Disassembly And Assembly: Disassembly

CAUTION:

Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
Work or a rubber mat and keep it clean at all times.
Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
If the transaxle body has been damaged, disassemble and clean the cooler system.

Remove the torque converter.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt gauge, gaskets and the oil cooler feed tube.
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 1: Removing Input & Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.
Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.

Fig 2: Removing Manual Control Lever Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the Sealing cap and O-ring.

Fig 3: Removing Sealing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 4: Removing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control shaft detent.

Fig 5: Removing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.

Fig 6: Disconnecting Solenoid Valve Harness From Valve Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See 8.
Remove the valve body mounting bolts (27 pieces).

Fig 7: Removing Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket, and the two steel balls.

Fig 8: Removing Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.

Fig 9: Removing Snap Ring From Connector
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 10: Removing Strainer & Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring.

Fig 11: Removing Each Accumulator Piston & Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 12: Piston & Spring Specifications Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 13: Removing Manual Control Lever Shaft & Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (18 bolts), and then remove the torque converter housing.
Remove the differential bearing outer race and spacer from the torque converter housing.

Fig 14: Removing Differential Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (two pieces).

Fig 15: Removing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.
Remove the differential bearing outer race from the transaxle case.

Fig 16: Removing Differential Bearing Outer Race From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 17: Removing Oil Filter
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Remove the oil pump mounting bolts (six bolts).
Install special tool MD998333 in hole "A."

Fig 18: Installing Special Tool In Hole "A"
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 19: Removing Oil Pump Using Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 20: Removing Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 21: Removing Underdrive Clutch & Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 22: Removing Thrust Bearing Number 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 23: Removing Underdrive Clutch Hub
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Remove the rear cover and input shaft rear bearing.

Fig 24: Removing Rear Cover
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Remove thrust race number 8.
Remove the seal rings (four pieces).
Remove the O-rings (three pieces).

Fig 25: Removing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 26: Removing Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 27: Removing Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 28: Removing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 29: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 30: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 31: Removing Second Brake Piston & Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure plate, brake discs and brake plate.
Number of brake discs and plates:

Fig 32: Removing Pressure Plate, Brake Discs & Brake Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 33: Brake Discs & Brake Plate Specifications Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 34: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 35: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reaction plate and the brake disc.

Fig 36: Removing Reaction Plate & Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 37: Remove Snap Ring
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Remove the brake plates (four pieces), brake discs (five pieces) and pressure plate.

Fig 38: Removing Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 39: Removing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 40: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the two parking roller support shafts, and then remove the parking roller support.

Fig 41: Removing Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998903 and MD998924, compress the one-way clutch inner race.
  
  Fig 42: Compressing One-Way Clutch Inner Rack Using Special Tools
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
Remove the four or three transfer drive gear bearing mounting bolts. Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

Fig 43: Removing Four Or Three Transfer Drive Gear Bearing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 44: Removing Transfer Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cap by jabbing a screw driver in to the center of the cap and prying it up.

Fig 45: Removing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a chisel, straighten the staked portions from the output shaft nut.

Fig 46: Straightening Staked Portions From Output Shaft Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 47: Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolt.

Fig 48: Removing Bearing Retainer Mounting Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 49: Tapping Rear End of Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.

Fig 50: Tapping Out Outer Race & Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.