Mitsubishi Car 1999-05

Transaxle Removal & Installation

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NOTE
If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.


NOTE
The suspension components should not be tightened until the vehicles weight is resting on the ground.

  1. Remove the battery and battery tray.
  2.  
  3. Remove the air cleaner assembly and vacuum hoses.
  4.  
  5. Note the locations and disconnect the shifter cables.
  6.  
  7. If equipped with 1.6L engine, remove the tension rod.
  8.  
  9. Detach the backup lamp switch connector, speedometer cable connection and remove the starter motor.
  10.  
  11. Raise the vehicle and support safely.
  12.  
  13. Remove the front wheels and the inner wheel panels.
  14.  
  15. Remove the undercover and splash pan.
  16.  
  17. Drain the transaxle oil into a suitable container.
  18.  
  19. Support the engine and remove the crossmember.
  20.  
  21. Remove the upper transaxle mounting bolt and bracket.
  22.  
  23. Disconnect the stabilizer bar, tie rod ends and the lower ball joint connections.
  24.  
  25. Remove the clutch release cylinder and clutch oil line bracket. Do not disconnect the fluid lines and secure the slave cylinder with wire.
  26.  
  27. Disconnect the clutch cable, if equipped with cable controlled clutch system.
  28.  
  29. Remove the halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft. Doing so damages the inboard joint. Do not insert the prybar so far the oil seal in the case is damaged.
  30.  


NOTE
It is not necessary to disconnect the halfshafts from the steering knuckle. Remove the shaft with the hub and knuckle as an assembly. Tie the shafts aside. Note the circle clip on the end of the inboard shafts should not be reused.

  1. Remove the bellhousing lower cover.
  2.  
  3. Remove the transaxle to engine bolts and lower the transaxle from the vehicle.
  4.  

To install:


NOTE
When installing the transaxle, be sure to align the splines of the transaxle with the clutch disc.

  1. Install the transaxle to the engine and install the mounting bolts. Tighten the bolts to 31-40 ft. lbs. (43-55 Nm) on 1990-92 models and 35 ft. lbs. (48 Nm) on 1993-00 models.
  2.  
  3. Install the bellhousing cover.
  4.  


NOTE
When installing the halfshafts, use new circlips on the axle ends. Care must be taken to ensure that the oil seal lip of the transaxle is not damaged by the serrated part of the driveshaft.

  1. Install and fully seat the halfshafts into the transaxle.
  2.  
  3. Install the slave cylinder.
  4.  
  5. Connect the ball joints, tie rod ends and the stabilizer bar connections.
  6.  
  7. Install the upper transaxle mounting bracket and bolt.
  8.  
  9. Install the crossmember.
  10.  
  11. Install the undercover.
  12.  
  13. Install the upper transaxle-to-engine mounting bolts. Tighten the bolts to 31-40 ft. lbs. (43-55 Nm) on 1990-92 models and 35 ft. lbs. (48 Nm) on 1993-00 models.
  14.  
  15. Install the starter motor.
  16.  
  17. Connect the backup light switch connector and speedometer cable.
  18.  
  19. Connect and adjust the shifter cables.
  20.  
  21. Install the air cleaner assembly.
  22.  
  23. Install the front wheels.
  24.  
  25. Make sure the vehicle is level when refilling the transaxle. Use Hypoid gear oil or equivalent, GL-4 or higher.
  26.  
  27. Connect the negative battery cable and check the transaxle for proper operation. Make sure the reverse lights operate when in reverse.
  28.  

