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Disassembly & Assembly

CAUTION: Perform the following items when replacing the control valve.
  • Check that the part number and serial number (A) of the new control valve are identical to those of the attached CD.
    G16071465Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  • If old QR code sticker is affixed to shift actuator, remove the QR code sticker and affix new QR code sticker included with new control valve.
NOTE: The CD provided with the new control valve contains important calibration data that must be installed with M.U.T.-III SE after installation of the new control valve. Never discard the CD.
  1. Disconnect battery negative terminal. Refer to REMOVAL AND INSTALLATION .
  2. Remove drain plug from oil pan and then drain the CVT fluid.
  3. Remove drain plug gasket.
  4. Remove the oil pan bolts, and then remove the oil pan and oil pan gasket.
  5. Remove the magnets from the oil pan.
    NOTE: Be sure to note the location of the magnets in the oil pan before removal.
  6. Use a suitable tool (A) between the manual plate (3) and bolt (B) and remove lock nut (1). Remove spring washer (2) and manual plate from manual shaft (C).
    CAUTION:
    • Insert suitable tool between the manual plate and bolt and remove lock nut while holding the manual plate in a fixed position.
    • Be sure not to damage the control valve while using suitable tool.
    G16071466Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Front
  7. Remove the oil strainer assembly bolts (A) and remove the oil strainer assembly.
    G16071467Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Remove CVT fluid temperature sensor bracket (1) and disconnect control valve harness connector (A).
    G16071512Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
    : Front
  9. Remove bolts.
    G16071469Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Front
  10. Disconnect control valve harness connector (A).
  11. Remove the control valve bolts (A) and (B), and then remove the control valve from the transaxle case.
    G16071470Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Front
    CAUTION: Never drop the control valve, ratio control valve and manual shaft.
    NOTE: Control valve bolt heads may be marked with a number "7". Bolts marked as "7" are the bolts that need to be removed in order to remove the control valve.
  12. Remove the lip seal (1) from the transaxle case.
    G16071471Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Front
  13. Temporarily install the oil pan gasket and oil pan with four oil pan bolts ( ) to corners of the oil pan, hand tight.
    G16071516Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: It is not necessary for the control valve to be installed, a new one will be installed later in the service procedure.
  14. Remove the CVT from the vehicle. Refer to REMOVAL AND INSTALLATION .
  15. Mount the CVT on a workbench with the oil pan side down.
    NOTE: Use plastic or wood blocks to stabilize the CVT assembly on the work bench if needed.
    CAUTION: Be sure not to deform the oil pan.
  16. Remove the torque converter (1).
    G16071517Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  17. Drain the CVT fluid out of the torque converter (1).
    G16071518Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    A : Drain pan
  18. Remove mounting bolt ( ) and remove primary speed sensor (1) from transaxle assembly.
    G16071519Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never impact the primary speed sensor when removing or installing primary speed sensor.
  19. Remove the converter housing fixing bolts.
    G16071520Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE:
    • These bolts will be replaced with new ones and will not be reused.
    • Apply rust remover to the dowel pins if needed.
    (A) : Front bolts
    (B) : Back side bolts
  20. Separate and then remove the converter housing from the transaxle case. Use the slide hammer [SST: KV315J0610 (J-25721-A)] (A), slide hammer nut and bolt kit [SST: KV315J0630 (J-50255-UPD)] (B), and J-hook case separator [SST: KV315J0620 (J-51923)] (C) at the cut out areas similar to the one shown in figure.
    G16071521Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    (D) : Cutout area (total 3 places)
    CAUTION: Never use a pry-bar, chisel, etc. to separate the converter housing from the transaxle case.
  21. Check that retaining pin of manual shaft (1) locates on the original position.
    G16071522Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  22. Remove the O-ring (1) from the input shaft.
    G16071523Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  23. Carefully remove the reduction gear assembly (1) and the differential assembly (2).
    G16071524Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Remove the following oil seals using suitable tool:
    CAUTION: Be careful not to damage any of the seal bore surfaces.
