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Reassembly Service Point

CAUTION: When the outer races of reduction gear bearing and differential side bearing are removed, measure the mounting bore diameters of outer race in the converter housing and transaxle case, and replace the housing case or the CVT assembly if the standard value is not satisfied. The standard values are listed in "SERVICE SPECIFICATIONS."
CAUTION:
  • Do not re-use the reverse brake piston.
  • Apply transmission fluid when installing the reverse brake piston.
  1. Install the reverse brake piston, while turning it, on the transaxle case.
    Fig 1: Installing Reverse Brake Piston On Transaxle Case
    G05375934Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.
    Fig 2: Identifying Spring Retainer Assembly And Protrusion
    G10223105Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When installing the retaining plate, align the tangs at positions A, B, C in the diagram.
  3. Install the retaining plate on the transaxle case.
    Fig 3: Installing Retaining Plate On Transaxle Case
    G05375938Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 4: Identifying Retaining Plate Tangs Position
    G10223107Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Set the spring compressor right on top of the spring of spring retainer assembly.
    • Do not re-use the snap ring.
    • When installing the snap ring, make sure that the joint falls in the area A in the diagram.
  4. Using the special tool, Spring compressor (MB992139), compress the return spring, and install the snap ring on the transaxle case by means of a flat blade screwdriver etc.
    Fig 5: Installing Snap Ring On Transaxle Case
    G10223100Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 6: Identifying Snap Ring Joint Falls Area
    G10223109Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  5. Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case.
    Fig 7: Installing Reverse Brake Retaining Plate And Dish Plate On Transaxle Case
    G10223110Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • When conducting measurements, measure two or more places, and find the average value.
    • Do not re-use the snap ring.
    • When installing the snap ring, make sure that the joint falls in the area A in the diagram.
  6. Using a flat blade screwdriver etc., install the snap-ring on the transaxle case, and measure clearance between the snap ring and retaining plate. Select the snap ring so as to obtain standard value of the clearance. For selection of the snap ring, refer to "SERVICE SPECIFICATIONS ."

    Standard value: 1.2 - 1.5 mm (0.05 - 0.06 in) 

    (For reverse brake clearance) 

    Fig 8: Measuring Clearance Between Snap Ring And Retaining Plate
    G05375943Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 9: Identifying Snap Ring Joint Falls Area
    G10223109Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Apply vaseline when installing the needle bearing.
    • Be careful to attach the needle bearing in right direction.
  7. Install the needle bearing on the reverse brake piston. Refer to A in the "IDENTIFICATION OF NEEDLE BEARINGS  " for right direction.
    Fig 10: Installing Needle Bearing On Reverse Brake Piston
    G05375945Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the planet carrier on the reverse brake.
    Fig 11: Installing Planet Carrier On Reverse Brake
    G05375929Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Apply vaseline when installing the needle bearing.
    • Be careful to attach the needle bearing in right direction.
  9. Install the needle bearing on the primary pulley side of the sun gear. Refer to B in the "IDENTIFICATION OF NEEDLE BEARINGS  " for right direction.
    Fig 12: Installing Needle Bearing On Primary Pulley Side Of Sun Gear
    G05375928Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  10. Install the sun gear on the planet carrier.
    Fig 13: Installing Sun Gear On Planet Carrier
    G05375927Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Apply vaseline when installing the needle bearing.
    • Be careful to attach the needle bearing in right direction.
  11. Install the needle bearing on the forward clutch drum side of the sun gear. Refer to C in the "IDENTIFICATION OF NEEDLE BEARINGS  " for right direction.
    Fig 14: Installing Needle Bearing On Forward Clutch Drum Side Of Sun Gear
    G05375926Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  12. Install the forward clutch assembly on the transaxle case.
    Fig 15: Installing Forward Clutch Assembly On Transaxle Case
    G05375925Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When conducting measurements, measure two or more places, and find the average value.
  13. Measure the total end play A in the following way.
    Fig 16: Measuring Total End Play
    G10223119Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the distance M1 from the oil pump cover mounting surface of the transaxle case to the needle bearing mounting surface of the forward clutch drum.
      Fig 17: Measuring Distance From Transaxle Case To Forward Clutch Drum
      G10223120Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transaxle case.
    3. Calculate the total end play by the following expression. Select the needle bearing so that the total end play meets its standard value.