  1. Disconnect the negative battery cable and wait at least 90 seconds before performing any work.
  2.  
  3. Remove the air cleaner and intake hoses.
  4.  
  5. Drain the transaxle into a suitable waste container.
  6.  
  7. Remove the cotter pins and clips securing the select and shift cables and remove the cable ends from the transaxle.
  8.  
  9. If equipped with Active-ECS, disconnect the air compressor.
  10.  
  11. Disconnect the backup light switch harness and position aside.
  12.  
  13. Disconnect the speedometer electrical connector, from the transaxle assembly.
  14.  
  15. Remove the starter motor and position aside.
  16.  
  17. Using special tool MZ203827 or equivalent, support the engine assembly.
  18.  
  19. Remove the rear roll stopper mounting bracket.
  20.  
  21. Remove the transaxle mount bracket.
  22.  
  23. Remove the upper transaxle mounting bolts.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Remove the front wheel assemblies.
  28.  
  29. Remove the right hand undercover.
  30.  
  31. Remove the cotter pin and disconnect the tie rod end, from the steering knuckle.
  32.  
  33. Disconnect the stabilizer bar link, from the damper fork.
  34.  
  35. Disconnect the damper fork, from the lateral lower control arm.
  36.  
  37. Disconnect the later lower arm, and the compression arm, lower ball joints, from the steering knuckle.
  38.  
  39. Pry the halfshafts from the transaxle, and secure aside.
  40.  
  41. Remove the connection for the clutch release cylinder and without disconnecting the hydraulic line, secure aside.
  42.  
  43. Remove the cover from the transaxle bellhousing.
  44.  
  45. Remove the engine front roll stopper through-bolt.
  46.  
  47. Remove the crossmember and the triangular right hand stay.
  48.  
  49. Support the transaxle, using a transmission jack, and remove the transaxle lower coupling bolt.
  50.  


NOTE
The coupling bolt threads from the engine side, into the transaxle, and is located just above the halfshaft opening.

  1. Slide the transaxle rearward and carefully lower it from the vehicle.
  2.  

To install:

  1. Install the transaxle to the engine. Install the mounting bolts and tighten to 35 ft. lbs. (48 Nm). Install the transaxle lower coupling bolt and tighten to 22-25 ft. lbs. (30-34 Nm).
  2.  
  3. Install the cover to the transaxle bellhousing and tighten the mounting bolts to 7 ft. lbs. (9 Nm).
  4.  
  5. Install the crossmember and tighten the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 Nm). Install the front engine roll stopper through-bolt and hand-tighten. Once the full weight of the engine is on the mounts, tighten the bolt to 42 ft. lbs. (57 Nm).
  6.  
  7. Install the triangular stay bracket and tighten the mounting bolts to 65 ft. lbs. (88 Nm).
  8.  
  9. Connect the clutch release cylinder.
  10.  
  11. Install the halfshafts, using new circlips on the axle ends.
  12.  


WARNING
When installing the axleshaft, keep the inboard joint straight in relation to the axle, so not to damage the oil seal lip of the transaxle, with the serrated part of the halfshaft.

  1. Connect the tie rod and ball joints to the steering knuckle. Tighten the ball joint self-locking nuts to 48 ft. lbs. (65 Nm). Tighten the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin.
  2.  
  3. Connect the damper fork to the lower control arm and tighten the through-bolt to 65 ft. lbs. (88 Nm).
  4.  
  5. Connect the stabilizer link to the damper fork, and tighten the self-locking nut to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the underpan.
  8.  
  9. Install wheels and lower vehicle.
  10.  
  11. Install the transaxle mount bracket to the transaxle, and tighten the mounting nuts to 32 ft. lbs. (43 Nm).
  12.  
  13. Install the rear roll stopper mounting bracket.
  14.  
  15. Remove the engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper through-bolt.
  16.  
  17. Install the upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm).
  18.  
  19. Install the starter motor.
  20.  
  21. Attach the backup light switch and the speedometer connector.
  22.  
  23. Connect the select and shift cables and install new cotter pins.
  24.  
  25. Install the air cleaner and the air intake hose.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Make sure the vehicle is level, and refill the transaxle.
  30.  
  31. Check the transaxle for proper operation. Make sure the reverse lights come on when in reverse.
  32.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels and the inner wheel panels
     
    Air cleaner assembly and vacuum hoses
     

  4.  
  5. Note the locations and disconnect the shifter cables.

