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MITSUBISHI
MOTORS
Technical Service Bulletin
SUBJECT No: TSB-15-23-003
NOISE FROM CVT AT ALL ENGINE SPEEDS DATE: February, 2015
MODEL: See below
CIRCULATE TO: I[ ]GENERAL MANAGER I[X l PARTS MANAGER I[X l TECHNICIAN
[ X] SERVICE ADVISOR I[X l SERVICE MANAGER I[X l WARRANTY PROCESSOR I[ l SALES MANAGER
PURPOSE
A clicking noise (along with whining/humming), directly related to vehicle speed, is heard in the passenger
compartment. As vehicle speed increases, the clicking speed increases (engine speed has no effect on
the noise). Due to engine and road noises, the sound typically cannot be heard at vehicle speeds above
40 MPH. Click the following speaker icon to hear to an audible recording of the noise.

This TSB provides instructions to remove the transmission and replace two primary pulley shaft bearings
and one secondary pulley shaft bearing.
AFFECTED VEHICLES
2008-2010 Outlander built prior to October 1, 2010
2008-2010 Lancer built prior to October 1, 2010
2009-2010 Lancer Sportback built prior to October 1, 2010
2011 Outlander Sport equipped built prior to October 1, 2010
OVERVIEW
Prior to removal, drain the transaxle and remove the oil pan. Inspect the two magnets in the pan for debris
and foreign material. Compare the magnets to the photos below.

If the magnets show typical accumulation as shown If the magnets show foreign material along with
above, reinstall the pan and perform this TSB to typical accumulation, reinstall the pan and replace
replace the pulley bearings. the CVT assembly.
Following is a brief outline of the repair steps contained in this TSB. Specific procedures to be followed
after the transaxle has been removed begin on page 3.

• Transaxle Disassembly (page 3) • Bearing Replacement (page 17)

• Side Cover Disassembly (Page 13) • Transaxle Reassembly (page 26)
• Cleaning (page 15) • Transaxle Flushing (page 40)
• Case Seals and O-Rings (page 17)

Copyright 2015, Mitsubishi Motors North America, Inc. Continued

The information contained in this bulletin is subject to change. For the latest version of this document, go to the Mitsubishi Dealer Link,
MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com) (4081)
Page 2 of 41
TSB-15-23-003

Technician Note:
If additional components are found defective while performing this TSB, proceed with repairs as
needed.

TOOLS:
In addition to the CVT special tools specified in the service manual Group 23B, the following
tools are required to complete this repair.
NOTE: A limited quantity of the following special tools are available USED at a substantial
savings. Place an order through your facing PDC.

Number Description Number Description

MB990847-01 Installer MB995049-01 Press Button
MB991448-01 Bushing Remover and Installer Base MD998412 Guide Pins
MB992140-01 Oil Sealer Installer MD998824-01 50mm Adapter
MB991389-01 Remover Base Bushing MD998829-01 Installer Adapter
MLR-C-4660-A Roller Bearing Puller MD998917-01 Remover
MB992984 Compressor Set, Pulley Piston MI T304180-A Installer
MB992985 CVT Pulley Base (Holding Fixture) MIT18594 Protective Sleeve
MB992986 Primary Pulley Holder (Splined Socket)
Common 3 Jaw Puller
40mm 1/2" Drive Socket

Parts List:
Number Description Quantity Number Description Quantity
2702A006 Converter Housing Seal 1 2791A029 Oil Pump Seal Rings 2
2702A014 Axle Seal 2 2800A031 Valve Seal 1
2702A078 O-ring 1 2824A006 Oil Filter 1
2705A015 Oil Pan Gasket 1 2824A007 Oil Filter 1
2761A009 O-ring 1 2920A096 O-ring 2
2771A001 Bearing Retainer 1 2931A005 Seal Rings 2
2771A002 Bearing Retainer 1 2950A047 Bearing 1
2771A003 Lock Nut 1 2950A048 Bearing 1
2771A004 Lock Nut 1 2950A049 Bearing 1
2791A012 O-rings 7 3200A103 O-ring 1
2791A014 Oil Pump Gasket 1 8652A017 O-rings 2
2791A018 Snap Ring 1 MD743612 O-ring 1
2791A024 Oil Pump Chain 1
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TRANSAXLE REMOVAL With the transaxle still in the vehicle,

unfasten the control harness cable bracket
from the dipstick. Remove the dipstick and
transaxle mount. Remove the transaxle from
the vehicle.

