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

Disassembly Service Point

CAUTION: Do not disassemble parts other than specified in this service information.
  1. Remove the transfer from the transaxle.
  2. Remove the roll rod adapter bracket from the transaxle.
  3. Remove the harness bracket, corrugate clamp bracket and air breather bracket from the transaxle.
  4. Remove the oil filler tube and oil level gage from the transaxle.
  5. Remove the control cable bracket and breather hose from the transaxle.
  6. Remove the torque converter from the transaxle.
    Fig 1: Removing Torque Converter From Transaxle
    G10223036Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  7. Remove the plug from the transaxle case.
    Fig 2: Removing Plug From Transaxle Case
    G07043823Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Remove the O-ring from the plug.
    Fig 3: Removing O-Ring From Plug
    G10223038Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. 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 From Converter Housing
    G10223039Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  10. 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 From Transaxle Case
    G10223040Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  11. Remove the manual control lever from the manual shaft.
    Fig 6: Locating Manual Control Lever From Manual Shaft
    G10223041Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  12. Remove the transmission range switch from the transaxle case.
    Fig 7: Removing Transmission Range Switch From Transaxle Case
    G05375875Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful not to cause damage to the terminal body.
  13. Remove the O-ring from the terminal body, and press the terminal body into the transaxle case.
    Fig 8: Removing O-Ring From Terminal Body
    G10223043Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Remove the transmission fluid cooler from the transaxle case, and detach the O-ring from the cooler.
    Fig 9: Locating Transmission Fluid Cooler From Transaxle Case (Without)
    G10223044Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 10: Locating Transmission Fluid Cooler From Transaxle Case (With)
    G10223045Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  15. Remove the transmission fluid filter from the transaxle case.
    Fig 11: Removing Transmission Fluid Filter From Transaxle Case
    G05375878Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Remove the mounting bolt of converter housing.
    Bolt symbol A B
    Shank length mm (in) 30 (1.2) 35 (1.4)
    Quantity 18 5
    Fig 12: Removing Mounting Bolt Of Converter Housing
    G10223047Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful because adjusting shim of the drive sprocket may depart.
  17. Remove the converter housing by tapping with a plastic hammer etc.
    Fig 13: Tapping Converter Housing With Plastic Hammer
    G05375880Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  18. Using the special tools, remove the outer race of reduction gear bearing from the converter housing.
    • Rear axle shaft oil seal remover (MB990590)
    • Slide hammer puller (MB992039)
  19. 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: Measuring Mounting Bore Diameter Of Reduction Gear Bearing Outer Race At Converter Housing Side
    G10223049Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  20. Using the special tools, remove the outer race of differential side bearing from the converter housing.
    • Rear axle shaft oil seal remover (MB990590)
    • Slide hammer puller (MB992039)
  21. 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) < F1CJA > 
    • ø84.941 - 84.976 mm (ø3.3441 - 3.3455 in) < W1CJA > 
      Fig 15: Measuring Mounting Bore Diameter Of Differential Side Bearing Outer Race At Converter Housing Side
      G10223050Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When removing the oil seal, be careful not to cause damage to the converter housing.
  22. Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.
    Fig 16: Removing Converter Housing Oil Seal From Housing
    G05375883Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  23. Remove the clip.
    Fig 17: Locating Clip
    G10223052Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When removing the pipe, be careful not to strain it.
  24. Remove the pipe from the converter housing.
    Fig 18: Removing Pipe From Converter Housing
    G05375885Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. Remove the plug from the converter housing.
    Fig 19: Locating Plug From Converter Housing (F1CJA)
    G10223054Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 20: Locating Plug From Converter Housing (W1CJA)
    G10223055Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  26. Remove the O-ring from the plug.
    Fig 21: Removing O-Ring From Plug
    G10223038Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Remove the O-ring from the input shaft.
    Fig 22: Locating O-Ring From Input Shaft
    G10223057Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  28. Remove the chain cover.
    Fig 23: Locating Chain Cover
    G10223058Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  29. Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.
    Fig 24: Identifying Snap Ring
    G10223059Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 25: Removing Driven Sprocket, Oil Pump Chain And Drive Sprocket
    G10223060Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  30. Remove the thrust washer from the oil pump cover.
    Fig 26: Locating Thrust Washer From Oil Pump Cover
    G10223061Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Remove the snap ring from the oil pump.
    Fig 27: Locating Snap Ring From Oil Pump
    G10223062Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Remove the reduction gear assembly from the transaxle case.
    Fig 28: Removing Reduction Gear Assembly From Transaxle Case
    G05375895Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Remove the differential assembly from the transaxle case.
    Fig 29: Removing Differential Assembly From Transaxle Case (F1CJA)
    G10223064Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 30: Removing Differential Assembly From Transaxle Case (W1CJA)
    G10223065Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Remove the bracket.
    Fig 31: Locating Bracket
    G10223066Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. Remove the oil guide.
    Fig 32: Locating Oil Guide
    G10223067Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Remove the baffle plate.
    Fig 33: Locating Baffle Plate
    G10223068Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Remove the oil pump cover from the transaxle case.
    Fig 34: Locating Oil Pump Cover From Transaxle Case
    G10223069Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Remove the seal ring from the oil pump cover.
    Fig 35: Locating Seal Ring From Oil Pump Cover
    G10223070Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Remove the needle bearing from the forward clutch assembly.
    Fig 36: Removing Needle Bearing From Forward Clutch Assembly
    G05375902Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Remove the oil pan from the transaxle case.
  41. Remove the magnet from the oil pan.
    Fig 37: Removing Oil Pan From Transaxle Case
    G05375903Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  42. Remove the oil pan gasket from the transaxle case.
    Fig 38: Removing Oil Pan Gasket From Transaxle Case
    G05375904Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Remove the oil strainer.
    Bolt symbol A B C
    Shank length mm (in) 12 (0.5) 44 (1.7) 12 (0.5)
    Quantity 1 1 1
    Fig 39: Removing Oil Strainer
    G10223074Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Remove the O-ring from the oil strainer.
    Fig 40: Removing O-Ring From Oil Strainer
    G05375906Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  45. Remove the bracket from the control valve assembly.
    Fig 41: Locating Bracket From Control Valve Assembly
    G10223076Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  46. Remove the manual valve lever.
    Fig 42: Locating Manual Valve Lever
    G10223077Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Remove the control valve assembly from the transaxle case in the following way.
    1. Insert pins etc. (ø3 mm [ø0.1 in]) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.
      Fig 43: Inserting Pins Into Linkage Stopper Holes Of Control Valve Assembly To Pulley Ratio Linkage
      G10223078Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Remove mounting bolt of the control valve assembly.
      Bolt symbol A B
      Shank length mm (in) 54 (2.1) 44 (1.7)
      Quantity 10 1
      Fig 44: Removing Mounting Bolt Of Control Valve Assembly
      G10223079Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. 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 Control Valve Assembly From Transaxle Case
    G07043865Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  48. Remove the bush from the control valve.
    Fig 46: Removing Bush From Control Valve
    G05375912Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  49. Remove the lip seal from the transaxle case.
    Fig 47: Locating Lip Seal From Transaxle Case
    G10223082Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  50. Remove the valve body harness from the control valve.
    Fig 48: Removing Valve Body Harness From Control Valve
    G05375914Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  51. Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)
    Fig 49: Removing Oil Pump From Transaxle Case
    G10223084Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  52. Remove the O-ring from the oil pump fastening bolt.
    Fig 50: Removing O-Ring From Oil Pump Fastening Bolt
    G05375917Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Remove the lip seal from the transaxle case.
    Fig 51: Locating Lip Seal From Transaxle Case
    G10223086Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Using the special tools, remove outer race of the differential side bearing from the transaxle case.
    • Rear axle shaft oil seal remover (MB990590)
    • Slide hammer puller (MB992039)
  55. 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) 