    • Differential side oil seal (1) of transaxle case
      G16071525Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Converter housing oil seal (1)
      G16071526Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Differential side oil seal (1) of converter housing
    G16071527Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. Remove the baffle plate (chain cover) (1).
    G16071528Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Nut
  26. Remove the oil pump chain (1), driven sprocket (2) and drive sprocket (3) as one assembly in the following procedure.
    G16071529Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Spread the snap ring (1) using snap ring pliers.
      G16071530Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Lift the driven sprocket and the drive sprocket horizontally.
      CAUTION: The drive sprocket has a specific top and bottom. Keep the sprockets and chain together after they are removed.
  27. Remove the thrust washer (1).
    G16071531Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  28. Remove the snap ring (1).
    G16071532Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  29. Remove the bracket (1).
    G16071533Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
  30. Remove the baffle plate (1).
    G16071534Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
  31. Remove the chain guide (1).
    G16071535Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
  32. Remove the dummy cover (1).
    G16071536Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
    CAUTION:
    • Never grasp the input shaft and lift it.
    • Never remove the seal rings (1).
    G16071537Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Remove the thrust bearing (1) from clutch assembly. And wipe any metallic debris off of the face of the input speed sensor (3).
    G16071538Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful not to damage seal rings (2).
  34. Remove the oil pump fixing bolts (4 pieces) and then remove the oil pump (1).
    G16071539Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
  35. Remove CVT fluid filter as follows:
    1. Remove the bolts ( ) and then remove the fluid filter cover (1).
      G16071540Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Remove the CVT fluid filter (1) with grommet seal (3) and O-ring (2).
    G16071541Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Thoroughly clean the mating surfaces of the transaxle case and torque converter housing.
    NOTE: A plastic scraper can be used.
    CAUTION:
    • Never use sanding discs, similar abrasive tools, or metal blades.
    • Use parts cleaner or equivalent solvent and lint-free paper only.
    • Make sure the parts cleaner or solvents used are compatible with local regulations.
    • Prevent debris from entering in the CVT.
  37. Make sure rust and debris have been cleaned off of dowel pins (A) and receiving holes (B).
    G16071542Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: Use small wire brush or similar tool at the inside surface of dowel pin holes. Never scrape transaxle case mating surfaces.
  38. Clean the oil passages in the transaxle case, dummy cover, and CVT fluid filter area.
    NOTE:
    • Parts cleaner or a suitable cleaning solvent and compressed air will be used to clean out fluid passages in the CVT assembly.
    • Make sure the parts cleaner or solvents are compatible with local regulations.
    CAUTION:
    • Wear eye/face protection when using compressed air and cleaning fluids.
    • Regulate air pressure up to a maximum of 517 kPa (5.27 kg/cm2 , 75 psi).
    1. Clean the area where the CVT fluid filter fits (A) and the fluid passages (B) to and from the filter.
      G16071543Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      CAUTION: Make sure the old filter grommet seal is removed.
    2. Spray parts cleaner in all fluid passages (A) of the transaxle case where shown in figure.
      G16071544Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      CAUTION: Never spray parts cleaner into the clutch assembly.
    3. Apply compressed air in the same passage.
      CAUTION: Never stand in front of the passages while using compressed air.
  39. Temporarily install fluid filter cover.
  40. Install the O-ring (A) to the oil pump mounting bolt. (Only for the bolt installed from the outside of the transaxle case)
    G16071545Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never reuse the O-ring.
    • Apply the CVT fluid to the O-ring.
  41. Install the oil pump on the transaxle case and tighten the mounting bolts to the specified torque. (One of the oil pump retaining bolts is installed from the outside of the transaxle case in the rear part of the oil pump.)
    G16071539Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
    CAUTION: Never reuse the oil pump.
  42. Install the snap ring (1).
    G16071532Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never reuse the oil pump snap ring.
  43. Temporarily install the dummy cover (1) with 3 bolts ( ) .
    G16071548Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never install the thrust bearing to the clutch assembly bore at this time.