Before transaxle disassembly, always clean

any debris from the outside of the transaxle
case.

TRANSAXLE DISASSEMBLY

1. Remove the torque converter from the

transaxle and drain.

2. Remove the secondary pulley speed sensor

mounting bolt.

3. At the same time the secondary pulley speed

sensor is being removed from the transaxle
case, using a stick magnet to remove the
secondary pulley speed sensor shim washer.

NOTE: If the shim washer is omitted, the

speed sensor will rub against the
Secondary Pulley and damage the tip
of the sensor.
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4. Remove the primary pulley speed sensor.

5. Remove the retaining clip from the harness

connector.

6. Remove the warmer/cooler and large a-ring.

Discard the a-ring.

I &CAUTION I

The aluminum tubes on the warmer/

cooler are very soft. Take care as not to
bend, kink or crush them in any way.

7. Remove the ATF warmer/cooler filter and

rubber seal from the case and discard both.

NOTE: Verify the rubber filter seal

comes out with the filter.
 Page 5 of 41
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8. Rotate the transaxle on the bench so the

converter housing faces up.

9. Remove the five LONG converter housing

mounting bolts identified by the dimple
located in the center of the hex head. as
indicated by the arrows.

10. Remove the eighteen SHORT converter

housing mounting bolts.

Use a deadblow mallet to carefully remove

the converter housing from the transaxle
case.

11. Remove and discard the input shaft a-ring.

12. Remove the two selective thrust washers

from the oil pump drive sprocket.

NOTE: The drive sprocket used

with transaxles starting with
serial # Y08808317 was redesigned
which eliminated the need for selective
shims.
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13. Remove the two oil pump driven sprocket

baffle mounting nuts, then remove the baffle

14. Rotate the oil pump driven sprocket until one

of the three cutouts in the driven sprocket
lines up with the opening in the snap ring.

15. Using a pair of external snap ring pliers,

expand the snap ring and slide both
sprockets and the chain upward to remove
them from the transaxle.

Discard the chain.

16. Remove the snap ring from the oil pump

~\ housing bearing bore.
~ SnapRing -
~ Discard the snap ring.
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17. Remove the three tang thrust washer from

the pump cover (stator support).

18. Remove the reduction gear assembly.

Carefully inspect the bearings for roughness

or damage. Replace as necessary.

19. Remove the differential assembly.

Carefully inspect the bearings for roughness

or damage. Replace as necessary.

20. Remove the two oil pump chain baffle

mounting bolts, then remove the oil pump
chain baffle
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21. Remove the two oil pump to pump cover

(stator support) bracket mounting bolts, then
remove the bracket.

22. Remove the two differential baffle mounting

bolts, then remove the baffle

23. Remove the remaining five oil pump cover

(stator support) mounting bolts, then remove
the oil pump cover (Stator support) from the
case.

24. Cut a small piece of fuel hose and install it

onto the manual control shaft is shown.
Using your fingers or a stick magnet remove
the manual control shaft locating pin from
the case.

I &CAUTION I

Failure to install the fuel hose will cause

damage to the non-serviceable manual
shaft seal.
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25. Remove the selective needle bearing

assembly from the forward clutch drum.

NOTE: The selective needle bearing

assembly may have come out with the oil
pump cover (stator support).

26. Remove the forward clutch drum assembly

from the transaxle case.

27. Remove the needle bearing assembly from

the sun gear.

NOTE: The needle bearing may have

come out with the forward clutch
drum.

28. Remove the sun gear.

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29. Remove the planet carrier (reverse brake

clutch hub) assembly from the transaxle
case.

30. Remove the pan.

Discard the pan gasket.

31. Remove the oil strainer and a-ring.

Discard both the strainer and a-ring.

32. Remove the one oil pump mounting bolt from

the rear of the transaxle case.

Remove and discard the a-ring.

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33. Remove the three alien head oil pump

mounting bolts.

Remove the oil pump from the transaxle.

I &CAUTION I

DO NOT remove the four hex head

bolts from the oil pump assembly,
this will cause damage to the oil
pump.

34. Remove and discard the metal clad lip seal

from the transaxle case.

35. Remove the oil strainer mounting bracket

from the valve body.

36. Remove the nut and lock washer from the

manual control shaft.

Remove the manual valve control lever.

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37. Using a magnet, remove the manual control

shaft sleeve from the valve body.