      Total end play = M1 - M2 - bearing thickness 

      Standard value: 0.25 - 0.55 mm (0.010 - 0.021 in) 

      (For total end play) 

      Fig 18: Measuring Distance From Oil Pump Cover Edge To Transaxle Case Mounting Surface
      G10223121Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Apply vaseline when installing the needle bearing.
    • Be careful to attach the needle bearing in right direction.
  14. Install the selected needle bearing on the forward clutch assembly. Refer to D in the "IDENTIFICATION OF NEEDLE BEARINGS  " for right direction.
    Fig 19: Installing Selected Needle Bearing On Forward Clutch Assembly
    G05375902Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the seal rings.
    • Apply vaseline when installing the seal rings.
  15. Install the seal rings on the oil pump cover.
    Fig 20: Locating Seal Rings On Oil Pump Cover
    G10223070Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the bolt.
  16. Install the detent spring on the transaxle case, and tighten the fastening bolt at the specified torque of 6.9 N.m (61 in-lb).
    Fig 21: Locating Detent Spring On Transaxle Case
    G10223092Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
  17. Install the O-ring on the plug.
    Fig 22: Installing O-Ring On Plug
    G10223038Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  18. Install the plug on the converter housing to the specified torque of 7.5 N.m (66 in-lb).
    Fig 23: Locating Plug On Converter Housing (F1CJA)
    G10223054Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 24: Locating Plug On Converter Housing (W1CJA)
    G10223055Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not strain the pipe when attaching it.
  19. Install the pipe on the converter housing.
    Fig 25: Installing Pipe On Converter Housing
    G05375885Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  20. Install the clip, and tighten the bolt at the specified torque of 5.9 N.m (52 in-lb).
    Fig 26: Locating Clip
    G10223052Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the outer race.
    • Replace the outer race together with the inner race.
  21. Using the special tools, Install the differential bearing outer race.
    • Bar (MB990779) < F1CJA >
    • Real axle shaft bushing installer (MB990780) < F1CJA >
    • Differential oil seal installer (MB991168) < W1CJA >
    • Adapter (MB991702) < W1CJA >
      Fig 27: Installing Differential Bearing Outer Race (F1CJA)
      G10223130Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 28: Installing Differential Bearing Outer Race (W1CJA)
      G10223131Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
    • When conducting measurements, measure two or more places, and find the average value.
  22. Measure the preload A of the differential assembly in the following way.
    Fig 29: Measuring Preload Of Differential Assembly
    G10223132Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the distance M3 from the edge of transaxle case to the mounting surface of adjusting shim.
      Fig 30: Measuring Distance From Edge Of Transaxle Case To Mounting Surface Of Adjusting Shim
      G10223133Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing.
      Fig 31: Measuring Distance From Differential Case To Edge Of Converter Housing
      G10223134Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. Install the outer race on differential side bearing, and measure the distance M5 from the differential case to the outer race of differential side bearing.
    4. Using the following expression, calculate the distance M6 from the edge of converter housing to the outer race of differential side bearing.

      M6 = M4 - M5 

    5. Using the following expression, calculate thickness of the adjusting shim.
      Fig 32: Measuring Distance From Differential Case To Outer Race Of Differential Side Bearing
      G10223135Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

      Thickness of adjusting shim = M3 - M6 + preload 

      Standard value: 0.17 - 0.23 mm (0.007 - 0.009 in) 

      (For differential preload) 

    CAUTION: Do not re-use the adjusting shim.
  23. Install the selected shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ."
    Fig 33: Installing Selected Shim On Transaxle Case
    G05375920Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the outer race.
    • Replace the outer race together with the inner race.
  24. Using the special tool, Real axle shaft bushing installer (MB990780), install the outer race of differential side bearing on the transaxle case.
    Fig 34: Installing Outer Race Of Differential Side Bearing On Transaxle Case
    G10223137Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the outer race.
    • Replace the outer race together with the inner race.
  25. Using the special tools, install the outer race of reduction gear bearing on the converter housing.
    • Installer adapter (MB990932)
    • Installer bar (MB990938)
      Fig 35: Installing Outer Race Of Reduction Gear Bearing On Converter Housing
      G10223138Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • When adjusting the preload, apply transmission fluid to the bearing to make it roll smoothly.
    • When conducting measurements, measure two or more places, and find the average value.
  26. Measure the preload A of the reduction gear assembly in the following way.
    Fig 36: Measuring Preload Of Reduction Gear Assembly
    G10223139Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Measure the distance M7 from the edge of transaxle case to the mounting surface of adjusting shim.
      Fig 37: Measuring Distance From Edge Of Transaxle Case To Mounting Surface Of Adjusting Shim
      G10223140Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install the reduction gear assembly on the converter housing, and measure the distance M8 from the edge of reduction gear assembly to the edge of converter housing.
      Fig 38: Measuring Distance From Edge Of Reduction Gear Assembly To Edge Of Converter Housing
      G10223141Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    3. Install the outer race of reduction gear side bearing on the bearing, and measure the distance M9 from the edge of reduction gear assembly to the outer race of reduction gear bearing.
    4. Using the following expression, calculate the difference M10 from the outer race of reduction gear bearing to the edge of converter housing.

