (0.005 - 0.008 in)
  
  (For reduction gear preload)
CAUTION: Do not reuse the adjusting shim.
Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ".

Fig 38: Installing Selected Adjusting Shim On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse 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 39: Identifying Special Tools MB990932 And MB990938
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the lip seal.
- Apply transmission fluid when installing the lip seal.
Install the lip seal on the transaxle case.

Fig 40: Locating Lip Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-rings.
- Apply transmission fluid when installing the O-rings.
Install the O-rings on the oil pump fastening bolts.

Fig 41: Identifying O-Rings
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 42: Locating Oil Pump Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the snap ring.
Install the snap ring on the oil pump.

Fig 43: Locating Oil Pump Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the lip seal.
- Apply transmission fluid or Vaseline when installing the lip seal.
Install the lip seal on the transaxle case.

Fig 44: Locating Lip Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body harness on the control valve.

Fig 45: Identifying Valve Body Harness
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Insert pins etc. ( 3 mm (0.12 in)) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.

Fig 46: Identifying Pin And Control Valve Assembly
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 47: 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.
Slide the control valve assembly from the bottom, and install it on the transaxle case.
CAUTION: Apply transmission fluid when attaching the bush.

Fig 48: Identifying Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 49: Identifying Notch Of Pulley Ratio Linkage
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the bush on the control valve assembly.

Fig 50: Identifying 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: 7.9 N.m (70 in-lb)

BOLT SYMBOL REFERENCE

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

Fig 51: Identifying Control Valve Assembly Bolts

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 52: 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 53: Locating Bracket On Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the oil strainer.

Fig 54: Identifying 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: 7.9 N.m (70 in-lb)

BOLT SYMBOL REFERENCE

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

Fig 55: Identifying Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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.

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

Fig 56: Identifying 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 57: Identifying Dowel Pin Holes
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse 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 58: Locating Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the baffle plate, and fix the fastening bolts temporarily.

Fig 59: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the baffle plate and tighten the bolt to the specified torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 60: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the bracket, and then tighten the fastening bolts of the oil pump cover, the baffle plate and the bracket to the specified torque.
Tightening torque: 26 N.m (19 ft-lb)

Fig 61: Locating Bracket
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 62: Locating Oil Pump Cover Thrust Washer
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 63: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 64: Identifying Driven Sprocket, Oil Pump Chain And Drive Sprocket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure the clearance A between the oil pump drive sprocket and the converter housing as follows:

Fig 65: Identifying Clearance Between Oil Pump Drive Sprocket And Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure the distance M11 between the edge of transaxle case and the adjusting shim mounting surface of drive sprocket.
  
  Fig 66: Identifying Distance M11 Between Of Transaxle Case And Adjusting Shim Mounting Surface Of Drive Sprocket
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure the distance M12 between the edge of converter housing and the surface contacting the adjusting shim.
3. Use the following expression, to select the adjusting shim having the standard value.
  Standard value of clearance = M11 + M12 - thickness of adjusting shim
  
  Standard value: 0.10 - 0.23 mm (0.004 - 0.009 in)
  
  (For oil pump drive sprocket to converter housing)
  
  Fig 67: Identifying Distance M12 Between Of Converter Housing And Surface Contacting Adjusting Shim
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  CAUTION: Apply Vaseline when installing the adjusting shim.
4. Install the selected adjusting shim on the drive sprocket. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ".
Fig 68: Locating Drive Sprocket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the baffle plate, and tighten the fastening nuts to the specified torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 69: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the input shaft.

Fig 70: Locating Input Shaft O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential assembly on the transaxle case.

Fig 71: Identifying Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear assembly on the transaxle case.

Fig 72: Identifying Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse 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 73: Identifying Special Tools MB992141 And MB992075
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse 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 74: Installing Converter Housing Side Oil Seal Using 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.

Specified sealant: Loctite 509

SEALANT SPECIFICATION

L1	9 mm (0.35 in)
L2	5 mm (0.20 in)
L3	1.5 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	17 mm (0.67 in)
L8	3.5 mm (0.137 in)

Fig 75: Identifying Sealant Applying Area

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 76: Applying Sealant On Converter Housing

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: 45 N.m (33 ft-lb)

BOLT SYMBOL REFERENCE

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

Fig 77: Identifying Converter Housing Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the snap ring.

Install the snap ring on the terminal body.

Fig 78: Identifying Snap Ring And Terminal Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the side oil seal.
- Apply transmission fluid when installing the side oil seal.
Using the special tools 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 79: Identifying Special Tool MB992140 And MB992075
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the inhibitor switch.
Install the inhibitor switch on the transaxle case as follows:
1. Install the inhibitor switch on the transaxle case.
  
  Fig 80: Identifying Inhibitor 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.
  Tightening torque: 17.2 N.m (13 ft-lb)
3. Set the manual shaft at N position.
  
  Fig 81: Identifying Shift Lever
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Insert pins etc. (5 mm (0.20 in)) 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)
  
  Fig 82: Identifying Adjusting Hole In Inhibitor Switch
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the oil ring on the primary pulley speed sensor.

Fig 83: Locating 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 84: Locating Primary Pulley Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the secondary pulley speed sensor.

Fig 85: 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 86: Locating Secondary Pulley Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply transmission fluid or Vaseline when installing the transmission fluid filter.
- Do-not reuse the transmission fluid filter.
Install the transmission fluid filter on the transaxle case.

Fig 87: Identifying CVT Fluid Cooler Filter On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
Install the O-ring on the transmission fluid filter.

Fig 88: Identifying O-Ring On CVT 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 89: Locating Transmission Fluid Cooler
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 90: Identifying Transmission Fluid Cooler Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Do not reuse the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the plug.

Fig 91: Identifying 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 92: Identifying Plug On Transaxle Case
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.
Tightening torque: 9.0 ± 3.0 N.m (80 ± 26 in-lb)
Install the control cable bracket and breather hose on the transaxle.
Tightening torque: 25 ± 4 N.m (18 ± 2 ft-lb)

Fig 93: Identifying Converter On Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the harness bracket on the transaxle.
Tightening torque: 25 ± 4 N.m (18 ± 2 ft-lb)
Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle.
Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)