    Back-up lamp switch connector
     
    Speedometer cable and remove the starter motor
     
    Upper transaxle-to-engine mounting bolts
     

  6.  
  7. Remove the undercover and splash pan.
  8.  
  9. Drain the transaxle oil.
  10.  
  11. Support the engine and remove the crossmember.
  12.  
  13. Remove or disconnect the following:

    Upper transaxle mounting bolt and bracket
     
    Stabilizer bar, tie rod ends and the lower ball joint connections
     
    Clutch release cylinder and clutch oil line bracket. Disconnect the clutch cable, if equipped with cable controlled clutch system.
     
    Halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft.
     
    Bell housing lower cover
     
    Transaxle to engine bolts and lower the transaxle from the vehicle
     

  14.  

To install:

  1. Install or connect the following:

    Transaxle to the engine and install the mounting bolts
     
    Bell housing cover
     

  2.  


NOTE
When installing the halfshafts, use new circlips on the axle ends.

  1. Install or connect the following:

    Halfshafts into the transaxle
     
    Slave cylinder or connect the clutch cable
     
    Ball joints, tie rod ends and stabilizer bar connections
     
    Upper transaxle mounting bracket and bolt
     
    Crossmember
     
    Undercover
     
    Upper transaxle-to-engine mounting bolts
     
    Starter motor
     
    Back-up light switch connector and speedometer cable
     
    Shifter cables, adjust
     
    Air cleaner assembly
     
    Front wheels
     
    Negative battery cable and check the transaxle for proper operation
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Raise the vehicle and support safely.
  6.  
  7. If equipped with AWD, disconnect the exhaust pipe. Remove the mounting bolts and lower the transfer case from the vehicle.
  8.  
  9. Remove the left side splash shield and engine undercover.
  10.  
  11. Remove the air cleaner assembly and all adjoining duct work.
  12.  
  13. Disconnect the shifter control cables and speedometer connector.
  14.  
  15. Remove the clutch release cylinder.
  16.  
  17. Disconnect the reverse light switch.
  18.  
  19. Support the weight of the transaxle and remove the transaxle mount through-bolt. Remove the access plug, remove the bolts for the bracket and remove the brackets.
  20.  
  21. Disconnect the transaxle ground cable.
  22.  
  23. Disconnect the tie rod end and ball joint from the steering knuckle.
  24.  
  25. Remove the right frame member.
  26.  
  27. Remove the starter motor.
  28.  
  29. Remove the halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft. Doing so damages the inboard joint. Tie the shafts aside.
  30.  
  31. Remove the transaxle brackets.
  32.  
  33. Remove the transaxle assembly.
  34.  

To install:

  1. Install the transaxle to the engine and install the mounting bolts.
  2.  
  3. Install the halfshafts. Use new circlips on the axle ends.
  4.  
  5. Install the starter motor and cover.
  6.  
  7. Install the right side frame member.
  8.  
  9. Install the ball joint and tie rod to the steering knuckle.
  10.  
  11. Connect the transaxle ground cable.
  12.  
  13. Install the side mount brackets and install the access plug.
  14.  
  15. Connect the reverse light switch.
  16.  
  17. Install the clutch release cylinder.
  18.  
  19. Connect the shifter control cables and speedometer connector.
  20.  
  21. Install the transfer case and related items on AWD vehicles.
  22.  
  23. Install the air cleaner assembly and all adjoining duct work.
  24.  
  25. Install the left side splash shield.
  26.  
  27. Install the battery tray and battery.
  28.  
  29. Connect the negative battery cable and check the transaxle and transfer case for proper operation.
  30.  

  1. Remove or disconnect the following:

    Battery and the air intake hoses
     
    Battery tray and support
     
    Auto-cruise actuator and bracket, if equipped with cruise control
     
    Charcoal canister and bracket
     
    Shift and select cables from the transaxle
     
    Back-up light switch and the Vehicle Speed Sensor (VSS) connectors
     
    Starter assembly
     
    Engine support fixture to the engine and remove the transaxle mounting bolts
     

  2.  
  3. Remove or disconnect the following:

    Rear roll stopper bracket mounting bolts
     
    Transaxle mounting bracket mounting nuts
     
    Engine undercovers
     



    Axle shafts
     
    Slave cylinder from the bell housing without disconnecting the fluid line. Position it out of the way.
     
