Mitsubishi Outlander manuals

Mitsubishi Outlander: Transaxle

DISASSEMBLY AND ASSEMBLY

CAUTION

<F1CJA>

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. RR roll stopper bracket
  2. FR roll stopper bracket
  3. Harness bracket
  4. Oil level gage
  5. Oil filler tube
  6. Control cable bracket
  7. Breather hose

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Washer
  2. Shift lever
  3. Inhibitor switch
  4. CVT fluid filter
  5. O-ring
  6. CVT fluid cooler
  7. Secondary pulley speed sensor
  8. O-ring
  9. O-ring
  10. Plug
  11. Control valve
  12. Bracket
  13. O-ring
  14. Oil strainer
  15. Spring washer
  16. Manual lever
  17. Bush
  18. Lip seal
  19. Snap ring
  20. Valve body harness
  21. Oil pan gasket
  22. Magnet
  23. Drain plug gasket
  24. Drain plug
  25. Oil pan
  26. Torque converter
  27. O-ring
  28. Primary pulley speed sensor
  29. O-ring
  30. O-ring
  31. Plug
  32. Stud bolt

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. O-ring
  2. Side oil shim
  3. Adjusting shim
  4. Outer race
  5. Reduction gear assembly
  6. Outer race
  7. Adjusting shim
  8. Outer race
  9. Differential assembly
  10. Outer race
  11. Forward clutch assembly
  12. Needle bearing
  13. Seal ring
  14. Oil pump cover
  15. Baffle plate
  16. Bracket
  17. Clip
  18. Pipe
  19. Converter housing
  20. Converter housing oil seal
  21. Converter housing side oil seal
  22. Oil pump chain
  23. Drive sprocket
  24. Thrust washer
  25. Chain cover
  26. Driven sprocket
  27. Oil guide
  28. Oil pump
  29. Lip seal
  30. Snap ring
  31. Driven plate
  32. Needle bearing
  33. Sun gear
  34. Needle bearing
  35. Planet carrier
  36. Needle bearing
  37. Snap ring
  38. Retaining plate
  39. Drive plate
  40. Dish plate
  41. Snap ring
  42. Retaining plate
  43. Spring retainer assembly
  44. Reverse brake piston
  45. Detent spring

<W1CJA>

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Transfer
  2. RR roll stopper bracket
  3. FR roll stopper bracket
  4. Harness bracket
  5. Oil filler tube
  6. Oil level gage
  7. Control cable bracket
  8. Breather hose

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Washer
  2. Shift lever
  3. Inhibitor switch
  4. CVT fluid filter
  5. O-ring
  6. CVT fluid cooler
  7. Secondary pulley speed sensor
  8. O-ring
  9. O-ring
  10. Plug
  11. Control valve
  12. Bracket
  13. O-ring
  14. Oil strainer
  15. Spring washer
  16. Manual lever
  17. Bush
  18. Lip seal
  19. Snap ring
  20. Valve body harness
  21. Oil pan gasket
  22. Magnet
  23. Drain plug gasket
  24. Drain plug
  25. Oil pan
  26. Torque converter
  27. O-ring
  28. Primary pulley speed sensor
  29. O-ring
  30. O-ring
  31. Plug
  32. Stud bolt

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. O-ring
  2. Side oil shim
  3. Adjusting shim
  4. Outer race
  5. Reduction gear assembly
  6. Outer race
  7. Adjusting shim
  8. Outer race
  9. Differential assembly
  10. Outer race
  11. Forward clutch assembly
  12. Needle bearing
  13. Seal ring
  14. Oil pump cover
  15. Baffle plate
  16. Bracket
  17. Clip
  18. Pipe
  19. Converter housing
  20. Converter housing oil seal
  21. Oil pump chain
  22. Drive sprocket
  23. Thrust washer
  24. Chain cover
  25. Driven sprocket
  26. Oil guide
  27. Oil pump
  28. Lip seal
  29. Snap ring
  30. Driven plate
  31. Needle bearing
  32. Sun gear
  33. Needle bearing
  34. Planet carrier
  35. Needle bearing
  36. Snap ring
  37. Retaining plate
  38. Drive plate
  39. Dish plate
  40. Snap ring
  41. Retaining plate
  42. Spring retainer assembly
  43. Reverse brake piston
  44. Detent spring

Required special tools:

DISASSEMBLY SERVICE POINT

CAUTION Do not disassemble parts other than specified in this manual.

