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Home >> Mitsubishi >> 2015 >> Outlander ES >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Continuously Variable Transaxle (CVT) Overhaul >> Pulley >> Disassembly And Assembly >> Disassembly

Disassembly And Assembly: Disassembly

CAUTION: Be careful not to damage the other part(s). If you damage them, replace the CVT assembly.
CAUTION: Place pieces of wood around the differential oil seal to protect it.
  1. Place pieces of wood under the engine contacting surface with the side cover facing up.
    Fig 1: Placing Pieces Of Wood Under Engine Contacting Surface With Side Cover
    G10223231Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Remove the side cover bearing retainer mounting bolts as shown.
    Fig 2: Locating Side Cover Bearing Retainer Mounting Bolts
    G10223232Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Remove the side cover mounting bolts.
  4. If fitted, do not remove bolt A shown in the figure.
  5. Pull up the side cover evenly to remove.
    Fig 3: Locating Side Cover Mounting Bolts
    G10223233Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Remove the secondary pulley shim from the side cover.
    Fig 4: Removing Secondary Pulley Shim From Side Cover
    G10223234Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  7. Remove the pulley sensor from the transaxle case.
  8. Remove the O-ring from the transaxle case.
    Fig 5: Removing Pulley Sensor From Transaxle Case
    G10223235Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Move the selector lever to the P range to pull up the parking rod.
    Fig 6: Moving Selector Lever To P Range
    G10223236Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  10. Insert the parking rod as shown with the parking rod pulled up.
    Fig 7: Inserting Parking Rod
    G10223237Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  11. Install the side cover to the transaxle case by taping the cover with a plastic hammer lightly.
    NOTE: If the side cover is not seated to the transaxle case easily, move the select lever to the N position.
    NOTE: If the side cover is not seated to the transaxle case tightly, remove the side cover and repeat the installation procedure.
    Fig 8: Tapping Side Cover To Transaxle Case
    G10223238Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  12. Tighten the mounting bolts as shown to install the side cover temporarily.
  13. Place the transaxle case horizontally through pieces of wood on a workbench with the side cover facing down.
    Fig 9: Locating Side Cover Mounting Bolts
    G10223239Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Remove the temporarily secured side cover bolts.
    Fig 10: Locating Side Cover Bolts
    G10223240Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  15. Remove the transaxle case from the side cover.
    Fig 11: Removing Transaxle Case From Side Cover
    G10223241Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Obtain commercially-available four plastic covers, one spiral tube and two cable tie wraps to avoid damage to the steel belt and the pulley assembly.
    Fig 12: Identifying Plastic Covers, Spiral Tube And Cable Tie Wrap
    G10223242Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  17. Tie the steel belt segments and the steel rings together at the two diagonal positions by using cable tie-wraps.
    NOTE: Note the direction of the steel belt.
    Fig 13: Tying Steel Belt Segments And Steel Rings
    G10223243Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Be careful that special tools do not hit against the steel belt and the pulley to avoid damage.
    • Be careful that any foreign materials do not enter the oil channels.
  18. Engage the special tool Secondary pulley piston compressor (MB992984) with the secondary pulley assembly. The band of the special tool should be placed as shown.
    NOTE: Do not forget to install the adapter as shown, which is supplied with the special tool.
    Fig 14: Engaging Special Tool Secondary Pulley Piston Compressor (MB992984) With Secondary Pulley Assembly
    G10223244Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • The steel belt will be loosened when the slide pulley is pulled up. Be careful that the loosened steel belt does not touch the parking lock mounting bolt. If it touches, the belt may be damaged.
    • Make sure that the band of the special tool does not slide. If so, retighten it.
  19. Pull up the slide pulley by tightening the special tool Secondary pulley piston compressor (MB992984). Pull it up until the clearance between the ball bearing and the pulley reaches 3 mm (0.12 in).
    Fig 15: Locating Parking Lock Mounting Bolt
    G10223245Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  20. Wrap the spiral tube around the steel belt to avoid damage to the pulley. The entire steel belt should be protected as possible.
  21. Protect the steel belt sliding surfaces of the pulley at four positions with the plastic cover.
    NOTE: Secure the upper plastic cover with adhesive tape.
    NOTE: Bend the lower plastic cover securely.
    Fig 16: Identifying Upper Plastic Cover With Adhesive Tape
    G10223246Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 17: Identifying Lower Plastic Cover
    G10223247Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  22. A second mechanic is required for this operation. One mechanic must lift the secondary pulley assembly and the special tool Secondary pulley piston compressor (MB992984) with both hands. The other mechanic must grasp the belt with one hand, and tap the side cover around the secondary pulley assembly with a plastic hammer if necessary to pull out the secondary pulley assembly from the side cover.