    • If cover does not seat flush, refer to TROUBLE SHOOTING .
  44. Temporarily install the converter housing onto the transaxle case with 3 bolts ( ) .
    G16071549Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When fitting the CVT case surfaces, never use the bolts to draw in the case halves. Make sure the case surfaces are flush, and have no gaps prior to installing the bolts.
  45. Reposition the CVT assembly on the work bench with the side cover side facing up.
    NOTE:
    • CVT lifter bracket [SST: - (J-51595)] (B) and CVT lifting eye/swivel assembly [SST: - (J-51595-1)] (A) can be used for this step.
      G16071550Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Use plastic or wood blocks to stabilize the CVT assembly on the work bench if needed.
    CAUTION:
    • Never hit the manual shaft (1) while repositioning the CVT; the manual shaft is longer than the oil pan mating surface  .
      G16071551Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Never pinch the terminal connector harness between the transaxle case and work bench or supporting block.
  46. Rotate the primary pulley (1) by hand to check the pulley's rotational characteristics.
    G16071552Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never place fingers between the pulley and the transaxle case (A).
    NOTE: Remember the pulley's rotational characteristics. This will be used as a reference after the new side cover-pulleys and belt sub-assembly (sub-assembly) have been installed.
  47. Remove the side cover fixing bolts.
    G16071553Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
    NOTE: When working with sub-assembly install, uninstall, and bracket attachment, it is critical that CVT and sub-assembly are level.
  48. Attach the CVT universal lifting fixture [SST: KV315J0100 (J-52082)] (B) with spacers [SST: - (J-52082-2)] (A) to the side cover.
    G16071554Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: Tighten the wing-nut bolts on the CVT universal lifting fixture [SST: KV315J0100 (J-52082)] finger tight in the following order:
    1. Remove the pulley bracket bolts ( ) from side cover (A).
      G16071555Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install medium (A) and long (B) shafts of CVT universal lifting fixture [SST: KV315J0100 (J-52082)].
      G16071556Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. Install spacers [SST: - (J-52082-2)] (A) and CVT universal lifting fixture [SST: KV315J0100 (J-52082)] (B) to shafts.
    G16071554Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Install CVT universal lifting (A) properly.
    G16071558Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  49. Attach the CVT assembly guide pins [SST: KV315J0200 (J-51959)] (A) as shown in figure.
    G16071559Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    G16071560Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Guide pins must be placed next to dowel pins (B).
  50. Lift up the CVT universal lifting fixture [SST: KV315J0100 (J-52082)] so that the CVT assembly weight is mostly supported by the CVT universal lifting fixture and just slightly raised off of the work surface.
  51. Loosen the side cover with a slide hammer at the three points.
    G16071561Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never use a pry-bar, chisel, etc. to separate the side cover from the transaxle case.
    NOTE: Apply rust penetrant to the two dowel pins as needed.
  52. Lift up the CVT universal lifting fixture [SST: KV315J0100 (J-52082)] to remove the sub-assembly (1) from the transaxle case.
    G16071562Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Remove the CVT universal lifting fixture from the sub-assembly.
    NOTE: Check that dowel pins have remained in the transaxle case. If not, remove dowel pins from the sub-assembly and relocate back to the transaxle case.
  54. Install all six original bolts into the old sub-assembly
  55. Thoroughly clean the mating surfaces (A) of the CVT case that the subassembly was just separated from.
    G16071563Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never use sanding discs, similar abrasive tools, or metal blades.
    • Use parts cleaner or equivalent solvent and lint-free paper only.
    • Make sure the parts cleaner or solvents used are compatible with local regulations.
    • Prevent debris from entering in the CVT.
    • Make sure rust and debris have been cleaned off of dowel pins and receiving holes.
    • Use small wire brush or similar tool at the inside surface of dowel pin holes. Never scrape transaxle case mating surfaces.
    NOTE: The CVT assembly guide pins [SST: KV315J0200 (J-51959)] can be temporarily removed for cleaning purposes.
