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Home › Mitsubishi › 2015 › Outlander ES › Repair and Diagnosis › Transmission › Automatic Trans › Continuously Variable Transaxle (CVT) Overhaul › Pulley › Disassembly And Assembly › Assembly

Disassembly And Assembly: Assembly

CAUTION: Be careful not to damage the other part(s). If you damage them, replace the CVT assembly.
  1. Install the new bearing retainer together with the ball bearing to the secondary pulley with the retainer projection facing up.
  2. Use the following special tools to drive the rear ball bearing into the secondary pulley with a press.
    • Installer cap (MD998812)
    • Installer-100 (MD998813)
    • Installer adapter (MD998829)
      Fig 1: Installing Bearing Retainer With Ball Bearing To Secondary Pulley
      G10223259Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the lock nut to the secondary pulley assembly by hand.
  4. Secure the special tool Pulley clamp base (MB992985) by using the four holes.
  5. Engage the temporarily installed rear lock nut with the hexagonal opening of the special tool Pulley clamp base (MB992985).
  6. Use a socket wrench (width across flat; 40 mm (1.6 in)) to tighten the front lock nut of the secondary pulley assembly to the specified torque (310 N.m (229 ft-lb)).
    Fig 2: Locating Special Tool Pulley Clamp Base Holes
    G10223257Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Make sure that the primary pulley assembly is separated.
  7. Install the new bearing retainer together with the ball bearing to the primary pulley assembly with the retainer projection facing down.
    Fig 3: Locating Bearing Retainer
    G10223261Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Use the following special tools to drive the rear ball bearing into the primary pulley with a press.
    • Installer cap (MD998812)
    • Installer-100 (MD998813)
    • Installer adapter (MD998823)
      Fig 4: Pressing Rear Ball Bearing Into Primary Pulley
      G10223262Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Install the lock nut to the primary pulley assembly by hand.
  10. Secure the special tool Pulley clamp base (MB992985) by using the four holes.
  11. Engage the temporarily installed rear lock nut with the hexagonal opening of the special tool Pulley clamp base (MB992985).
  12. Use the special tool Primary pulley holder (MB992986) to tighten the front lock nut of the primary pulley assembly to the specified torque (130 N.m (96 ft-lb)).
    Fig 5: Installing Lock Nut To Primary Pulley Assembly
    G10223253Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Set the front ball bearing to the primary pulley as shown.
    Fig 6: Locating Front Ball Bearing To Primary Pulley
    G10223264Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Use the special tool Bush remover base (MB991389) to drive the front ball bearing into the primary pulley with a press.
    Fig 7: Pressing Front Ball Bearing Into Primary Pulley
    G10223265Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  15. Install the O-rings to the side cover as shown.
    Fig 8: Installing O-Rings To Side Cover
    G10223250Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Use pieces of wood to place the pulley assembly so that its installation surface is horizontal.
    NOTE: If it is not horizontal, you cannot install the pulley assembly easily.
    Fig 9: Placing Pulley Assembly Using Pieces Of Wood
    G10223267Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  17. Install the primary pulley assembly to the side cover. The shown dimension should reach 1.5 - 2.0 mm (0.06 - 0.07 in).

    Set the special tools to the secondary pulley assembly.