38. Insert a 0.120" (3 mm) diameter, 5.0" (126

mm) long pin into the retaining pin hole in the
valve body.

NOTE: Cut a 5.0 in. piece out of an old

coat hanger or use special tool
MB995015-01.

39. Remove the one short valve body bolt

indicated by the circle, then remove the
remaining ten long valve body mounting
bolts.

40. Remove the valve body by carefully sliding

it back off of the manual control shaft while
pushing the harness connector into the
transaxle case.
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SIDE COVER DISASSEMBLY

41. Remove 19 case bolts as shown by the

arrows.

Note the 2 bolts marked with * in the picture

are 5mm longer than the remaining 17 bolts.

17 bolts - 30mm long

2 bolts - 35mm long

42. Remove the 6 bearing retainer bolts from the

side cover as indicated by the arrows.

Rotate the transaxle onto the side cover

(converter housing pointing up) and level the
assembly with wood blocks.

43. Separate the transaxle case from the side

cover to expose the pulley assemblies.

44. Keep the drive belt from separating during

further disassembly by securely attaching
two tie-wraps around the belt at the locations
shown by the arrows .

•
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45. Note of the direction arrow marked on the

belt.

On reassembly, the belt MUST be reinstalled

with the arrow pointing in the same direction
as it was removed.

46. Place a 1.375" step adapter on the shaft.

Attach piston compressor (MB992984) to the

secondary pulley and tighten the clamp nut
securely. Make certain the compressor does
not slide on the pulley housing.

NOTE: This tool compresses the

pulley's internal spring, expand-
ing the pulley width allowing belt to
be removed.

47. Turn the forcing screw clockwise. STOP

turning when 3mm is measured at the
location shown.

I &CAUTION I

Overtightening the forcing screw

will damage the secondary return
spring.

48. To prevent damaging the belt during further

steps, wind 28" protective tubing
(MIT18594) around its entire length.
 Page 15 of 41
TSB-15-23-003
49. Firmly grasp the compressor with both hands
and lift the secondary pulley assembly from
the side cover.

This step may require the assistance of

another technician to strike the case with
a dead blow mallet to dislodge the bearing
from the side cover.

50. Once the bearing is free from the side cover,

move the secondary pulley assembly toward
the primary pulley. The added slack in the
belt will enable another technician to slide
the belt up and over the primary pulley as
shown here.

51. Once the secondary pulley is removed, lift

the primary pulley from the side cover.

CLEANING

52. While wearing eye protection, use a non-

chlorinated aerosol cleaner to flush each
fluid passage indicated by the arrows.

Immediately follow with compressed air to

remove any debris and cleaner residue.
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53. Remove all residual liquid gasket sealer from

these mating surfaces:

• Converter Housing to Transaxle Case

• Transaxle Case to Side Cover

54. Thoroughly clean the transaxle pan and

magnets.

Magnets
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CASE SEALS and 0-RINGS

,~,
2702A014
55. Before proceeding further, replace the
converter housing seal and axle shaft seals.
If necessary, consult service manual Group
23B for procedures and special tools.

Converter Housing Seal: 2702A006

Axle Seals: 2702A014

56. If the vehicle is equipped with AWD, replace

the transfer case a-rings as shown here.

Apply petroleum jelly to the recess in the

case where the small a-ring sits, then install
the new a-ring (MD743612) into the recess.

BEARING REPLACEMENT

57. Press the primary pulley's front bearing

from the shaft using special tools
MD998917-01 and MB991448-01 as
shown. Discard the bearing.

NOTE: Ensure the bearing splitter's

jaws are fully seated under the
bearing outer race. Do not use the
bearing's C-ring groove to perform this
step.

58. Ensure all surfaces are free of debris. Use

special tool MB991389-01 or MLR-C-4660-
A to press the new bearing (2950A049)
onto the primary pulley shaft.

Ensure the bearing's C-ring groove faces the

pulley flange as indicated by the arro .
Page 18 of 41
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59. Clamp the holding fixture (MB992985) to

the workbench. Place the primary pulley
assembly (lock nut down) into the 50mm
hexagonal opening in the fixture as shown.

Place the primary pulley holder (MB992986)

onto the splines. Using a breaker bar, loosen
the lock nut.

Turn the assembly over, remove the lock nut

and discard it.

60. Use a common 3-jaw puller (e.g. OTC-1023)

to remove the primary pulley's rear bearing.
Discard the bearing and bearing retainer.