1. Remove the transfer from the transaxle. <W1CJA>

2. Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.

3. Remove the harness 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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

7. Remove the plug from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

8. Remove the O-ring from the plug.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

9. Remove the secondary pulley speed sensor from the converter housing, and detach the O-ring from the sensor.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

10.Remove the primary pulley speed sensor from the transaxle case, and detach the O-ring from the sensor.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

11.Remove the shift lever from the manual shaft.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

12.Remove the inhibitor switch from the transaxle.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Be careful not to cause damage to the terminal body.

13.Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

14.Remove the CVT fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

15.Remove the CVT fluid filter from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

16.Remove the fastening bolts of converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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

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

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

18.Using the special tools MB990590 and MB992039, remove the outer race of reduction gear bearing from the converter housing.

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
φ61.949 − 61.979 mm (φ2.4389 − 2.4401 in)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

20.Using the special tools MB990590 and MB992039, remove the outer race of differential side bearing from the converter housing.

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

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

23.Remove the clip.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION When removing the pipe, be careful not to bend it.

24.Remove the pipe from the converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

25.Remove the plug from the converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

26.Remove the O-ring from the plug.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

27.Remove the O-ring from the input shaft.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

28.Remove the chain cover.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

29.Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

30.Remove the thrust washer from the oil pump cover.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

31.Remove the snap ring from the oil pump.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

32.Remove the reduction gear assembly from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

33.Remove the differential assembly from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

34.Remove the bracket.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

35.Remove the oil guide.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

36.Remove the baffle plate.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

37.Remove the oil pump cover from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

38.Remove the seal rings from the oil pump cover.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

39.Remove the needle bearing from the forward clutch assembly.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

40.Remove the oil pan from the transaxle case.

41.Remove the magnet from the oil pan.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

42.Remove the oil pan gasket from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

43.Remove the oil strainer

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

44.Remove the O-ring from the oil strainer.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

45.Remove the bracket from the control valve assembly.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

46.Remove the manual lever.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

47.Remove the control valve assembly from the transaxle case as follows:

  1. Insert pins etc. (φ3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Remove fastening bolts of the control valve assembly.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. 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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

48.Remove the bush from the control valve.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

49.Remove the lip seal from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

50.Remove the valve body harness from the control valve.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

51.Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

52.Remove the O-ring from the oil pump fastening bolt.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

53.Remove the lip seal from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

54.Using the special tools MB990590 and MB992039, remove outer race of the differential side bearing from the transaxle case.

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
φ67.949 − 67.979 mm (φ2.6752 − 2.6763 in)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

56.Remove the adjusting shim from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

57.Using the special tools MB990590 and MB992039, remove outer race of the reduction gear bearing from the transaxle case.

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
φ61.949 − 61.979 mm (φ2.4389 − 2.4401 in)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

59.Remove the adjusting shim from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

61.Remove the detent spring from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

62.Remove the forward clutch assembly from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

63.Remove the needle bearing on forward clutch drum side from the sun gear.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

64.Remove the sun gear from the planet carrier.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

65.Remove the needle bearing on primary pulley side from the sun gear.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

66.Remove the planet carrier from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

67.Remove the needle bearing from the planet carrier.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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.

68.Using a flat blade screwdriver etc., remove the reverse brake retaining plate, drive plate, driven plate, and dish plate from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

69.Using the special tool MB992139, compress the return spring, and remove the snap ring from the transaxle case.

70.Remove the retaining plate and return spring assembly.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.

71.Feed the air in the oil hole shown in the diagram, and remove the reverse brake piston from the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

IDENTIFICATION OF NEEDLE BEARINGS

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

ASSEMBLY 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

1. Install the reverse brake piston, while turning it, on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

2. Align the spring portion of spring retainer assembly with the projections of the reverse brake piston, and install the spring retainer assembly.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

4. Using the special tool MB992139, compress the return spring, and install the snap ring on the transaxle case by means of a flat blade screwdriver etc.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

5. Install the reverse brake retaining plate, drive plate, driven plate, and dish plate on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

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 clutch clearance)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

7. Install the needle bearing on the reverse brake piston. Refer to A in the "IDENTIFICATION OF NEEDLE BEARINGS" for right direction.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

8. Install the planet carrier on the reverse brake.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

10.Install the sun gear on the planet carrier.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

12.Install the forward clutch assembly on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION When conducting measurements, measure two or more places, and find the average value.

