Disassembly Service Point

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

Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.
Remove the harness bracket from the transaxle.
Remove the oil filler tube and oil level gage from the transaxle.
Remove the control cable bracket and breather hose from the transaxle.
Remove the torque converter from the transaxle.

Fig 1: Removing Torque Converter From Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the plug from the transaxle case.

Fig 2: Identifying Plug On Transaxle Case
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Remove the O-ring from the plug.

Fig 3: Identifying O-Ring On Plug
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Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.

Fig 4: Locating Secondary Pulley Speed Sensor
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Remove the primary pulley speed sensor from the transaxle case, and detach the O-ring from the sensor.

Fig 5: Locating Primary Pulley Speed Sensor
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Remove the shift lever from the manual shaft.

Fig 6: Identifying Shift Lever
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Remove the inhibitor switch from the transaxle.

Fig 7: Identifying Inhibitor Switch
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CAUTION: Be careful not to cause damage to the terminal body.
Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.

Fig 8: Identifying Snap Ring And Terminal Body
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Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Fig 9: Locating Transmission Fluid Cooler
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Fig 10: Identifying Transmission Fluid Cooler Bolts
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Remove the transmission fluid filter from the transaxle case.

Fig 11: Identifying CVT Fluid Cooler Filter On Transaxle Case
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Remove the fastening bolts of converter housing.

BOLT SYMBOL REFERENCE

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

Fig 12: Identifying Converter Housing Bolts

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CAUTION: Be careful because adjusting shim of the drive sprocket may depart.

Remove the converter housing by tapping with a plastic hammer etc.

Fig 13: Removing Converter Housing
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Using the special tools MB990590 and MB992039, remove the outer race of reduction gear bearing from the converter housing.
Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.
Standard value:

61.949 - 61.979 mm ( 2.4389 - 2.4401 in)

Fig 14: Removing Outer Race Of Reduction Gear Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB990590 and MB992039, remove the outer race of differential side bearing from the converter housing.
Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the converter housing side; if the standard value is not satisfied, then replace the converter housing.
Standard value:

67.949 - 67.979 mm ( 2.6752 - 2.6763 in)

Fig 15: Removing Outer Race Of Differential Side Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When removing the oil seal, be careful not to cause damage to the converter housing.
Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.

Fig 16: Removing Converter Housing Oil Seal From Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the clip.

Fig 17: Locating Clip
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CAUTION: When removing the pipe, be careful not to bend it.
Remove the pipe from the converter housing.

Fig 18: Installing Pipe On Converter Housing
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Remove the plug from the converter housing.

Fig 19: Locating Plug
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Remove the O-ring from the plug.

Fig 20: Identifying O-Ring On Plug
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Remove the O-ring from the input shaft.

Fig 21: Locating Input Shaft O-Ring
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Remove the adjusting shim from the drive sprocket.

Fig 22: Locating Drive Sprocket
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Remove the baffle plate.

Fig 23: Locating Baffle Plate
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Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Fig 24: Identifying Snap Ring
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Fig 25: Expanding Snap Ring
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Remove the thrust washer from the oil pump cover.

Fig 26: Locating Oil Pump Cover Thrust Washer
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Remove the snap ring from the oil pump.

Fig 27: Locating Oil Pump Snap Ring
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Remove the reduction gear assembly from the transaxle case.

Fig 28: Identifying Reduction Gear Assembly
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Remove the differential assembly from the transaxle case.

Fig 29: Identifying Differential Assembly
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Remove the bracket.

Fig 30: Locating Bracket
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Remove the baffle plate.

Fig 31: Locating Baffle Plate
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Remove the baffle plate.

Fig 32: Locating Baffle Plate
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Remove the oil pump cover from the transaxle case.

Fig 33: Locating Oil Pump Cover
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Remove the seal rings from the oil pump cover.

Fig 34: Locating Oil Pump Cover Seal Rings
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Remove the needle bearing from the forward clutch assembly.