  56. Replace the O-ring (1).
    CAUTION: Apply CVT fluid to O-ring.
    G16071564Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. Remove the thrust bearing (1) from the planetary carrier assembly.
    G16071565Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: If not found on the planetary carrier assembly, the thrust bearing may still be attached to the primary pulley.
  58. Rotate the shift select lever (1) clockwise on the side of the CVT to adjust the parking rod (2) to the lowest position.
    G16071566Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Remove the pulley bracket bolts ( ) from the side cover (1) of the new sub-assembly.
    G16071555Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  60. Attach the appropriate CVT universal lifting fixture [SST: KV315J0100 (J-52082)] (A) to the new sub-assembly, and then lift up sub-assembly out of the shipping box.
    G16071558Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Apply Loctite 5460 on the transaxle case installation surface of the sub-assembly.
    CAUTION:
    • Confirm that the mating surfaces are clean before applying sealant.
    • The sealant width is 2.0 mm (0.079 in).
    • Check that the starting point and the ending point are about the middle between the bolts. The overlap both ends (A) of the bead by 3 - 5 mm (0.12 - 0.20 in).
      G16071569Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Be careful not to contact or contaminate the sealant. If the sealant has been disturbed or contaminated in any way before case assembly, thoroughly clean the mating surfaces of the transaxle case and re-apply.
  62. Install the original thrust bearing (1) on the primary pulley (2) of the new sub-assembly.
    G16071570Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Pay close attention to the direction of the thrust bearing when installing.
      G16071571Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      : Primary pulley 
    • Apply a small amount of petroleum jelly or equivalent to the original thrust bearing to hold it in place on the primary pulley.
  63. Apply CVT fluid to the primary pulley bearing, secondary pulley gear teeth and the secondary bearing when installing the new sub-assembly.
    G16071572Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never drip any CVT fluid onto the sealant.
  64. Attach the CVT assembly guide pins [SST: KV315J0200 (J-51959)] (A) to transaxle case when installing the new sub-assembly.
    G16071560Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Guide pins must be installed next to dowel pins (B).
  65. Install the new sub-assembly to transaxle case.
    CAUTION:
    • Never allow the output gear CD to hit the lubrication tube CD when the side cover is positioned over the guide pins.
      G16071574Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • In the following steps be careful not to contact or contaminate the sealant.
    • Never use hammer when installing the new sub-assembly.
    NOTE:
    • If the sub-assembly does not lower completely, physical interference is present. Check the "visual gap size" (A) below, between the sub-assembly and the transaxle case, to determine the cause of interference.
      G16071575Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Sub-assembly (1) cannot lower past 44 mm (1.73 inch). (Interference is present between the output gear (2) and bearing bore (A).)
      G16071576Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      (3) : Transaxle case
      (B) : Case gap
    • Sub-assembly cannot lower past 38 mm (1.50 inch).
      G16071577Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • When installing side cover, insert parking rod (1) to parking pawl area (A).
    • Install the parking rod into the parking pawl of the side cover with the following procedure.
      1. Rotate the shift select lever clockwise on the side of the CVT to adjust the park rod (1) to the highest position.
      2. Use a magnet or similar tool (B), to align the park rod (1) in the transaxle case with the opening in the parking pawl (2) in the side cover.
      (3) : Side cover
    • Sub-assembly (1) cannot lower past 19 mm (0.75 inch). (The primary and the secondary pulley bearings never align properly with their bores or are at an angle.)
      G16071578Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      (2) : Primary pulley bearing
      (3): Secondary pulley bearing
      (4): Transaxle case
      (A) : Primary pulley bearing bore
      (B): Secondary pulley bearing bore
      (C): Case gap
      CAUTION:
      • If this occurs, never force sub-assembly into case.
      • Level the sub-assembly (visually check the gap between case and sub-assembly side cover and confirm that it is even all around).
    • Sub-assembly (1) cannot lower past 6 mm (0.24 inch). (Primary pulley splines are not aligned.)
