Mitsubishi Outlander: Transaxle Assembly

REMOVAL AND INSTALLATION

CAUTION The parts indicated by the * are the bolts with friction coefficient stabilizer. In removal, ensure there is no damage, clean dust and soiling from bearing and thread surfaces, and tighten them to the specified torque.

Pre-removal operation

• Engine compartment under cover front A, B and side cover removal
• Transmission fluid draining
• Air cleaner bracket removal
• Battery and Battery Tray Removal
• ECM removal
• Wiper arm blade assembly and front deck garnish removal
• Strut Tower Bar Removal
• Drive shaft removal

Post-installation operation

• Drive shaft installation
• Strut Tower Bar Installation
• Wiper arm and blade assembly and front deck garnish installation
• Battery and battery tray installation
• ECM installation
• Air cleaner assembly installation
• Engine compartment under cover and side cover installation
• Transmission fluid refilling

Removal steps

1. Transaxle control cable connection
2. Transaxle control bracket
3. Secondary pulley rotation sensor harness connector
4. Crank angle sensor harness connector
5. Battery ground
6. Transmission fluid cooler hose

• Transmission fluid cooler hose assembly A connection.

7. CVT assembly connector
8. Primary pulley rotation sensor connector
9. Transmission range switch connector
10. Oil filler tube assembly

• Water tube assembly

11. O-ring
12. Starter mounting bolt
13. Transaxle assembly upper part coupling bolt

Removal steps

14. Cover
15. Torque converter and drive plate coupling bolt
16. Center member assembly

• Transfer assembly <AWD>

17. Rear rolling stopper connection <FWD>, Rear rolling stopper <AWD>
18. Transaxle case rear roll stopper bracket
19. Transaxle mounting bracket
20. Transaxle mounting insulator stopper
21. Transaxle mounting insulator

• Engine assembly holding

22. Transaxle assembly lower part coupling bolt
23. Transaxle assembly

REMOVAL SERVICE POINTS

CVT ASSEMBLY CONNECTOR REMOVAL

While pushing the part A shown in the figure, and turn the part B counterclockwise to disconnect the CVT assembly connector.

TRANSAXLE ASSEMBLY UPPER PART COUPLING BOLT REMOVAL

Only loosen the bolts from the engine and transaxle assembly (do not remove).

TORQUE CONVERTER AND DRIVE PLATE COUPLING BOLT REMOVAL

1. Remove the coupling bolts while turning the crankshaft.

2. Fully push the torque converter into the transaxle side so that it does not remain on the engine side.

TRANSAXLE MOUNTING BRACKET REMOVAL

1. Place a garage jack against the transaxle case with a piece of wood in between to support the engine and transaxle assembly.

2. Operate a garage jack so that the weight of the engine and transaxle assembly is not applied to the transaxle mounting insulator, and remove the transaxle mounting bracket.

ENGINE ASSEMBLY HOLDING

1. Install special tool engine hanger plate (MB991956) to the cylinder head.

2. <When special tool engine hanger (MB991928) is used>

1. Assemble the engine hanger (Special tool: MB991928).

   (Set the components below to the base hanger.)

• Slide bracket (HI)
• Foot x 2 (standard) (MB991932)
• Foot x 2 (short) (MB991933)
• Joint x 2 (90) (MB991930)

2. Set the feet of the special tool as shown in the figure.

   NOTE: Adjust the engine hanger balance by sliding the slide bracket (HI).

3. Set the chains of special tool engine hanger (MB991527) and special tool engine hanger balancer (MB991454) to support the engine and transaxle assembly. Remove the garage jack and then remove the transaxle assembly upper part coupling bolts that have been loosened previously.

3. <When using special tool engine mechanical hanger (MB991895)>

1. Set the foot of special tool engine mechanical hanger (MB991895) as shown in the figure.

   NOTE: Slide the front foot of special tool engine mechanical hanger (MB991895) to balance the engine hanger.

CAUTION Place rag between special tool engine mechanical hanger (MB991895) and the windshield to prevent the special tool from interfering with the windshield.

