Disassembly Service Point

CAUTION: Do not disassemble parts other than specified.

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 Transaxle Case Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the plug.

Fig 3: Locating O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever from the manual shaft.

Fig 6: Locating Shift Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the inhibitor switch from the transaxle.

Fig 7: Identifying Inhibitor Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Fig 9: Locating Transmission Fluid Cooler (Without Fluid Cooler Hose)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 10: Locating Transmission Fluid Cooler (With Fluid Cooler Hose)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transmission fluid filter from the transaxle case.

Fig 11: Removing/Installing Transmission Fluid Filter On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the fastening bolts of converter housing.

CONVERTER HOUSING BOLT SPECIFICATIONS

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

Fig 12: Identifying Converter Housing Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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:

ø 61.949 - 61.979 mm (ø2.4389 - 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:

ø67.949 - 67.979 mm (ø2.6752 - 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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 18: Locating Converter Housing Pipe
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the plug from the converter housing.

Fig 19: Locating Converter Housing Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the plug.

Fig 20: Locating O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the input shaft.

Fig 21: Locating O-Ring On Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the chain cover.

Fig 22: Locating Chain Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Fig 23: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 24: Identifying Driven Sprocket, Oil Pump Chain, And Drive Sprocket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the thrust washer from the oil pump cover.

Fig 25: Locating Thrust Washer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the oil pump.

Fig 26: Locating Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear assembly from the transaxle case.

Fig 27: Identifying Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential assembly from the transaxle case.

Fig 28: Identifying Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket.

Fig 29: Locating Bracket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil guide.

Fig 30: Locating Oil Guide
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the baffle plate.

Fig 31: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump cover from the transaxle case.

Fig 32: Locating Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the seal rings from the oil pump cover.

Fig 33: Locating Seal Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the forward clutch assembly.

Fig 34: Removing Needle Bearing From 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 35: Identifying Oil Pan
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pan gasket from the transaxle case.

Fig 36: Removing Oil Pan Gasket From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the oil strainer

OIL STRAINER BOLT SPECIFICATIONS

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

Fig 37: Identifying Oil Strainer Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the O-ring from the oil strainer.

Fig 38: Removing O-Ring From Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket from the control valve assembly.

Fig 39: Locating Bracket On Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual valve lever.

Fig 40: Locating Manual Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the control valve assembly from the transaxle case as follows:

Insert pins etc. (ø3 mm (0.12 in)) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.

Fig 41: Inserting Pins Into Linkage Stopper Holes Of Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove fastening bolts of the control valve assembly.

CONTROL VALVE ASSEMBLY BOLT SPECIFICATIONS

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

Fig 42: 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 43: Removing/Installing Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the bush from the control valve.

Fig 44: Removing Bush From Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 45: Locating Lip Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body harness from the control valve.

Fig 46: Identifying Valve Body Harness
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)

Fig 47: Locating Oil Pump Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the oil pump fastening bolt.

Fig 48: Identifying O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 49: Locating Lip Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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:

ø67.949 - 67.979 mm (ø2.6752 - 2.6763 in)

Fig 50: 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 51: Removing/Installing Adjusting Shim At 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:

ø61.949 - 61.979 mm (ø2.4389 - 2.4401 in)

Fig 52: 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 53: Removing/Installing Adjusting Shim At 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 54: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring from the transaxle case.

Fig 55: Locating Detent Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the forward clutch assembly from the transaxle case.

Fig 56: Removing/Installing Forward Clutch Assembly At Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on forward clutch drum side from the sun gear.

Fig 57: Removing/Installing Needle Bearing On Forward Clutch Drum Side From Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sun gear from the planet carrier.

Fig 58: Removing/Installing Sun Gear At Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on primary pulley side from the sun gear.

Fig 59: Removing/Installing Needle Bearing On Primary Pulley Side At Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planet carrier from the transaxle case.

Fig 60: Removing/Installing Planet Carrier At Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the planet carrier.

Fig 61: Removing Needle Bearing From Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 62: 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 63: 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 64: Locating Oil Hole
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 65: Identifying Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.