    G16071579Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    (2) : Transaxle case
    (A): Primary pulley splines
    (B): Planetary carrier splines
    (C): Case gap
    CAUTION:
    • Never place fingers below primary pulley.
    • Be careful not to get fingers caught between the transaxle case and sub-assembly when seating.
    • If this occurs, never force sub-assembly into case.
    • Lift up the sub-assembly slightly so the weight is not completely on the primary pulley splines.
    • Check the dowel pins are clean and aligned and are not catching on the sub-assembly case cover.
  66. Remove bolts (A) from shift actuator and remove shift actuator.
    G16071455Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Install transmission range switch adjustment tool [SST: KV381100S0 (J-52508)] (A) over manual lever (2) and into alignment hole (B) on transmission range switch (1).
    G16071459Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Confirm the parking rod operation with the following procedure.
    1. Rotate the transmission range switch adjustment tool [SST: KV381100S0 (J-52508)] (A) counter clockwise and check that all detents for each of the P-R-N-D are detect.
      G16071582Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      (1): Transmission range switch
    2. Rotate the lever clockwise to return the rod back to the P position.
    3. If the lever does not rotate or if all detents are not detect, lift the sub-assembly and remove all sealant, and repeat from step  61.
  69. Remove transmission range switch adjustment tool.
  70. Apply grease evenly to the shift actuator spline (A).
    G16071456Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Install the shift actuator to the transaxle case.
  72. Tighten bolts (A).
    G16071455Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Remove the CVT assembly guide pins [SST: KV315J0200 (J-51959)].
  74. Install the new side cover bolts and temporary tighten them. And then, tighten the bolts to specified torque in the order shown.
    Fig 1: Side Cover Bolts Tightening Sequence
    G16071585Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never reuse the side cover bolts.
  75. Remove the CVT universal lifting fixture [SST: KV315J0100 (J-52082)].
  76. Install the new pulley bracket bolts and new O-rings finger tight to side cover (1).
    G16071586Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never reuse the pulley bracket bolts and the O-rings.
    • Apply the CVT fluid to the O-rings.
  77. Check the rotational smoothness of the primary pulley (1) with the following procedure.
    G16071587Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never insert fingers between the pulley and the transaxle case (A).
    1. With clean hand, access the primary pulley from the bottom of the CVT to rotate.
    2. Rotate the primary pulley by hand and confirm that the characteristic is the same as previously checked at step 45.
    3. If the rotational characteristic worse than before the sub-assembly was replaced, perform the following.
      • Remove the sub-assembly from the transaxle case.
      • Wipe and clean the sealant completely from both the transaxle case rim and side cover rim.
      • Restart sub-assembly installation from Step 60.
  78. Tighten pulley bracket bolts ( ) to the specified torque.
    G16071586Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    (1) : Side cover
  79. Install the differential side oil seal using the output seal installer (case side) [SST: KV31501200 (J-52281)] (A) and universal driver handle [SST: ST35325000 (J-8092)] (B).
    G16071589Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never reuse differential side oil seal.
    • Apply CVT fluid to the differential side of oil seal lip surface.
  80. Set the CVT on the work bench with the side cover facing down on the bench.
  81. Remove the converter housing which was temporarily installed with 3 bolts ( ) .
    G16071549Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Calculate total end play with the following procedure. (Thrust bearing selection)
    NOTE: The total end play (A) must always be adjusted with thrust bearing (3) between the dummy cover (1) and the forward clutch drum (2) when a new sub-assembly is installed.
    G16071591Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • The forward clutch is 2 - 3 mm (0.08 - 0.12 in) below the dummy cover surface.
    • If the gap is more than 2 - 3 mm (0.08 - 0.12 in), the component parts may be improperly installed. Refer to TROUBLE SHOOTING .
    • If the gap is less than 2 - 3 mm (0.08 - 0.12 in), the component parts may be missing or damaged.
    G16071592Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the average distance (D) from the dummy cover installation surface of the transaxle case (1) to the thrust bearing installation surface of the forward clutch drum (2).