    Bell housing cover and the right-hand center member stay (support)
     
    Center member
     

  4.  
  5. Place a transmission jack under the transaxle and remove the transaxle mounting bolt.
  6.  
  7. Remove the transaxle mounting and lower the transaxle.
  8.  

To install:

  1. Raise the transaxle into position and install the transaxle mounting. Torque the through-bolt to 50 ft. lbs. (69 Nm).
  2.  
  3. Install or connect the following:

    Transaxle assembly mounting bolt. Torque the bolt to 22-25 ft. lbs. (30-34 Nm).
     
    Center member assembly and the right-hand stay
     
    Bell housing cover and the slave cylinder
     
    Axle shafts. Be sure to install the washer in the proper direction.
     
    Engine undercovers and lower the vehicle
     
    Transaxle mounting bracket mounting nuts
     
    Rear roll stopper bracket mounting bolts
     
    Transaxle assembly mounting bolts. Torque the mounting bolts to 35 ft. lbs. (48 Nm).
     

  4.  
  5. Remove the engine support fixture.
  6.  
  7. Install or connect the following:

    Starter assembly
     
    VSS and the back-up light connectors
     
    Cruise control actuator if removed
     
    Battery tray support and the tray
     
    Charcoal canister bracket and the canister
     
    Air duct and the air cleaner assembly
     

  8.  

  1. Drain the transaxle fluid.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Evaporative canister
     
    Positive battery cable, battery and battery tray
     
    Shifter cables
     
    Back-up light switch and Vehicle Speed Sensor (VSS) connector
     
    Starter motor
     
    Clutch hose
     
    Upper engine-to-transaxle bolts
     
    Transaxle mount
     
    Transaxle mount stopper
     

  4.  
  5. Install a suitable engine support assembly, then raise and safely support the vehicle.

    Stabilizer bar
     
    Wheel Speed Sensor (WSS) connector, if equipped with Anti-lock Brakes (ABS)
     
    Brake hose clamp
     
    Tie rod end
     
    Lower control arm
     
    Center member
     
    Halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft.
     
    Bell housing lower cover
     
    Transaxle to engine bolts and lower the transaxle from the vehicle
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    When installing the halfshafts, use new circlips on the axle ends.



    Transaxle to the engine and install the lower mounting bolts
     
    Bell housing cover
     

  2.  
  3. Install or connect the following:

    Halfshafts into the transaxle
     
    Center member
     
    Lower control arm
     
    Tie rod end
     
    Brake hose clamp
     
    WSS connector, if equipped
     
    Stabilizer bar
     

  4.  
  5. Lower the vehicle, then remove the engine support.

    Transaxle mount bracket. Tighten the nuts to 35 ft. lbs. (47 Nm).
     
    Transaxle mount stopper. Tighten the nuts to 61 ft. lbs. (82 Nm).
     
    Transaxle mount
     
    Upper transaxle-to-engine bolts and torque to 36 ft. lbs. (48 Nm)
     
    Clutch line
     
    Starter motor
     
    VSS connector
     
    Back-up light switch connector
     
    Shifter cables, adjust
     
    Evaporative canister
     
    Battery and battery tray
     
    Engine undercover
     
    Positive and negative battery cables
     
    Transaxle with fluid
     

  6.  
  7. Bleed the clutch, check and adjust the front wheel alignment, then check the transaxle for proper operation.
  8.  