13.Measure the total end play as follows:

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Measure the distance M2 from the edge of oil pump cover to the mounting surface on the transaxle case.
  2. 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 − 0.022 in)
(For total end play)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

14.Install the selected needle bearing on the forward clutch assembly. Refer to D in the "IDENTIFICATION OF NEEDLE BEARINGS" for right direction.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

15.Install the seal rings on the oil pump cover.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Do not re-use the bolt.

16.Install the detent spring on the transaxle case and tighten the bolt to the specified torque.

Tightening torque: 6.9 N*m (61 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

17.Install the O-ring on the plug.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

18.Install the plug on the converter housing to the specified torque.

Tightening torque: 7.5 N*m (66 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Do not bend the pipe when attaching it.

19.Install the pipe on the converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

20.Install the clip and tighten the bolt to the specified torque.

Tightening torque: 5.9 N*m (52 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

21.Using the special tools MB990779 and MB990780 <F1CJA> or MB991168 and MB991702 <W1CJA>, Install the differential bearing outer race of differential side bearing on the converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

22.Measure the preload A of the differential assembly as follows:

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Measure the distance M3 from the edge of transaxle case to the mounting surface of adjusting shim.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Install the differential assembly on the converter housing, and measure the distance M4 from the differential case to the edge of converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. 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.
  2. 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

  3. Using the following expression, calculate thickness of the adjusting shim.

    Thickness of adjusting shim = M3 − M6 + preload
    Standard value: 0.17 − 0.23 mm (0.007 − 0.009 in)
    (For differential preload)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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".

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

24.Using the special tool MB990780, install the outer race of differential side bearing on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

25.Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

26.Measure the preload A of the reduction gear assembly in the following way.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Measure the distance M7 from the edge of transaxle case to the mounting surface of adjusting shim.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. 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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. 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.
  2. 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

  3. Using the following expression, calculate the thickness of adjusting shim.

    Thickness of adjusting shim = M7 − M10 + preload
    Standard value: 0.11 − 0.17 mm (0.004 − 0.006 in)
    (For reduction gear preload)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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".

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

28.Using the special tools MB990932 and MB990938, install the outer race of reduction gear bearing on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

29.Install the lip seal on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

30.Install the O-rings on the oil pump fastening bolts.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

31.Install the oil pump on the transaxle case and tighten the bolt to the specified torque. (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].)

Tightening torque: 19 N*m (14 ft-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Do not re-use the snap ring.

32.Install the snap ring on the oil pump.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

33.Install the lip seal on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

34.Install the valve body harness on the control valve.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

35.Install the control valve assembly on the transaxle case as follows:

  1. Insert pins etc. (φ3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the diagram.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Align the notch of pulley ratio linkage with the prong of pulley sensor.

  1. Slide the control valve assembly from the bottom, and install it on the transaxle case.

CAUTION Apply transmission fluid when attaching the bush.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Install the bush on the control valve assembly.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Install the fastening bolts of control valve assembly and tighten the bolt to the specified torque.

    Tightening torque: 7.9 N*m (70 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

36.Install the manual lever and tighten the bolt to the specified torque.

Tightening torque: 22.1 N*m (16 ft-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

37.Install the bracket on the control valve assembly and tighten the bolt to the specified torque.

Tightening torque: 7.9 N*m (70 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

38.Install the O-ring on the oil strainer.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

39.Install the oil strainer and tighten the bolt to the specified torque.

Tightening torque: 7.9 N*m (70 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

40.Install the oil pan gasket on the transaxle case.

41.Install the magnet on the oil pan.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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 bolts to the specified torque.

Tightening torque: 7.9 N*m (70 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Do not re-use the drain plug gasket.

43.Install the drain plug and drain plug gasket on the transaxle case and tighten the bolt to the specified torque.

Tightening torque: 34.3 N*m (25 ft-lb)

44.Install the oil pump cover on the transaxle case, and fix the fastening bolts temporarily.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

45.Install the baffle plate, and fix the fastening bolts temporarily.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

46.Install the oil guide and tighten the bolt to the specified torque.

Tightening torque: 5.9 N*m (52 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

47.Install the bracket, and tighten the fastening bolts of the bracket to the bolts to the specified torque.

Tightening torque: 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.

Tightening torque: 19 N*m (14 ft-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

49.Install the thrust washer on the oil pump cover.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

51.Install the chain cover, and tighten the fastening nuts to the specified torque.