61. Clean all surfaces of any debris. Position the

new bearing retainer (2771 A001) as shown
here.

Do not install the retainer upside down.

62. Set a new primary pulley bearing (2950A047)

in place.

Using special tool MB991448-01 to support

the assembly on the press table, seat the
new bearing onto the primary pulley shaft
with MIT304180-A and MD998214-01.
 Page 19 of 41
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63. Thread the new 50mm lock nut (2771A004)

in place.

64. Insert the assembly into the holding fixtur

(MB992985).

Use the primary pulley holder (splined

socket) (MB992986) to tighten the 50mm
lock nut to 130Nm (96 ft-lbs.).

65. Position the secondary pulley assembly (lock

nut down) in the holding fixture (MB992985)
as shown.

Use a 40mm socket and breaker bar on the

staked nut to loosen the 50mm lock nut being
held by the fixture

66. Before attaching a flange puller, place

the press button (from MB992984) onto the
shaft.
Use three 8mm x 1.25mm screws to attach
the puller to the bearing retainer. Turn the
forcing screw against the press button to
remove the secondary pulley's front bearing.

Discard the bearing and bearing retainer.

Retainer may be deformed during this step.

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67. Position the new bearing retainer (2771 A002)

and new bearing (2950A048) onto the
secondary shaft as shown here.

Do not install the bearing retainer upside

down.

68. Support the output gear on the press

table using special tools M IT304180-A and
MD998829-01.

Use a 40mm socket to press the bearing

onto the secondary pulley shaft.

69. Thread a new 50mm lock nut (2771A003)

onto the shaft and return the secondary pulley
assembly to the holding fixture (MB992985)
as shown.

Use a 40mm socket and torque wrench on

the staked nut to tighten the new lock nut
(held by the holding fixture) to 31 0Nm
(228 ft-lbs.).

70. Install a new sealing ring (2931A005) as

shown here.

NOTE: There may be 2 sealing rings

depending upon design. If so,
replace both.
 Page 21 of 41
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71. To make component installation easier,

level the side cover with wood block( s ).

72. Install the primary pulley into the side cover.

73. With slight downward pressure, shake the

primary pulley assembly until the bearing is
fully seated in the side cover.

Check the installed position by measuring

the dimension as shown.

The pulley flange should protrude above

the side cover mating surface by 1.5mm to
2.0mm (0.059" to 0.078").

74. Attach the compressor (MB992984) over

secondary pulley as shown in Step 39. Turn
the forcing screw clockwise. STOP turning
when 3mm (.118") is measured at the location
shown.

I &CAUTION I

Overtightening the forcing screw

will damage the secondary return
spring.
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75. Install the belt around the secondary pulley.

Note the directional arrow.

76. Verify the arrow's direction matches the

drawing shown here.
Primary
Pulley

Secondary
Pulley

77. Hold the compressor close to the primary

pulley while another technician slides the
belt into the primary pulley groove.

78. Once the belt is in position, install the

secondary pulley assembly into the side
cover.

Like the primary pulley installation, shake

the assembly until the bearing is seated.
 Page 23 of 41
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79. The pulley flange should stand 12mm (.472")

above the side cover when the bearing is
fully seated.

Once the secondary pulley assembly is fully

seated, remove the compressor (MB992985).

Remove the protective convolute tubing and

tie-wraps from the belt.

80. Shift to PARK position. Align the park rod into

position, shown by the arrow, and lower the
converter housing onto the side cover.

2.0" 81. To hold the secondary pulley assembly

stationary in the side cover as the transaxle
is flipped over in step 83, use a 2" x 1/2
fender washer.
1/2"

6
82. Insert fender washer into the space between
the output gear and the bearing.

Use flat washers underneath the fender

washer to level it.

Secure with a bolt, finger tight onl .

Page 24 of 41
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83. Install two bolts to hold the transaxle case

and side cover together temporarily.

Turn the transaxle over and position on wood

blocks with the side cover facing up. Verify
the output gear clears the workbench.

Remove the two bolts and remove the side

cover.

84. Install the primary pulley sensor. Note the

spring installation direction as shown by the
arrow.

85. Install the manual shaft locating pin.

Remove the fuel hose installed in step 23.

86. Install new a-ring (2702A078) as shown.

 Page 25 of 41
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87. To simplify aligning the bearing retainers

I MD998412 ---->
-I with the side cover bolt holes, loosely install
guide pins (MD998412) as shown.
\
NOTE: As the guide pin threads are
different than the retainer's threads,
do not tighten the guide pins.