      Average distance (D) : (D1 + D2)/2
      A : Gauge block [SST: KV315J0400 (J-50271)]
      B : Digital depth gauge [SST: KV315J0500 (J-50272)]
      G16071593Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      CAUTION: Never measure from the forward clutch assembly bore in (A).
      G16071594Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Clean the dummy cover surfaces (A) that contact the transaxle case and thrust beaning.
      G16071595Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      CAUTION:
      • Use parts cleaner or equivalent solvent and lint-free paper only.
      • Make sure the parts cleaner or solvents used are compatible with local regulations.
    3. Using digital depth gauge [SST: KV315J0500 (J-50272)], measure the distance (H) from the edge of the dummy cover (1) to the installation surface on the transaxle case.
      G16071596Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Average distance (H) : (H1 + H2)/2
      A : Gauge block [SST: KV315J0400 (J-50271)]
    4. Calculate the total end play with the following formula, and choose the appropriate bearing from table.

      (D) - (H) = Total end play (A)

      Total end play (A) Bearing thickness
      3.87 - 4.07 mm (0.1524 - 0.1602 inch) 3.57 mm (0.1406 inch)
      4.08 - 4.23 mm (0.1606 - 0.1665 inch) 3.75 mm (0.1476 inch)
      4.24 - 4.43 mm (0.1669 - 0.1744 inch) 3.93 mm (0.1547 inch)
      4.44 - 4.58 mm (0.1748 - 0.1803 inch) 4.1 mm (0.161 inch)
      4.59 - 4.78 mm (0.1807 - 0.1882 inch) 4.28 mm (0.1685 inch)
      4.79 - 4.94 mm (0.1886 - 0.1945 inch) 4.46 mm (0.1756 inch)
      4.95 - 5.09 mm (0.1949 - 0.2004 inch) 4.61 mm (0.1815 inch)
      5.10 - 5.29 mm (0.2008 - 0.2083 inch) 4.79 mm (0.1886 inch)
  83. Install the thrust bearing (1) to the clutch assembly bore.
    G16071597Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never reuse thrust bearing.
    • Apply petroleum jelly when installing the thrust bearing.
    • Pay close attention to the direction of the thrust bearing when attaching it.
    G16071598Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    (1) : Upper side
    (2): Lower side (Black surface)
  84. Remove the baffle plate (1) from the converter housing.
    G16071599Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
  85. Remove the bolt ( ) and then remove the lubrication tube (1) and clip (2).
    G16071600Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  86. Clean hydraulic circuit (A) of converter housing lubrication tube and dummy cover with parts cleaner and blowing air, check holes (B) for blowing air.
    CAUTION:
    • Never stand in front of the passages shown while using compressed air.
    • Wear eye/face protection when using compressed air and cleaning fluids.
    • Regulate air pressure up to a maximum of 517 kPa (5.27 kg/cm2 , 75 psi).
    G16071601Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  87. Install the lubrication tube (1) and clip (2).
    G16071600Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  88. Install the baffle plate (1) to the converter housing.
    G16071599Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Bolt
  89. Apply petroleum jelly to the seal rings (1) before installing the dummy cover (2) to the transaxle case and clean the area (A).
    G16071604Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Seal rings are in their appropriate slots. Carefully reposition seals as necessary.
    • Seal rings must be in their correct positions during final assembly to prevent driveability issues.
  90. Check the seal rings (1) of input shaft are in the correct positions and clean the area (A).
    G16071605Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Seal rings are in their appropriate slots. Carefully reposition seals as necessary.
    • Seal rings must be in their correct positions during final assembly to prevent driveability issues.
  91. Install the dummy cover (1) and chain guide (2).
    G16071606Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never torque bolts ( ) at this step.
    • Check that the dummy cover is fully seated on the transaxle case. If dummy cover does not seated, forward clutch may be improperly installed. Refer to TROUBLE SHOOTING .