2. Set the chains of special tool engine hanger (MB991527) and special tool engine hanger balancer (MB991454) to support the engine and transaxle assembly. Remove the garage jack and then remove the transaxle assembly upper part coupling bolts that have been loosened previously.

INSTALLATION SERVICE POINTS

TRANSAXLE ASSEMBLY INSTALLATION

Fully push the torque converter into the transaxle side, and then assemble the transaxle assembly to the engine.

TRANSAXLE MOUNTING INSULATOR

STOPPER INSTALLATION

Install the transaxle mounting insulator stopper as shown in the figure.

TRANSAXLE CONTROL CABLE (TRANSAXLE SIDE) INSTALLATION

1. Move the selector lever to the "N" range.

2. Move the manual control lever to Neutral position.

3. Align the hole at the end of the manual control lever and the hole in the inhibitor switch body flange (section A − A).

NOTE: Insert a φ5 mm (0.2 inch) bar into the aligned holes in the transmission range switch body flange and on the tip of the manual control lever to position the transmission range switch body.

4. Use the adjusting nut to tighten the transmission control cable to the specified torque.

Tightening torque: 9.5 +- 3.5 N*m (84 +- 31 in-lb)

5. Make sure that the transmission-side ranges that are corresponding to the transmission range operate and function without fail.

Transfer Assembly <AWD>

REMOVAL AND INSTALLATION

Pre-removal and post-installation operation

• Under cover removal and installation
• Transmission fluid draining and refilling
• Transfer oil draining and refilling
• Front exhaust pipe removal and installation
• Propeller shaft removal and installation
• Center member removal and installation
• Drive shaft <RH> and output shaft removal and installation

Removal steps

1. Exhaust manifold bracket B
2. Rear roll stopper center bolt
3. Transfer assembly
4. O-ring

REMOVAL SERVICE POINT

TRANSFER ASSEMBLY REMOVAL

Move the engine and transaxle assembly toward the front of the vehicle to make a gap between the engine/transaxle assembly and the crossmember. Pull out the transfer assembly through this gap.

INSTALLATION SERVICE POINT

EXHAUST MANIFOLD BRACKET B INSTALLATION

1. Make sure that the exhaust manifold bracket is closely contacted with the exhaust manifold and transfer assembly, and then temporarily tighten the bolts.

2. Tighten bolt A on the exhaust manifold side in the figure to the specified torque.

Tightening torque: 20 +- 5 N*m (15 +- 3 ft-lb)

3. Tighten bolt B on the transfer assembly side in the figure to the specified torque.

Tightening torque: 20 +- 5 N*m (15 +- 3 ft-lb)

Transaxle Control Module (TCM)

REMOVAL AND INSTALLATION

CAUTION To store the change gear ratio status of the CVT assembly in the TCM memory, drive the vehicle at 3 km/h or faster after replacing the TCM.

Pre-removal and post-installation operation

• Bottom cover assembly (passenger side) removal and installation
• Glove box assembly removal and installation

1. TCM
2. TCM bracket

Transmission Fluid Cooler and Cooler Line

REMOVAL AND INSTALLATION

Pre-removal and post-installation operation

• Engine room under cover front, engine room side cover

CVT fluid cooler line removal steps

1. Water feed hose B
2. Water feed hose A
3. Thermo valve assembly
4. Water return hose A
5. Water return hose B
6. Water tube assembly
7. CVT fluid cooler hose assembly
8. CVT fluid cooler bracket A
9. CVT fluid cooler bracket B
10. CVT fluid cooler assembly

THERMO VALVE CHECK

.1. Obtain a container filled with water and place the thermo valve in it with a stick [approximately 6 mm (0.24 inch) in diameter] inserted. Gradually warm up the water while stirring, and check that the thermo valve opening temperature is within the standard value. The stick rises when the thermo valve opens.

Standard value:
75 +- 1.5ºC (167 +- 2.7ºF)

2. Warm up the water to the full-open temperature of the thermo valve, and check that the valve lift amount is within the standard value.

Standard value:
Full-open temperature 95ºC (203ºF) or more
Valve lift amount when it is fully opened:
3 mm (0.12 inch) or more

NOTE: Measure the height of the fully closed valve in advance, and then measure the valve height at fully open temperature to calculate the lift amount.

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