    Fig 10: Identifying Primary Pulley Assembly To Side Cover Dimension
    G10223268Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  18. Engage the special tool Secondary pulley piston compressor (MB992984) with the secondary pulley assembly. The band of the special tool should be placed as shown.
    Fig 11: Engaging Special Tool Secondary Pulley Piston Compressor (MB992984) With Secondary Pulley Assembly
    G10223244Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Counterhold the special tools securely.
    • Make sure that the band of the special tool does not slide. If so, retighten it.
    • When pulling up the special tool, the clearance between the ball bearing and the pulley should not exceed 3 mm (0.1 in).
  19. Pull up the slide pulley by tightening the special tool Secondary pulley piston compressor (MB992984). Pull it up until the clearance between the ball bearing and the pulley reaches 3 mm (0.1 in).
    Fig 12: Checking Clearance Between Ball Bearing And Pulley
    G10223270Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  20. The other mechanic should check the rotation direction of the steel belt to apply the belt to the secondary pulley assembly.
    Fig 13: Checking Rotation Direction Of Steel Belt
    G10223243Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  21. Lift the secondary pulley assembly and the steel belt as a set, and slide the assembly toward the primary pulley to apply the steel belt to the primary pulley.
    Fig 14: Removing Secondary Pulley Assembly And Steel Belt
    G10223272Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  22. Install the secondary pulley assembly to the side cover.
    NOTE: If the ball bearing is engaged into the insertion hole, seat the secondary pulley assembly by tapping the side cover lightly with a plastic hammer.
  23. The shown dimension should be approx. 12 mm (0.5 in).
    CAUTION: Be careful not to damage the steel belt and the pulley.
  24. Remove the plastic cover from the pulley sliding surface. Then detach the spiral tube from the steel belt.
    Fig 15: Checking Dimension Of Secondary Pulley Assembly To Side Cover
    G10223273Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. Pull down the slide pulley which has been lifted by the special tool Secondary pulley piston compressor (MB992984).
  26. Remove the Secondary piston pulley compressor (MB992984) from the secondary pulley assembly.
  27. Remove the cable tie-wraps from the steel belt.
  28. Move the selector lever to the P range to pull up the parking rod.
    Fig 16: Moving Selector Lever To P Range
    G10223236Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  29. Insert the parking rod as shown with the parking rod pulled up.
    Fig 17: Inserting Parking Rod
    G10223275Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  30. Install the transaxle case to the side cover.
    NOTE: If the side cover is not seated to the transaxle case easily, move the select lever to the N position.
    NOTE: If the side cover is not seated to the transaxle case tightly, remove the side cover and repeat the installation procedure.
    Fig 18: Installing Transaxle Case To Side Cover
    G10223241Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Tighten the mounting bolts as shown to install the side cover temporarily.
    Fig 19: Locating Side Cover Mounting Bolts
    G10223240Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Check that the manual shaft locating pin has not fallen out.
    Fig 20: Identifying Manual Shaft Locating Pin
    G10223278Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Place pieces of wood around the differential oil seal to protect it.
  33. Place the transaxle case with its engine mounting surface facing down via pieces of wood.
    Fig 21: Placing Transaxle Case With Engine Mounting Surface
    G10223231Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Remove the temporarily tightened bolt from the side cover, and pull away the side cover evenly.
    Fig 22: Locating Side Cover Bolts
    G10223239Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. Install the pulley sensor, the shaft and spring assembly to the transaxle case in that order.
  36. Install the O-ring to the transaxle case.
    Fig 23: Identifying Pulley Sensor, Shaft And Spring Assembly
    G10223281Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 24: Installing O-Ring To Transaxle Case
    G10223282Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the special tool Guide (MD998412) to the bearing retainers of the primary pulley assembly and the secondary pulley assembly as shown.
    Fig 25: Installing Special Tool Guide (MD998412) To Bearing Retainers
    G10223283Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • The sealant application surface should be free of humidity, oil or residual sealant.
    • The ends of the sealant should be midway between the bolts.
  38. Apply a 5 mm (0.2 in)-diameter bead of sealant to the transaxle case mounting surface on the side cover. The ends of the sealant bead should overlap by 3 - 5 mm (0.12 - 0.19 in).

    SEALANTS 

    Brand name: Loctite 509 

    Fig 26: Locating Sealant Applying Area To Transaxle Case Mounting Surface On Side Cover
    G10223284Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Apply petroleum jelly to the pulley shim, and install it to the side cover.
    Fig 27: Applying Petroleum Jelly To Pulley Shim
    G10223234Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Move the selector lever to the P range to pull up the parking rod.
    Fig 28: Moving Selector Lever To P Range
    G10223236Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When installing the side cover, make sure that the sealant bead is not broken.
  41. Install the side cover to the transaxle case. Insert the parking rod as shown with the parking rod pulled up.
  42. Make sure that the parking rod is inserted slightly. Then move the select lever to the neutral position.
    Fig 29: Inserting Parking Rod
    G10223237Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. The pulley sensor shaft, the two ball bearings and the two knock pins should be aligned with the corresponding recesses on the side cover.
    Fig 30: Identifying Knock Pin On Side Cover
    G10223288Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Tap the entire perimeter of the side cover with a plastic hammer to engage it into the transaxle case.
    NOTE: If the side cover is not seated to the transaxle case tightly, remove the side cover and repeat the installation procedure.
    Fig 31: Tapping Entire Perimeter Of Side Cover With Plastic Hammer
    G10223238Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  45. Tighten the side cover mounting bolts in the order shown to 45 N.m (33 ft-lb).

    Bolt shank length 

    1. 35 mm (1.4 in)

      The others: 30 mm (1.2 in)

  46. Replace the O-rings of the bearing retainer mounting bolts.
    Fig 32: Locating Side Cover Mounting Bolts
    G10223290Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Tighten the bearing retainer mounting bolts to 28 N.m (21 ft-lb) as shown.
    Fig 33: Locating Bearing Retainer Mounting Bolts
    G10223232Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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