  92. Install baffle plate (1) and bracket (2) with the related bolts finger tight. And tighten the bolts to the specified torque.
    G16071607Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    (A) : 5.9 N.m (0.6 kg-m, 52 in-lb.)
    (B) : 25.5 N.m (2.6 kg-m, 19 ft-lb).
    (C) : 19.0 N.m (1.9 kg-m, 14 ft-lb.)
  93. Install the thrust washer (1) onto the dummy cover (2).
    G16071608Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: Use petroleum jelly to hold the thrust washer in place.
  94. Install the drive sprocket (1), driven sprocket (2), and oil pump chain (3) as an assembly.
    G16449303Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: Wider edge (A) on the drive sprocket is facing up.
  95. Spread the snap ring (1) using snap ring pliers.
    G16071530Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  96. Press down on the driven sprocket until it "snaps" and locks into place.
  97. Pull up after install sprocket and check lockup to confirm adopt correctly.
  98. Install baffle plate (chain cover) (1) and tighten the mounting nut.
    G16071528Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Nut
  99. Install the differential assembly (1) into the transaxle case.
    G16071612Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Clean differential assembly before installing.
    • Apply CVT fluid to the bearings and gear teeth before installing.
  100. Install the reduction gear assembly (1) into the transaxle case.
    G16071613Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Clean reduction gear assembly before installing.
    • Apply CVT fluid to the bearings and gear teeth before installing.
  101. Install the new CVT fluid filter (1) with grommet seal (1) and O-ring (12).
    G16071541Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Apply CVT fluid to the grommet seal and O-ring.
  102. Install the CVT fluid filter cover (1) and tighten the bolts ( ) to the specified torque.
    G16071540Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  103. Check that retaining pin of manual shaft (1) locates on the original position.
    G16071522Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  104. Apply Loctite 5460 on the converter housing installation surface of the transaxle case.
    CAUTION:
    • Completely remove all moisture, oil and old sealant, etc. from the transaxle case and converter housing mounting surfaces.
    • The sealant width is 2.0 mm (0.079 in).
    • Check that the starting point and the ending point are about the middle between the bolts. The overlap both ends (A) of the bead by 3 - 5 mm (0.12 - 0.20 in).
      G16071617Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Be sure to apply, first sealant around the center bolt hole (B), and next around the mating surfaces (C).
  105. Install the converter housing onto the transaxle case and temporary tighten the new converter housing bolts. And then, tighten the bolts to specified torque in the order shown.
    Fig 2: Converter Housing Bolts Tightening Sequence
    G16071618Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Never reuse the converter housing bolts.
  106. Install the new converter housing oil seal (1) evenly using the oil pump seal installer [SST: KV31500700 (J-50818)] (A)
    G16071619Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    B : 0.5 mm (0.02 inch)
    CAUTION:
    • Set the torque converter housing flat during installation.
    • Apply CVT fluid to the seal lip surface.
    • Converter housing oil seal pulling direction is used as the reference.
  107. Install the differential side oil seal (1) using the output seal installer (torque converter side) [SST: KV31500910 (J-52282)] (A) and universal driver handle [SST: ST35325000 (J-8092)] (B).
    G16071620Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    (2) : Converter housing
    CAUTION:
    • Never reuse differential side oil seal.
    • Apply CVT fluid to the differential side oil seal lip surface.
  108. Install the O-ring (1) on the input shaft.
    G16071621Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never reuse the O-ring.
    • Apply the CVT fluid when installing the O-ring.
  109. Install the lip seal (1) to the transaxle case.
    G16071471Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never reuse lip seal.
    • Apply petroleum jelly to lip seal.
    : Front
  110. Install the control valve to the transaxle case.
    G16071473Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Never drop the control valve, ratio control valve and manual shaft.
    • Ensure the harness (A) is correctly routed and does not get pinched.
  111. Secure the control valve using bolts (A), (B) and (C).
    G16071474Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Ensure the harness is correctly routed and does not get pinched.
    NOTE:
    • Leave bolt holes (D) blank at this step.
