Reassembly Service Point

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 1: Transaxle Case Lip Seal

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the valve body assembly on the transaxle case as follows.

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 2: Valve Body Harness Assembly
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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 3: Aligning Detent Of Terminal Body With Transaxle Case
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Fig 4: Terminal Body Of Transaxle Case
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Slide the valve body assembly from the bottom, and install it on the transaxle case.

Fig 5: Removing Valve Body Assembly
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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 6: Valve Body Assembly Mounting Bolt Loosening Sequence

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Install the manual valve lever, and tighten the fastening nuts to the specified torque of 22.1 N-m (16 ft-lb).

Fig 7: Manual Valve Lever Fastening Nut
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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 8: Valve Body Assembly Bracket And Fastening Bolts
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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 9: Installing O-Ring On Oil Strainer
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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 10: Oil Strainer Mounting Bolt Tightening Sequence

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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.

Fig 11: Transaxle Case Oil Pan Gasket
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Install the magnet on the oil pan.

Fig 12: Oil Pan Magnet
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CAUTION: When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
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 13: Oil Pan Mounting Bolt Tightening Sequence
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CAUTION: Do not re-use the snap ring.
Install the snap ring on the terminal body.

Fig 14: Installing Snap Ring On Terminal Body
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CAUTION:
- Do not re-use the converter housing oil seal.
- Apply transmission fluid when installing the converter housing oil seal.
Using the special tools, install the converter housing oil seal on the converter housing.
- Oil seal installer (MB992141)
- Handle (MB992075)
Fig 15: Installing Converter Housing Oil Seal
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Depth from the case edge A:

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

Fig 16: Checking Depth From Case Edge
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CAUTION:
- Do not re-use the side oil seal.
- Apply transmission fluid when installing the side oil seal.
Using the special tool, install the side oil seal on the transaxle case.
- Oil seal installer (MB992140)
- Handle (MB992075)
Fig 17: Installing Side Oil Seal On Transaxle Case
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Depth from the case edge A:

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

Fig 18: Checking Depth From Case Edge
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CAUTION:
- Do not re-use the side oil seal.
- Apply transmission fluid when installing the side oil seal.
Using the special tools, install the side oil seal on the converter housing. <F1CJC>
- Oil seal installer (MB992206)
- Handle (MB992075)
Fig 19: Installing Side Oil Seal On Converter Housing
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 20: Checking Depth From Case Edge
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CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring and CVT fluid filter on the transaxle case.

Fig 21: CVT Fluid Filter O-Ring
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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 22: Transaxle Fluid Filter Cover
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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 23: CVT Fluid Cooler
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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 24: 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 25: Manual Control Lever
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Insert pins etc. [45 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 26: Shift Lever, Inhibitor Switch, Adjusting Holes And Fastening Bolts
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  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 27: Installing O-Ring On Secondary Pulley Speed Sensor
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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 28: Secondary Pulley Speed Sensor
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CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the primary pulley speed sensor.

Fig 29: Installing O-Ring On Secondary Pulley Speed Sensor
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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 30: Primary Pulley Speed Sensor
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CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the turbine speed sensor.

Fig 31: Turbine Speed Sensor O-Ring
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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 32: Turbine Speed Sensor
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CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Install the O-ring on the plug.

Fig 33: Installing O-Ring On Plug
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Fasten the plug on the transaxle case to the specified torque of 7.5 N-m (66 in-lb).
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
Fig 34: Transaxle Case Plug
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Install the O-ring on the input shaft.

Fig 35: Input Shaft O-Ring
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CAUTION: When conducting measurements, measure two or more places, and find the average value.
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 36: Measuring Dimension Between Torque Converter And Transaxle
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CAUTION: Do not re-use the drain plug gasket.
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.
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)
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).
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).
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).
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).
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>