    Fig 18: Tapping Side Cover Around Secondary Pulley Assembly With Plastic Hammer
    G10223248Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Make sure that the hammer does not touch the steel belt to avoid damage to the belt.
    • Place the removed secondary pulley assembly and the steel belt on a paper towel to avoid damage.
    • Do not bend the steel belt.
  23. One mechanic must slide the special tool Secondary pulley piston compressor (MB992984) toward the primary pulley with both hands with the compressor lifted. The other mechanic must grasp the steel belt to remove it from the secondary pulley assembly.
    Fig 19: Removing Steel Belt From Secondary Pulley Assembly
    G10223249Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Remove the primary pulley assembly from the side cover.
  25. Remove the O-rings from the side cover as shown.
    Fig 20: Removing O-Rings From Side Cover
    G10223250Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Be careful no to engage the remover with the C-ring by mistake. Make sure that the bearing is installed securely.
    • After the ball bearing is removed, the primary pulley assembly should be stored with its front side facing down to prevent tilting.
  26. Use the following special tool Bearing remover (MD998917) to drive out the front ball bearing of the primary pulley assembly from the primary pulley with a press.
    Fig 21: Pressing Primary Pulley Assembly
    G10223251Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Secure the special tool Pulley clamp base (MB992985) by using the four holes.
  28. Engage the lock nut of the primary pulley assembly with the hexagonal opening at the center of the special tool Pulley clamp base (MB992985).
    Fig 22: Securing Special Tool Pulley Clamp Base (MB992985) Using Four Holes
    G10223252Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  29. Use the special tool Primary pulley holder (MB992986) to remove the rear lock nut of the primary pulley assembly.
    Fig 23: Removing Rear Lock Nut Of Primary Pulley Assembly
    G10223253Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use an old bolt as the bolt securing the special tool to the bearing retainer may be bent.
  30. Install the following special tools to the bearing retainer side of the primary pulley assembly with nuts and bolts.
    • Puller set (MB992221)
    • Working base adapter (MB991116)
      Fig 24: Installing Puller Set (MB992221) To Bearing Retainer
      G10223254Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 25: Installing Working Base Adapter (MB991116) To Bearing Retainer
      G10223255Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. To avoid damage to the primary pulley assembly, install a nut (width across flat; 8 mm (0.3 in)) to the top end.
  32. Adjust the bearing retainers so that they depress the bearing evenly.
    Fig 26: Adjusting Bearing Retainers
    G10223256Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Store the bearing retainers so that the primary one is not confused with the secondary one.
    • After the ball bearing is removed, the primary pulley assembly should be stored with its front side facing down to prevent tilting.
  33. Apply a ring spanner to the hexagonal portion of the special tool Puller set (MB992221) to counterhold the assembly.
  34. Remove the ball bearing and the bearing retainers by tightening the center bolt.
  35. Secure the special tool Pulley clamp base (MB992985) by using the four holes.
  36. Place the secondary pulley assembly on the special tool Pulley clamp base (MB992985).
    CAUTION: Note that the rear lock nut is tightened to 310 N.m (229 ft-lb).
  37. Use a socket wrench (width across flat; 40 mm (1.6 in)) to remove the rear lock nut of the secondary pulley assembly.
    Fig 27: Locating Special Tool Pulley Clamp Base Holes
    G10223257Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: After the ball bearing and the bearing retainers are removed, the secondary pulley assembly should be stored with its rear side facing down to prevent tilting.
  38. Assemble the following special tools to the rear bearing retainer of the secondary pulley assembly.
    • Puller set (MB992221)
    • Working base adapter (MB991116)
  39. Insert the adapter supplied with special tool Secondary pulley piston compressor (MB992984) to prevent the center bolt from touching the secondary pulley assembly directly.
  40. Apply a ring spanner to the hexagonal portion of the special tool Puller set (MB992221) to counterhold the assembly.
    Fig 28: Inserting Adapter With Special Tool Secondary Pulley Piston Compressor (MB992984) To Center Bolt
    G10223258Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Store the bearing retainers so that the primary one is not confused with the secondary one.
  41. Remove the ball bearing and the bearing retainers by tightening the center bolt.
    CAUTION: On completion, clean the power train, the pulley assembly and the steel belt.
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