    • Install bolts (C) without the strainer bracket.
    Bolt Bolt length mm (in) Number of bolt
    (A) 54 (2.13) 7
    (B) 44 (1.73) 2
    (C) 25 (0.98) 2
    : Front
  112. Connect the control valve harness connector (A).
    G16071475Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    : Front
    CAUTION: Securely insert the harness connector until it clicks and locks.
  113. Install the CVT fluid temperature sensor bracket to the valve body with bolt (A).
    G16071476Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Bolt Bolt length mm (in) Number of bolt
    (A) 54 (2.13) 1
    NOTE: Leave bolt hole (B) blank as it will be used to secure the oil strainer at a later step.
  114. Install new O-ring to oil strainer assembly.
    CAUTION:
    • Never reuse O-ring.
    • Apply CVT fluid to O-ring.
    NOTE: New oil strainer come with a new O-ring already installed.
  115. Install new oil strainer with bolts (A).
    G16071467Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Bolt Bolt length mm (in) Number of bolt
    (A) 54 (2.13) 2
  116. Install the manual plate (1) using the steps below:
    G16071478Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Align the slot of the manual plate with the manual shaft (C).
    • Align the end of the manual plate with the cutout ( ) of the manual valve.
      CAUTION: Install the end of the manual plate into the cutout of the manual valve.
    • Install spring washer (2) and lock nut (3).
    • Insert suitable tool (A) between manual plate and bolt (B) and tighten lock nut.
      CAUTION: Using suitable tool, be sure to hold the manual plate in a fixed position. Be sure not to damage control valve while using suitable tool.
    : Front
  117. Install the spring washer (2) and the lock-nut (3), and then tighten to the specified torque.
    CAUTION: To tighten nut, fix manual plate with suitable tool.
  118. Install the magnets into the oil pan in their original location.
    CAUTION: Completely clean the iron powder from the magnet area of oil pan and the magnet.
  119. Install the oil pan to the transaxle case with the following procedure.
    1. Install the oil pan gasket to the oil pan.
      CAUTION:
      • Completely wipe out any moisture, oil, and old gasket from the oil pan gasket surface and bolt hole of oil pan and transaxle case.
      • Never reuse oil pan gasket.
    2. Install the oil pan assembly to the transaxle case, and then temporarily tighten the oil pan bolts.
    3. Tighten the oil pan bolts in the order shown to the specified torque.
      Fig 3: Oil Pan Bolts Tightening Sequence
      G16071463Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      : Front
    4. Tighten the oil pan bolts again clockwise from (1) shown to the specified torque.
  120. Install drain plug gasket to drain plug.
    CAUTION: Never reuse drain plug gasket.
  121. Install drain plug to oil pan.
  122. Install new QR code sticker (1) on shift actuator (2).
    G16071480Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: If sticker is not included with parts, contact Powertrain Call Center to report.
  123. Install the torque converter (1) to the transaxle in the following procedure.
    G16071517Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Insert the pawl (A) of the torque converter to the drive sprocket hole (B) on the transaxle assembly side.
      G16071632Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      CAUTION:
      • Rotate the torque converter for installing torque converter.
      • Never damage the bushing inside the torque converter sleeve when installing the converter housing oil seal.
    2. After inserting a torque converter to the CVT, check dimension (A) with in the reference value limit.
      G16071500Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      B : Scale
      C : Straightedge
      Dimension (A) : Refer to TORQUE CONVERTER 
  124. Install the primary speed sensor.
    CAUTION:
    • Never reuse O-ring.
    • Apply CVT fluid to the O-ring.
  125. Install the transaxle assembly to the vehicle. Refer to REMOVAL AND INSTALLATION .
  126. Flush the CVT fluid cooler and lines.
  127. Fill the transaxle assembly with CVT fluid. Refer to REFILLING .
  128. Perform "ADDITIONAL SERVICE WHEN REPLACING CONTROL VALVE." Refer to DESCRIPTION .
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