Evolution (5-Speed)



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the transfer case. Remove the starter. Remove the air cleaner bracket.
  4.  
  5. Remove the rear roll rod assembly.
  6.  
  7. Disconnect the transaxle harness clamp, backup light switch connector and the VSS connector.
  8.  
  9. Remove the clutch release cylinder and clutch oil pipe. Remove the snap pin. Remove the cable bracket and cable assembly (transaxle side). Remove the rear roll mount bracket.
  10.  
  11. While supporting the engine and transaxle with a floor jack, remove the transaxle mounting insulator assembly.
  12.  
  13. Remove the upper transaxle assembly retaining bolts. Remove the upper transaxle mounting insulator assembly. Remove the transaxle mounting insulator stopper. Remove the transaxle mounting insulator.
  14.  
  15. Install engine support tool MB991895. Set the tool to the front fender rear mounting bolts and the upper radiator support insulator mounting bolts, which are located in the engine compartment.
  16.  
  17. Use tool MB991454 to hold the engine and transaxle assembly in place.
  18.  
  19. Remove the cover from the clutch release service hole in the clutch housing.
    NOTE
    If it is hard to turn the suitable tool, to pry off the release bearing, remove the tool and repeat the procedure below, after pushing the release fork fully in direction -A- two or three times. Forcibly prying can cause the release bearing to be damaged.



    Click image to see an enlarged view

    Fig. Clutch release bearing separation location points-Evolution

  20.  
  21. While pushing the release fork by hand in direction -A- (in the illustration), insert a suitable tool between the release bearing and the wedge collar.
    NOTE
    Be sure to push the release fork in direction -A- before inserting the suitable tool.

  22.  
  23. Separate the release bearing from the wedge collar by prying the suitable tool at a 90 degree angle.
    NOTE
    The release fork is forced to move fully in direction -B- (in the illustration) by the return spring as soon as it is separated from the wedge collar.

  24.  
  25. Remove the transaxle assembly lower retaining bolts. Remove the transaxle from the vehicle.
  26.  

To install:

  1. Raise the transaxle into position and install the lower transaxle retaining bolts.
  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Check and adjust fluid levels, as required.
  6.  

Evolution (6-Speed)



  1. Disconnect the negative battery cable. Remove the battery. Remove the battery tray.
  2.  
  3. Remove the transfer case. Remove the starter. Remove the air cleaner bracket.
  4.  
  5. Remove the strut tower bar assembly. Remove the air duct, air cleaner assembly and air intake hose.
  6.  
  7. Remove the air bypass hose, air hoses and air pipe. Remove the starter.
  8.  
  9. Disconnect the main harness clamp connection. Disconnect the backup light switch connector, VSS sensor electrical connector and the snap pin.
  10.  
  11. Disconnect the shift cable connection and the select cable connection. Disconnect the cable control cable assembly and bracket bolt (transaxle side). Remove the release cylinder and clutch oil pipe. Remove the transaxle upper retaining bolts.
  12.  
  13. Remove the harness clamp and clamp mounting bolt.
  14.  
  15. Using a floor jack support the engine and transaxle assembly. Remove the transaxle mounting insulator assembly.
  16.  
  17. Remove the transaxle mounting insulator stopper. Remove the transaxle mounting insulator.
  18.  
  19. Install engine support tool MB991895. Set the tool to the front fender rear mounting bolts and the upper radiator support insulator mounting bolts, which are located in the engine compartment.
  20.  
  21. Use tool MB991454 to hold the engine and transaxle assembly in place.
  22.  
  23. Remove the cover from the clutch release service hole in the clutch housing.
    NOTE
    If it is hard to turn the suitable tool, to pry off the release bearing, remove the tool and repeat the procedure below, after pushing the release fork fully in direction -A- two or three times. Forcibly prying can cause the release bearing to be damaged.

  24.  
  25. While pushing the release fork by hand in direction -A- (in the illustration), insert a suitable tool between the release bearing and the wedge collar.
    NOTE
    Be sure to push the release fork in direction -A- before inserting the suitable tool.

  26.  
  27. Separate the release bearing from the wedge collar by prying the suitable tool at a 90 degree angle.
    NOTE
    The release fork is forced to move fully in direction -B- (in the illustration) by the return spring as soon as it is separated from the wedge collar.

  28.  
  29. Remove the transaxle assembly lower retaining bolts. Remove the transaxle from the vehicle.
  30.  

To install:

  1. Raise the transaxle into position and install the lower transaxle retaining bolts.
  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Check and adjust fluid levels, as required.
  6.  

 
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