Fig 35: Installing Needle Bearing On Forward Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pan from the transaxle case.
Remove the magnet from the oil pan.

Fig 36: Identifying Oil Pan
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Remove the oil pan gasket from the transaxle case.

Fig 37: Removing Oil Pan Gasket From Transaxle Case
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Remove the oil strainer

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 38: Identifying Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the O-ring from the oil strainer.

Fig 39: Removing O-Ring From Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket from the control valve assembly.

Fig 40: Locating Bracket On Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual lever.

Fig 41: Locating Manual Lever
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Remove the control valve assembly from 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 42: Identifying Pin And Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove fastening bolts of the control valve assembly.

BOLT SYMBOL REFERENCE

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

Fig 43: Identifying Control Valve Assembly Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the control valve assembly from the transaxle case.
NOTE: Tilt the control valve assembly, and after removing from the manual shaft side, remove the terminal body from the transaxle case.

Fig 44: Identifying Control Valve Assembly
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Remove the bush from the control valve.

Fig 45: Removing Bush From Control Valve
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Remove the lip seal from the transaxle case.

Fig 46: Locating Lip Seal
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Remove the valve body harness from the control valve.

Fig 47: Identifying Valve Body Harness
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Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)

Fig 48: Locating Oil Pump Bolts
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Remove the O-ring from the oil pump fastening bolt.

Fig 49: Identifying O-Rings
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Remove the lip seal from the transaxle case.

Fig 50: Locating Lip Seal
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Using the special tools MB990590 and MB992039, remove outer race of the differential side bearing from the transaxle case.
Using cylinder gage etc., measure the mounting bore diameter of differential side bearing outer race at the transaxle case side; if the standard value is not satisfied, then replace the CVT assembly.
Standard value:

67.949 - 67.979 mm ( 2.6752 - 2.6763 in)

Fig 51: Removing Outer Race Of Differential Side Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 52: Installing Selected Shim On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB990590 and MB992039, remove outer race of the reduction gear bearing from the transaxle case.
Using cylinder gage etc., measure the mounting bore diameter of reduction gear bearing outer race at the transaxle case side; if the standard value is not satisfied, then replace the CVT assembly.
Standard value:

61.949 - 61.979 mm ( 2.4389 - 2.4401 in)

Fig 53: Removing Outer Race Of Reduction Gear Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 54: Installing Selected Adjusting Shim On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When removing the side oil seal, be careful not to cause damage to the transaxle case.
Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.

Fig 55: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring from the transaxle case.

Fig 56: Locating Detent Spring
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Remove the forward clutch assembly from the transaxle case.

Fig 57: Installing Forward Clutch Assembly On Transaxle Case
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Remove the needle bearing on forward clutch drum side from the sun gear.

Fig 58: Installing Needle Bearing On Forward Clutch Drum Side Of Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sun gear from the planet carrier.

Fig 59: Installing Sun Gear On Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on primary pulley side from the sun gear.

Fig 60: Installing Needle Bearing On Primary Pulley Side Of Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planet carrier from the transaxle case.

Fig 61: Installing Planet Carrier On Reverse Brake
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the planet carrier.

Fig 62: Removing Needle Bearing From Planet Carrier
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CAUTION: Check if there is damage, deformation, burn marks or permanent sets of the dish plate, driven plate, snap ring, and drive plate. Replace any defective part.
Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case.

Fig 63: Removing Reverse Brake Retaining Plate, Drive Plate, Driven Plate And Dish Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Set the spring compressor right on top of the spring of spring retainer assembly.
- Do not remove the return spring from the spring retainer assembly.
Using the special tool MB992139, compress the return spring, and remove the snap ring from the transaxle case.
Remove the retaining plate and return spring assembly.

Fig 64: Compressing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.
Feed the air in the oil hole shown in the illustration, and remove the reverse brake piston from the transaxle case.

Fig 65: Identifying Oil Hole

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 66: Identifying Reverse Brake Piston

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