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.
Remove the torque converter from the transaxle.

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

Fig 2: Removing Plug From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the plug.

Fig 3: Locating O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 On Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the shift lever from the manual shaft.

Fig 6: Locating Shift Lever On Manual Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the inhibitor switch from the transaxle.

Fig 7: Identifying Inhibitor Switch On Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful not to cause damage to the terminal body.
Remove the snap ring from the terminal body, and press the terminal body into the transaxle case.

Fig 8: Identifying Snap Ring On Terminal Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the CVT fluid cooler from the transaxle case, and detach the O-ring from the cooler.

Fig 9: Identifying CVT Fluid Cooler On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the CVT fluid filter from the transaxle case.

Fig 10: Removing CVT Fluid Filter From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the fastening bolts of converter housing.

BOLT SPECIFICATIONS REFERENCE CHART

Bolt symbol	A	B
Shank length mm	30	35
Quantity	18	5

Fig 11: Identifying Fastening Bolts Of Converter Housing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

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

Fig 12: Removing Convertor Housing Using Plastic Hammer
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 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 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)
  
  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.
CAUTION: When removing the oil seal, be careful not to cause damage to the converter housing.
Using a flat blade screwdriver etc., remove the converter housing oil seal from the housing.

Fig 15: Removing Converter Housing Oil Seal Using Flat Blade Screw Driver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the clip.

Fig 16: Locating Clip
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When removing the pipe, be careful not to bend it.
Remove the pipe from the converter housing.

Fig 17: Removing Pipe From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the plug from the converter housing.

Fig 18: Locating Plug On Converter Housing (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 19: Locating Plug On Converter Housing (W1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the plug.

Fig 20: Locating O-Ring On Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the input shaft.

Fig 21: Locating O-Ring On Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the chain cover.

Fig 22: Locating Chain Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Expand the snap ring, and remove the driven sprocket, oil pump chain, and drive sprocket.

Fig 23: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 24: Removing Driven Sprocket, Oil Pump Chain And Drive Sprocket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the thrust washer from the oil pump cover.

Fig 25: Locating Thrust Washer On Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the oil pump.

Fig 26: Locating Snap Ring On Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear assembly from the transaxle case.

Fig 27: Identifying Reduction Gear Assembly On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential assembly from the transaxle case.

Fig 28: Identifying Differential Assembly On Transaxle Case (F1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 29: Identifying Differential Assembly On Transaxle Case (W1CJA)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket.

Fig 30: Locating Bracket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil guide.

Fig 31: Locating Oil Guide
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the baffle plate.

Fig 32: Locating Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump cover from the transaxle case.

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

Fig 34: Locating Seal Rings On Oil Pump Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the forward clutch assembly.

Fig 35: Removing Needle Bearing From Forward Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pan from the transaxle case.
Remove the magnet from the oil pan.

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

Fig 37: Removing Oil Pan Gasket From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the oil strainer

BOLT SPECIFICATIONS REFERENCE CHART

Bolt symbol	A	B	C
Shank length mm	12	44	12
Quantity	1	1	1

Fig 38: Identifying Oil Strainer

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the O-ring from the oil strainer.

Fig 39: Removing O-Ring From Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bracket from the control valve assembly.

Fig 40: Locating Bracket On Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual lever.

Fig 41: Locating Manual Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 42: Inserting Pins Into Stopper Holes Of Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove fastening bolts of the control valve assembly.

BOLT SPECIFICATIONS REFERENCE CHART

Bolt symbol	A	B
Shank length mm	54	44
Quantity	10	1

Fig 43: Identifying Bolts Of Control Valve Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 44: Removing Control Valve Assembly From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the bush from the control valve.

Fig 45: Removing Bush From Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 46: Locating Lip Seal On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body harness from the control valve.

Fig 47: Identifying Valve Body Harness On Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump from the transaxle case. (One fastening bolt is installed at the backside from the transaxle case side.)

Fig 48: Locating Bolts On Backside Of Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the oil pump fastening bolt.

Fig 49: Removing O-Ring From Oil Pump Fastening Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the lip seal from the transaxle case.

Fig 50: Locating Lip Seal On Transaxle Case
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 51: Removing Outer Race Of Differential Side Bearing From Transaxle Case Using Special Tools (MB990590 And MB992039)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the adjusting shim from the transaxle case.

Fig 52: Removing Adjusting Shim From Transaxle Case
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 (ø.4389 - 2.4401 in)

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.
Remove the adjusting shim from the transaxle case.

Fig 54: Removing Adjusting Shim From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When removing the side oil seal, be careful not to cause damage to the transaxle case.
Using a flat blade screwdriver etc., remove the side oil seal from the transaxle case.

Fig 55: Removing Side Oil Seal Of Transaxle Case Using Flat Blade Screw Driver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring from the transaxle case.

Fig 56: Locating Detent Spring On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the forward clutch assembly from the transaxle case.

Fig 57: Removing Forward Clutch Assembly From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on forward clutch drum side from the sun gear.

Fig 58: Removing Forward Clutch Drum Side Needle Bearing From Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sun gear from the planet carrier.

Fig 59: Removing Sun Gear From Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing on primary pulley side from the sun gear.

Fig 60: Removing Primary Pulley Side Needle Bearing From Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planet carrier from the transaxle case.

Fig 61: Removing Planet Carrier From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the planet carrier.

Fig 62: Removing Needle Bearing From Planet Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 63: Removing Reverse Brake Retaining Plate, Drive Plate, Driven Plate And Dish Plate From Transaxle Case
Courtesy 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.
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.

Fig 64: Identifying Special Tool MB992139
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful. Do not use to much air pressure as this may cause the reverse brake piston be stuck.
Feed the air in the oil hole shown in the illustration, and remove the reverse brake piston from the transaxle case.

Fig 65: Locating Oil Hole
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 66: Identifying Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.