      M10 = M8 - M9 

    5. Using the following expression, calculate the thickness of adjusting shim.
      Fig 39: Measuring Distance From Edge Of Reduction Gear Assembly To Outer Race Of Reduction Gear Bearing
      G10223142Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

      Thickness of adjusting shim = M7 - M10 + preload 

      Standard value: 0.11 - 0.17 mm (0.005 - 0.006 in) 

      (For reduction gear preload) 

    CAUTION: Do not re-use the adjusting shim.
  27. Install the selected adjusting shim on the transaxle case. For selection of the adjusting shim, refer to "SERVICE SPECIFICATIONS ."
    Fig 40: Installing Selected Adjusting Shim On Transaxle Case
    G05375922Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the outer race.
    • Replace the outer race together with the inner race.
  28. Using the special tools, install the outer race of reduction gear bearing on the transaxle case.
    • Installer adapter (MB990932)
    • Installer bar (MB990938)
      Fig 41: Installing Outer Race Of Reduction Gear Bearing On Transaxle Case
      G10223144Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the lip seal.
    • Apply transmission fluid when installing the lip seal.
  29. Install the lip seal on the transaxle case.
    Fig 42: Locating Lip Seal On Transaxle Case
    G10223086Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-rings.
    • Apply transmission fluid when installing the O-rings.
  30. Install the O-rings on the oil pump mounting bolt.
    Fig 43: Installing O-Rings On Oil Pump Mounting Bolt
    G05375917Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Install the oil pump on the transaxle case to the specified tightening torque of 19 N.m (14 ft-lb). (One fastening bolt is installed at the backside from the transaxle case side. Only this bolt should be tightened to the specified torque of 28 N.m [21 ft-lb].)
    Fig 44: Installing Oil Pump On Transaxle Case
    G10223084Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the snap ring.
  32. Install the snap ring on the oil pump.
    Fig 45: Locating Snap Ring On Oil Pump
    G10223062Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the lip seal.
    • Apply transmission fluid or vaseline when installing the lip seal.
  33. Install the lip seal on the transaxle case.
    Fig 46: Locating Lip Seal On Transaxle Case
    G10223082Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the valve body harness on the control valve.
  35. Install the control valve assembly on the transaxle case in the following way.
    Fig 47: Installing Valve Body Harness On Control Valve
    G05375914Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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 48: Inserting Pins Into Linkage Stopper Holes Of Control Valve Assembly To Pulley Ratio Linkage
      G10223078Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. 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 49: Installing Terminal Body On Transaxle Case
      G10223152Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      CAUTION: Align the notch of pulley ratio linkage with the prong of pulley sensor.
    3. Slide the control valve assembly from the bottom, and install it on the transaxle case.
      CAUTION: Apply transmission fluid when attaching the bush.
      Fig 50: Removing Control Valve Assembly
      G07043865Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 51: Identifying Control Valve Assembly Notch
      G10223154Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    4. Install the bush on the control valve assembly.
      Fig 52: Installing Bush On Control Valve Assembly
      G05375985Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    5. Install the mounting bolt of control valve assembly, and tighten to the specified torque of 7.9 N.m (70 in-lb).
    Bolt symbol A B
    Shank length mm (in) 54 (2.1) 44 (1.7)
    Quantity 10 1
    Fig 53: Installing Mounting Bolt Of Control Valve Assembly
    G10223079Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the manual valve lever, and tighten the fastening nuts to the specified torque of 22.1 N.m (16 ft-lb).
    Fig 54: Locating Manual Valve Lever