88. Apply a 1.5mm (0.060") bead of Loctite 509

(or equivalent) to the mating surface of the
side cover.

89. Install the secondary pulley side cover shim.

Because the side cover will be turned over in

the next step, use petroleum jelly to keep the
shim in place.

90. Verify the shift linkage is in PARK. Lower

the side cover onto the transaxle case using
the guide pins (MD998412) to position the
bearing retainers with their bolt holes.

Take care to guide the park rod and speed

sensor into their locations in the side cover.

When properly aligned, seat the converter

housing to the side cover with a deadblow
mallet.
Page 26 of 41
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91. Install the 19 case bolts and tighten to 45Nm

(33 ft-lbs.) in the numbered sequence shown.

Make certain to install the two longer 35mm

bolts at locations 14 and 15.

92. Install new a-rings (2791 A012) on the six

bearing retainer bolts.

93. After verifying the bearing retainers are

properly aligned, thread one bolt into each
retainer to maintain their positions.

Remove the guide pins.

Install the remaining bolts and tighten to

28Nm (21 ft-lbs.).

REASSEMBLY PROCEDURES
94. Turn the transaxle over on the workbench
as shown, supporting the side cover with
blocks.

Installed in step 81, remove the fender

washer from under the output gear.
 Page 27 of 41
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95. Install the needle bearing assembly #4

located between the output shaft and planet
carrier with the OUTER bearing race facing
upward, over top of the primary pulley drive
splines.

96. Install the planet carrier into the transaxle

case. Rotate the planet carrier back and
forth to make sure all clutch friction discs
are engaged with the hub. Continue until
the planet carrier is sitting down against the
needle thrust bearing.

97. Install the needle bearing assembly #3

located between the planet carrier and the
sun gear using petroleum jelly to hold it
onto the bottom side of the sun gear with its
OUTER race facing the sun gear.

98. Install the sun gear down into the planet

carrier, rotate it back and forth until it seats
on top of the needle bearing.
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99. Install the needle bearing assembly #2

between the sun gear and forward clutch
drum down into the top side of the sun gear
with the OUTER race facing downward
toward the sun gear.

100. Apply a coating of petroleum jelly to the

sealing rings and bushing surface on the
back of the input shaft.

101. Install the forward clutch assembly into the

transaxle case. Rotate the assembly back
and forth until it is drops down and is seated
against the needle thrust bearing.

102. Install the selective needle bearing assembly

#1 down into the forward clutch drum with
the OUTER race facing up.

103. Verify the bearing is not sitting on top of any

of the locating tabs on the forward clutch
drum.
 Page 29 of 41
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104. Install a new oil pump metal clad lip seal

(2791 A014) into the recess in the transaxle
case using petroleum jelly to hold it in
position.

105. Lower the oil pump into the transaxle case.

Install the three allen head oil pump mounting

bolts finger tight only at this time

3 ILong Bolts I70 mm (2.75 in.)

106. Install a new a-ring (2791 A012) onto the rear

pump mounting bolt. Then apply a coating of
petroleum jelly to the a-ring.

107. Install the rear oil pump mounting bolt into

the back side of the transaxle case finger
tight only at this time.

108. Tighten the three allen head oil pump

mounting bolts to 19Nm (14 ft-lbs.)

Tighten the rear mounting bolt to 28Nm

(21 ft-lbs.)
Page 30 of 41
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109. Apply a coating of petroleum jelly to the

new sealing rings (2791 A029) and bushing
surfaces on the input shaft and pump cover
(stator support).

110. Install the pump cover (stator support) and

the five mounting bolts into the locations
indicated, finger tight only at this time

5 ILong Bolts I30 mm (1.18 in.)

111. Install the oil pump chain baffle in the location
shown using two mounting bolts.

Tighten all of the pump cover (stator support)

and oil pump chain baffle mounting bolts to
19Nm (14 ft-lbs.)

2 ILong Bolts I30 mm (1.18 in.)

112. Install the differential baffle plate and the two

mounting bolts.

Tighten the bolts to 5.8Nm (52 in-lbs.)

2 IShort Bolts I16 mm (.630 in.)

113. Install the oil pump bracket with the two

bracket mounting bolts.

Tighten the bolts to 25Nm (19 ft-lbs.)

