Disassembly Service Point

CAUTION: Do not disassemble parts other than specified in this Service Information.

Remove the transfer from the transaxle. < W1CJA >
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.

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

Fig 2: Identifying Plug On Transaxle Case
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Remove the plug from the transaxle case.

Fig 3: Locating O-Ring On Plug
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Remove the O-ring from the plug.

Fig 4: Locating Secondary Pulley Speed Sensor
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Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.

Fig 5: Locating Primary 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 6: Locating Manual Shaft Shift Lever
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Remove the shift lever from the manual shaft.

Fig 7: Identifying Inhibitor Switch On Transaxle
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Remove the inhibitor switch from the transaxle.
CAUTION: Be careful not to cause damage to the terminal body.

Fig 8: Identifying Terminal Body Snap Ring
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Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.

Fig 9: Identifying Transmission Fluid Cooler
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Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Fig 10: Removing Transmission Fluid Filter From Transaxle Case
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Remove the transmission fluid filter from the transaxle case.

Fig 11: Identifying Converter Housing Bolts
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Remove the fastening bolts of converter housing.

CONVERTER HOUSING BOLTS IDENTIFICATION

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

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

Fig 12: Remove Converter Housing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 13: Removing Outer Race Of Reduction Gear Bearing From Converter Housing Using Special Tools MB990590 And MB992039
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

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

Fig 14: Removing Outer Race Of Differential Side Bearing From Converter Housing Using Special Tools MB990590 And MB992039
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
- F1CJA: ø67.949 - 67.979 mm (ø2.6752 - 2.6763 in)
- W1CJA: ø84.941 - 84.976 mm (ø3.3441 - 3.3455 in)
CAUTION: When removing the oil seal, be careful not to cause damage to the converter housing.

Fig 15: Removing Converter Housing Oil Seal From Housing Using Flat Blade Screwdriver
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Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.

Fig 16: Locating Clip
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Remove the clip.
CAUTION: When removing the pipe, be careful not to bend it.

Fig 17: Removing Pipe From Converter Housing
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Remove the pipe from the converter housing.

Fig 18: Locating Converter Housing Plug (F1CJA)
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Remove the plug from the converter housing.

Fig 19: Locating Converter Housing Plug (W1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 20: Locating O-Ring On Plug
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Remove the O-ring from the plug.

Fig 21: Locating Input Shaft O-Ring
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Remove the O-ring from the input shaft.

Fig 22: Locating Chain Cover
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Remove the chain cover.

Fig 23: Identifying Oil Pump Chain Driven Sprocket Snap Ring
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Fig 24: Expanding Oil Pump Chain Driven Sprocket And Drive Sprocket Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Fig 25: Locating Oil Pump Cover Thrust Washer
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Remove the thrust washer from the oil pump cover.

Fig 26: Locating Oil Pump Snap Ring
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Remove the snap ring from the oil pump.

Fig 27: Identifying Transaxle Case Reduction Gear Assembly
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Remove the reduction gear assembly from the transaxle case.

Fig 28: Identifying Transaxle Case Differential Assembly (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential assembly from the transaxle case.

Fig 29: Identifying Transaxle Case Differential Assembly (W1CJA)
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Fig 30: Locating Bracket
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Remove the bracket.

Fig 31: Locating Oil Guide
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Remove the oil guide.

Fig 32: Locating Baffle Plate
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Remove the baffle plate.

Fig 33: Locating Transaxle Case Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump cover from the transaxle case.

Fig 34: Locating Oil Pump Cover Seal Rings
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Remove the seal rings from the oil pump cover.

Fig 35: Removing Needle Bearing From Forward Clutch Assembly
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Remove the needle bearing from the forward clutch assembly.

Fig 36: Identifying Magnet On Oil Pan
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pan from the transaxle case.
Remove the magnet from the oil pan.

Fig 37: Removing Oil Pan Gasket From Transaxle Case
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Remove the oil pan gasket from the transaxle case.

Fig 38: Identifying Oil Strainer Bolts
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Remove the oil strainer

OIL STRAINER BOLTS IDENTIFICATION

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

Fig 39: Removing O-Ring From Oil Strainer

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the O-ring from the oil strainer.

Fig 40: Locating Control Valve Assembly Bracket
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Remove the bracket from the control valve assembly.

Fig 41: Locating Manual Lever
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Remove the manual lever.

Fig 42: Inserting Pins Into Linkage Stopper Holes Of Control Valve Assembly
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Remove the control valve assembly from the transaxle case as follows:

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

Fig 43: Identifying Control Valve Assembly Fastening Bolts
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Remove fastening bolts of the control valve assembly.

CONTROL VALVE ASSEMBLY BOLT IDENTIFICATION

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

Fig 44: Removing Control Valve Assembly From Transaxle Case

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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 45: Removing Bush From Control Valve

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Remove the bush from the control valve.

Fig 46: Locating Transaxle Case Lip Seal
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Remove the lip seal from the transaxle case.

Fig 47: Identifying Control Valve Body Harness
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Remove the valve body harness from the control valve.

Fig 48: Locating Transaxle Case Oil Pump Mounting Bolts
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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 49: Removing O-Ring From Oil Pump Fastening Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the oil pump fastening bolt.

Fig 50: Locating Transaxle Case Lip Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 51: Removing Outer Race Of Differential Side Bearing From Transaxle Case Using Special Tools MB990590 And MB992039
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 52: Removing Adjusting Shim From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 53: Removing Outer Race Of Reduction Gear Bearing From Transaxle Case Using Special Tools MB990590 And MB992039
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 54: Removing Adjusting Shim From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.
CAUTION: When removing the side oil seal, be careful not to cause damage to the transaxle case.

Fig 55: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.

Fig 56: Locating Transaxle Case Detent Spring
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Remove the detent spring from the transaxle case.

Fig 57: Removing Forward Clutch Assembly From Transaxle Case
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Remove the forward clutch assembly from the transaxle case.

Fig 58: Removing Needle Bearing On Forward Clutch Drum Side From Sun Gear
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Remove the needle bearing on forward clutch drum side from the sun gear.

Fig 59: Removing Sun Gear From Planet Carrier
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Remove the sun gear from the planet carrier.

Fig 60: Removing Needle Bearing On Primary Pulley Side From Sun Gear
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Remove the needle bearing on primary pulley side from the sun gear.

Fig 61: Removing Planet Carrier From Transaxle Case
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Remove the planet carrier from the transaxle case.

Fig 62: Removing Needle Bearing From Planet Carrier
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Remove the needle bearing from the planet carrier.
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.

Fig 63: Removing Reverse Brake Retaining Plate, Drive Plate, Driven Plate And Dish Plate From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case.
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.
Fig 64: Removing Snap Ring From Transaxle Case Using Special Tool MB992139
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
CAUTION: Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.

Fig 65: Locating Oil Hole
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Fig 66: Identifying Reverse Brake Piston On Transaxle Case
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Feed the air in the oil hole shown in the illustration, and remove the reverse brake piston from the transaxle case.