Tightening torque: 5.9 N*m (52 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

52.Install the O-ring on the input shaft.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

53.Install the differential assembly on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

54.Install the reduction gear assembly on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

55.Using the special tools MB992141 and MB992075, install the converter housing oil seal on the converter housing.

Depth from the case edge: within − 1.0 +- 0.5 mm (recessed)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

56.Using the special tools MB992206 and MB992075, install the converter housing side oil seal on the converter housing.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

57.Apply the sealant on the converter housing mounting surface of the transaxle case in the following way.

Specified sealant: Loctite 509

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

58.Install the converter housing on the transaxle case, and tighten the fastening bolts to the specified torque.

Tightening torque: 45 N*m (33 ft-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Do not re-use the snap ring.

59.Install the snap ring on the terminal body.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

60.Using the special tool MB992140 and MB992075, install the side oil seal on the transaxle case.

Depth from the case edge: within − 1.8 +- 0.5 mm (recessed)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION Do not re-use the inhibitor switch.

61.Install the inhibitor switch on the transaxle case as follows:

  1. Install the inhibitor switch on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Install the shift lever on the manual shaft, and tighten the fastening nuts to the specified torque.

    Tightening torque: 17.2 N*m (13 ft-lb)

  2. Set the manual shaft at N position.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

  1. Insert pins etc. (φ5 mm) in adjusting holes in both inhibitor switch and shift lever, and after alignment, tighten the fastening bolts to the specified torque.

    Tightening torque: 5.5 N*m (49 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

62.Install the oil ring on the primary pulley speed sensor.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

63.Install the primary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque.

Tightening torque: 5.9 N*m (52 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

64.Install the O-ring on the secondary pulley speed sensor.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

65.Install the secondary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque.

Tightening torque: 5.9 N*m (52 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

66.Install the CVT fluid filter on the transaxle case.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

67.Install the O-ring on the CVT fluid filter.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

68.Install the CVT fluid cooler on the transaxle case, and tighten the fastening bolts to the specified torque.

Tightening torque: 4.2 N*m (37 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

CAUTION

69.Install the O-ring on the plug.

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

70.Fasten the plug on the transaxle case and tighten the bolt to the specified torque.

Tightening torque: 7.5 N*m (66 in-lb)

Mitsubishi Outlander. Continuously Variable Transaxle Overhaul

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 value: 15.9 mm (0.63 in)

72.Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque.

Tightening torque: 25 +- 4 N*m (18 +- 2 ft-lb)

73.Install the oil filler tube and oil level gage on the transaxle.

Refer to the following or the exploded view for the tightening torque.

Tightening torque: 8.5 +- 3.5 N*m (75 +- 31 in-lb)

74.Install the harness bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.

Tightening torque: 25 +- 4 N*m (18 +- 2 ft-lb)

75.Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.

Tightening torque: 90 +- 10 N*m (66 +- 7 ft-lb)

76.Install the transfer on the transaxle. Refer to the following or the exploded view for the tightening torque.

Tightening torque: 68 +- 9 N*m (50 +- 7 ft-lb)

READ NEXT:

 Forward Clutch

DISASSEMBLY AND ASSEMBLY Disassembly steps Snap ring Internal gear Snap ring Snap ring Seal ring (small) Seal ring (big) Input shaft Forward clutch sub-assembly DISASSEMBLY SERVICE POINT SN

 Reduction Gear

DISASSEMBLY AND ASSEMBLY Nut Reduction gear bearing Reduction gear bearing Reduction gear sub-assembly Adjusting shim Required special tools: MB990810: Side bearing puller MB990947: Lower a

 Differential

DISASSEMBLY AND ASSEMBLY Disassembly steps Differential side bearing Differential side bearing Differential sub-assembly Adjusting shim Required special tools: MB990810: Side bearing puller

SEE MORE:

 Balancer Shaft and Oil Pump Module

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Oil Pan Removal and Installation Removal steps Balancer shaft and oil pump module Required Special Tool: MB991614: Angle Gauge REMOVAL SERVICE POINT BALANCER SHAFT AND OIL PUMP MODULE REMOVAL CAUTION Never turn

 LW/MW/FM digital tuning radio with CDplayer

The audio system can only be used when the ignition switch is in the “ON” or “ACC” position. NOTE: ● When listening to the audio system with the engine stopped, be sure to turn the ignition switch to the “ACC” position. ● If a cellular phone is used inside the vehicle,

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