2 IShort Bolts I16 mm (.630 in.)

 Page 31 of 41
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114. Install the three tang Thrust Washer on the

pump cover (stator support) making sure
the three tangs on the thrust washer are in
the three holes in the pump cover (stator
support).

115. Install the new driven sprocket ball bearing

retaining snap ring (2791 A018) into the oil
pump housing with the opening in the snap
ring aligned with the cutout in the oil pump
housing.

Early Style Drive Sprocket 116. Set the drive sprocket on the bench with the
DEEP RECESS FACING UP. Set the driven
sprocket on the bench with the ball bearing
FACING DOWN.

Wrap the new chain (2791A024) around the

sprockets making sure the colored chain link
is FACING UP.

No Thrust Surface Deep Recess

Late Style Drive Sprocket

Thrust Surface Deep Recess

Page 32 of 41
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117. With the sprockets and chain as positioned

in step 115, slide the assembly down over
the shafts.

118. Rotate the oil pump driven sprocket until one

of the three cutouts in the driven sprocket
lines up with the opening in the snap ring.

119. Using a pair of external snap ring pliers,

expand the snap ring, at the same time
slide both the drive and driven sprockets
downward along with the chain until the drive
sprocket fully seats on the three tang thrust
washer.
120. While expanding the snap ring carefully
move the oil pump driven sprocket up and
down until the snap ring seats in the groove
in the outer race of the ball bearing.

121. Install the oil pump driven sprocket baffle on

the studs in the transaxle case.

Install the two 10mm mounting nuts and

tighten to 5.8Nm (52 in-lbs.).

122. Install a new a-ring (2761A009) into the

groove on the input shaft.
 Page 33 of 41
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123. Install the differential assembly into the

transaxle case.
If bearings were replaced, verify proper shim
thickness using Service Manual selection
procedures.

124. Install the reduction gear assembly into the

transaxle case.
If bearings were replaced, verify proper shim
thickness using Service Manual selection
procedures.

125. Place a 1.5mm (0.60") bead of Loctite 509

(or equivalent) on the transaxle case mating
surface.
Install the converter housing onto the
transaxle case, then install the five LONG
converter housing mounting bolts identified
by the Dimple located in the center of the
hex head into the indicated locations.

I 5 ILong Bolts I35 mm (1.38 in.)

126. Install eighteen SHORT converter housing
mounting bolts into the indicated locations.

Tighten all bolts to 45Nm (33 ft-lbs.)

I 18 IShort Bolts I30 mm (1.18 in.)

Page 34 of 41
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127. Apply petroleum jelly to the new reverse

brake clutch passage lip seal (2800A031)
and install it into the transaxle case.

NOTE: If the ratio control valve and

spring were to fall out of the valve
body during the disassembly
process, this drawing indicates the
correct location of the spring.

128. Position the ratio control valve lever so that

it is engaged over the yoke on the stepper
motor. Push the ratio control lever inward
toward the valve body.

129. While holding the ratio control lever in, insert

the long pin used in disassembly into the
hole in the valve body.
 Page 35 of 41
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130. Verify the ratio control valve lever is securely

positioned behind the pin.

\
131. Install the harness connector into the
transaxle case. Push the harness connector
toward the outside of the transaxle case until
the stopper is fully seated.

Be careful not to damage the a-ring.

132. Install the retaining clip into the groove on

the harness connector.

133. Locate the slider linkage pin. When installing

the valve body, the cutout in the ratio control
lever must engage with the slider linkage pin.
Page 36 of 41
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134. While holding the end of the long pin, install

the valve body into the case making sure the
ratio control valve linkage engages the pin
on the slider linkage and that the valve body
seats on to the dowel pins mounted in the
transaxle case.

135. While holding the valve body against the

transaxle case surface, install the one
SHORT valve body mounting bolt into the
location indicated and tighten it just enough
to keep the valve body on the dowel pins.

I 1 IShort Bolt I44 mm (1.73 in.)

136. Install the remaining ten LONG valve body

mounting bolts into the locations indicated
finger tight only at this time.

I10 ILong Bolts I54 mm (2.13 in.)

Remove the long pin (installed in step 128)
from the valve body.
Tighten all valve body bolts to 7.9Nm
(70 in-lbs.).

137. Install the oil strainer mounting bracket onto

the valve body with its mounting bolts.

Tighten the two bolts to 7.9Nm (70 in-lbs.).