    G10223077Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the bracket on the manual valve assembly, and tighten the mounting bolt to the specified torque of 7.9 N.m (70 in-lb).
    Fig 55: Locating Bracket On Manual Valve Assembly
    G10223076Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
  38. Install the O-ring on the oil strainer.
    Fig 56: Installing O-Ring On Oil Strainer
    G05375989Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install the oil strainer, and tighten the mounting bolt to the specified torque of 7.9 N.m (70 in-lb).
    Bolt symbol A B C
    Shank length mm (in) 12 (0.5) 44 (1.7) 12 (0.5)
    Quantity 1 1 1
    Fig 57: Identifying Oil Strainer And Mounting Bolt
    G10223074Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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.
  40. Install the oil pan gasket on the transaxle case.
  41. Install the magnet on the oil pan.
    Fig 58: Installing Oil Pan Gasket On Transaxle Case
    G10223161Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
  42. Install the oil pan on the transaxle case, and tighten the mounting bolt to the specified torque of 7.9 N.m (70 in-lb).
    Fig 59: Identifying Transaxle Case Dowel Pin Holes
    G10223162Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the drain plug gasket.
  43. 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).
  44. Install the oil pump cover on the transaxle case, and fix the mounting bolt temporarily.
    Fig 60: Locating Oil Pump Cover On Transaxle Case
    G10223069Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  45. Install the baffle plate, and fix the mounting bolt temporarily.
    Fig 61: Locating Baffle Plate
    G10223068Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  46. Install the oil guide, and tighten the mounting bolt to the specified torque of 5.9 N.m (52 in-lb).
    Fig 62: Locating Oil Guide
    G10223067Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Install the bracket, and tighten the fastening bolts of the bracket to the bolts to the specified torque of 26 N.m (19 ft-lb).
  48. Tighten the fastening bolts of the oil pump cover and baffle plate to the bolts to the specified torque of 19 N.m (14 ft-lb).
    Fig 63: Locating Oil Pump Cover And Baffle Plate Bolts
    G10223066Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Make sure the tang of thrust washer is aligned with the mounting hole of oil pump cover.
    • Apply vaseline when installing the thrust washer.
  49. Install the thrust washer on the oil pump cover.
    Fig 64: Locating Thrust Washer On Oil Pump Cover
    G10223061Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Pull the driven sprocket up softly to make sure it is securely attached.
  50. Expand the snap ring, and install the driven sprocket, oil pump chain, and drive sprocket.
    Fig 65: Identifying Snap Ring
    G10223059Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 66: Installing Driven Sprocket, Oil Pump Chain And Drive Sprocket
    G10223060Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  51. Install the chain cover, and tighten the mounting nut to the specified torque of 5.9 N.m (52 in-lb).
    Fig 67: Locating Chain Cover
    G10223058Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
  52. Install the O-ring on the input shaft.
    Fig 68: Locating O-Ring On Input Shaft
    G10223057Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Install the differential assembly on the transaxle case.
    Fig 69: Installing Differential Assembly On Transaxle Case (F1CJA)
    G10223064Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 70: Installing Differential Assembly On Transaxle Case (W1CJA)
    G10223065Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Install the reduction gear assembly on the transaxle case.
    Fig 71: Installing Reduction Gear Assembly On Transaxle Case
    G05375895Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the converter housing oil seal.
    • Apply transmission fluid when installing the converter housing oil seal.
  55. Using the special tools, install the converter housing oil seal on the converter housing.
    • Oil seal installer (MB992141)
    • Handle (MB992075)