    Fig 52: Measuring Mounting Bore Diameter Of Differential Side Bearing Outer Race At Transaxle Case Side
    G10223087Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Remove the adjusting shim from the transaxle case.
    Fig 53: Removing Adjusting Shim From Transaxle Case
    G05375920Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. Using the special tools, remove outer race of the reduction gear bearing from the transaxle case.
    • Rear axle shaft oil seal remover (MB990590)
    • Slide hammer puller (MB992039)
  58. 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) 

    Fig 54: Measuring Mounting Bore Diameter Of Reduction Gear Bearing Outer Race At Transaxle Case Side
    G10223089Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Remove the adjusting shim from the transaxle case.
    Fig 55: Removing Adjusting Shim From Transaxle Case
    G05375922Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When removing the side oil seal, be careful not to cause damage to the transaxle case.
  60. Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.
    Fig 56: Removing Side Oil Seal From Transaxle Case
    G05375923Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Remove the detent spring from the transaxle case.
    Fig 57: Locating Detent Spring From Transaxle Case
    G10223092Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  62. Remove the forward clutch assembly from the transaxle case.
    Fig 58: Removing Forward Clutch Assembly From Transaxle Case
    G05375925Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  63. Remove the needle bearing on forward clutch drum side from the sun gear.
    Fig 59: Removing Needle Bearing On Forward Clutch Drum Side From Sun Gear
    G05375926Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  64. Remove the sun gear from the planet carrier.
    Fig 60: Removing Sun Gear From Planet Carrier
    G05375927Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Remove the needle bearing on primary pulley side from the sun gear.
    Fig 61: Removing Needle Bearing On Primary Pulley Side From Sun Gear
    G05375928Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  66. Remove the planet carrier from the transaxle case.
    Fig 62: Removing Planet Carrier From Transaxle Case
    G05375929Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Remove the needle bearing from the planet carrier.
    Fig 63: Removing Needle Bearing From Planet Carrier
    G05375930Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Check if there is a damage, deformation, a burn mark or permanent set on the dish plate, driven plate, snap ring, and drive plate. Replace any defective part.
  68. Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case.
    Fig 64: Removing Reverse Brake Retaining Plate, Drive Plate And Dish Plate From Transaxle Case
    G05375931Courtesy 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.
  69. Using the special tool, Spring compressor (MB992139), compress the return spring, and remove the snap ring from the transaxle case.
  70. Remove the retaining plate and return spring assembly.
    Fig 65: Removing Retaining Plate And Return Spring Assembly
    G10223100Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful because that the reverse brake piston may be stuck if compressed air is fed excessively.
  71. Feed the air in the oil hole shown in the diagram, and remove the reverse brake piston from the transaxle case.
    Fig 66: Locating Air Oil Hole
    G10223101Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 67: Removing Reverse Brake Piston From Transaxle Case
    G05375934Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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