2 ILong Bolts I25 mm (.984 in.)

 Page 37 of 41
TSB-15-23-003

138. Verify the new a-ring is attached on the new

oil strainer (2824A007). Coat the new a-ring
with petroleum jelly, then install the new oil
strainer onto the valve body.
Install the one LONG and two SHORT oil
strainer mounting bolts into the locations
indicated. Tighten oil strainer mounting bolts
to 7.9Nm (70 in-lbs.).

1 Long Bolt 44 mm (1.73 in.)

2 Short Bolts 12 mm (.470 in.)

139. Verify the manual control shaft sleeve is flush

with the valve body surface.

140. Install the manual control valve lever onto

the manual control shaft, while at the same
time, position the manual control valve to
ensure the lever engages the cutout on the
manual control valve.

Install the lock washer and nut.

Tighten the nut to 21 Nm (16 ft-lbs.).

141. Install the new pan gasket (2705A015)

and oil pan onto the two dowel pins on the
transaxle case. Install the eighteen pan
bolts and tighten to 7.9Nm (70 in-lbs.).

I 18 IShort Bolts I15 mm (.590 in.)

Install a new drain plug gasket (2705A013).

Install the drain plug into the pan.

Page 38 of 41
TSB-15-23-003

142. Install a new a-ring (8652A017) into the

groove on the secondary pulley speed
sensor. Coat the a-ring with petroleum jelly.

, ---.,• • ~~=m.::::::;i~~'!.ir.-~=-=_=-:_ij_a7 143. Using a stick magnet, hold the shim into
position under the secondary pulley speed
sensor mounting tab while installing the
speed sensor into the transaxle case.

144. Install the secondary pulley speed sensor

mounting bolt.

Tighten the bolt to 5.8Nm (52 in-lbs.).

1 IShort Bolt I17 mm (.669 in.)

145. Install a new a-ring (8652A017) into the

groove on the primary pulley speed sensor.
Coat the a-ring with petroleum jelly.
 Page 39 of 41
TSB-15-23-003

146. Install the primary pulley speed sensor.

Tighten the bolt to 5.8Nm (52 in-lbs.).

1 IShort Bolt I17 mm (.669 in.)

147. Verify the rubber gasket is installed on the

new ATF warmer/ cooler filter (2824A006).
Apply a coating of petroleum jelly to the seal.

148. Install the new ATF warmer/ cooler filter into

the opening in the transaxle case as shown.

149. Install a new rubber a-ring (2920A096) in

the groove on the new ATF warmer/ cooler.
Coat the a-ring with petroleum jelly.

O-Ring
Page 40 of 41
TSB-15-23-003

150. Install the ATF warmer/ cooler onto the case

with the four mounting bolts.

Tighten the bolts to 4.1 Nm (37 in-lbs.).

4 ILong Bolts I24 mm (.944 in.)

151. Apply a coating of petroleum jelly to the input

shaft a-ring then install the torque converter
into the transaxle case. While lightly pushing
inward rotate the converter back and forth
until it is fully seated.

TRANSAXLE FLUSHING

152. Once the CVT has been reinstalled in the

vehicle, follow these steps to flush any
remaining debris from transaxle. Do not use
an automatic transmission flushing machine.

• With the engine running, add sufficien

DIA-QUEEN CVTF-J4 transmission flui
~-______.._II____;;._C____.._I _H____.._II_ to raise the level above the COLD range
on the dipstick.

• Drive the vehicle until the flui

temperature has reached at least 158°F.
(Monitor Data List Item #5.)

• Drain the fluid from the transaxle

• Refill the transaxle with CVTF-J4 flui

• Drive the vehicle for 5 minutes.

• Drain the fluid from the transaxle

• One last time, refill the transaxle wit

CVTF-J4 fluid
 Page 41 of 41
TSB-15-23-003

WARRANTY INFORMATION
This bulletin is supplied as technical information only and is not an authorization to repair. If an affected
vehicle is reported with the described condition, diagnose the condition, repair as described in this bulletin
and submit a normal warranty claim using the following information.

CVT Primary and Secondary Pulley Shaft Bearing Replacement

Nature Code: 80G Cause Code: 340
Labor Operation No.: 233010 9F Time Allowance: Follow L.O.T.S times
for labor operation no.
Warranty Coverage: Powertrain Coverage - Refer to the Superscreen for individual vehicle
warranty coverage terms.
Special Warranty Information: Normal warranty procedures apply.