    Depth from the case edge: within - 1.0 ± 0.5 mm (-0.04 ± 0.05 mm) 

    (Recessed). 

    Fig 72: Installing Converter Housing Oil Seal On Converter Housing (F1CJA)
    G10223175Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 73: Installing Converter Housing Oil Seal On Converter Housing (W1CJA)
    G10223176Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the converter housing side oil seal.
    • Apply transmission fluid when installing the converter housing side oil seal.
  56. Using the special tools, install the converter housing side oil seal on the converter housing. < F1CJA >
    • Oil seal installer (MB992206)
    • Handle (MB992075)
      Fig 74: Installing Converter Housing Side Oil Seal On Converter Housing
      G10223177Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
    • Make sure the starting point and the ending point are about the middle between the bolts.
  57. Apply the sealant on the converter housing mounting surface of the transaxle case in the following way.
    SEALANT SPECIFICATION

    L1 9 mm (0.4 in)
    L2 5 mm (0.2 in)
    L3 ø1.5 mm (ø0.06 in)
    L4 R8.5 mm (R0.33 in)
    L5 R5 - 8 mm (R0.2 - 0.3 in)
    L6 3 - 5 mm (0.1 - 0.2 in)
    L7 ø17 mm (ø0.7 in)
    L8 3.5 mm (0.14 in)
    Fig 75: Identifying Sealant Applying Dimension On Converter Housing Mounting Surface Of Transaxle Case (1 Of 2)
    G10223178Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 76: Identifying Sealant Applying Dimension On Converter Housing Mounting Surface Of Transaxle Case (2 Of 2)
    G10223179Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Install the converter housing on the transaxle case, and tighten the mounting bolt to the specified torque of 45 N.m (33 ft-lb).
    Bolt symbol A B
    Shank length mm (in) 30 (1.2) 35 (1.4)
    Quantity 18 5
    Fig 77: Identifying Converter Housing On Transaxle Case Mounting Bolt
    G10223047Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the snap ring.
  59. Install the snap ring on the terminal body.
    Fig 78: Installing Snap Ring On Terminal Body
    G10223181Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the side oil seal.
    • Apply transmission fluid when installing the side oil seal.
  60. Using the special tools, install the side oil seal on the transaxle case.
    • Oil seal installer (MB992140)
    • Handle (MB992075)

    Depth from the case edge: within - 1.8 ± 0.5 mm (-0.07 ± 0.02 mm) 

    (Recessed). 

  61. Install the transmission range switch on the transaxle case in the following way.
    Fig 79: Installing Side Oil Seal On Transaxle Case
    G10223182Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not re-use the transmission range switch.
    1. Install the transmission range switch on the transaxle case.
      Fig 80: Installing Transmission Range Switch On Transaxle Case
      G05375875Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Install the manual control 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 81: Locating Manual Control Lever On Manual Shaft
      G10223041Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    4. Insert pins etc. (ø5 mm[ø0.2 in]) in adjusting holes in both transmission range switch and manual control lever, and after alignment, tighten the mounting bolt to the specified torque of 5.5 N.m (49 in-lb).
      Fig 82: Adjusting Holes In Transmission Range Switch And Manual Control Lever
      G10223185Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
  62. Install the O-ring on the primary pulley speed sensor.
    Fig 83: Locating O-Ring On Primary Pulley Speed Sensor
    G10223186Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  63. Install the primary pulley speed sensor on the transaxle case, and tighten the mounting bolt to the specified torque of 5.9 N.m (52 in-lb).
    Fig 84: Locating Primary Pulley Speed Sensor On Transaxle Case
    G10223040Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
  64. Install the O-ring on the secondary pulley speed sensor.
    Fig 85: Installing O-Ring On Secondary Pulley Speed Sensor
    G10223188Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Install the secondary pulley speed sensor on the transaxle case, and tighten the mounting bolt to the specified torque of 5.9 N.m (52 in-lb).
    Fig 86: Locating Secondary Pulley Speed Sensor On Transaxle Case
    G10223039Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Apply transmission fluid or vaseline when installing the transmission fluid filter.
    • Do-not re-use the transmission fluid filter.
  66. Install the transmission fluid filter on the transaxle case.
    Fig 87: Installing Transmission Fluid Filter On Transaxle Case
    G05375878Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • When installing O-ring, make sure that projection of the O-ring is put into the groove on the filter.
  67. Install the O-ring on the transmission fluid filter.
    Fig 88: Installing O-Ring On Transmission Fluid Filter
    G05376023Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Install the transmission fluid cooler on the transaxle case, and tighten the mounting bolt to the specified torque of 4.2 N.m (37 in-lb).
    Fig 89: Locating Transmission Fluid Cooler On Transaxle Case (Without)
    G10223044Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 90: Locating Transmission Fluid Cooler On Transaxle Case (With)
    G10223045Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
  69. Install the O-ring on the plug.
    Fig 91: Installing O-Ring On Plug
    G10223038Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  70. Fasten the plug on the transaxle case to the specified torque of 7.5 N.m (66 in-lb).
    Fig 92: Identifying Plug On Transaxle Case
    G07043823Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: When conducting measurements, measure two or more places, and find the average value.
  71. Install the converter on the transaxle, and measure the size A to check if it meets the standard value.

    Standard size A: 15.9 mm (0.63 in) 

  72. Install the control cable bracket and breather hose on the transaxle to the specified torque of 25 ± 4 N.m (18 ± 2 ft-lb).
  73. Install the oil filler tube and oil level gage on the transaxle to the specified torque of 8.5 ± 3.5 N.m (75 ± 30 in-lb).
  74. Install the harness bracket, corrugate clamp bracket and air breather bracket on the transaxle to the specified torque of 25 ± 4 N.m (18 ± 2 ft-lb).
    Fig 93: Checking Converter On Transaxle Size
    G10223196Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  75. Install the roll rod adapter bracket on the transaxle to the specified torque of 90 ± 10 N.m (66 ± 7 ft-lb).
  76. Install the transfer on the transaxle to the specified torque of 69 ± 9 N.m (51 ± 6 ft-lb).
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