Disassembly And Assembly: Assembly

CAUTION:

Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
Do not use grease other than petroleum jelly (Vaseline).
Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
When replacing a bushing, replace the assembly which it belongs to.
Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.

Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case. Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.

Fig 1: Installing Special Tool In Installation Screw Hole Of Transfer Drive Gear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the eight mounting bolts of the transfer drive gear bearing to the specified torque.
Tightening torque : 34 +/- 2 N-m (25 +/- 1 ft-lb)

Fig 2: Tightening Mounting Bolts Of Transfer Drive Gear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
Fit a new O-ring into the groove of one-way clutch inner race.
Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.

Fig 3: Identifying Notches
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put the snap ring on the inner race.
Set special tools MD998338 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.

Fig 4: Using Special Tools And Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring onto the low-reverse brake piston.

Fig 5: Installing Wave Spring Onto Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
Install the six brake discs, five brake plates and snap ring as shown in the figure.
NOTE: Do not install the pressure plate at this time.
Install special tool MB991632 on the brake disc.
Install the reaction plate and the used snap ring.
Move special tool MB991632 to measure the end play of reaction plate. Then replace the snap ring installed in step 11 to adjust the end play to standard value.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)

Fig 6: Measuring End Play Of Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the brake discs and brake plates as shown in the figure.
Place special tool MB991632 on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.

Fig 7: Placing Special Tool On Top Of Brake Disc In Place Of Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move special tool MB991632 and measure its movement.
Standard value of end play (Reference): 1.09 - 1.55 mm (0.0429 - 0.0610 inch)
Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

Fig 8: Measuring Movement
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 9: Measuring Amount Of Movement
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PRESSURE PLATE

Fig 10: Pressure Plate Thickness Moving Amount Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn the transaxle over so that the installation surface of the torque converter housing is facing up.
Install special tool MD998913 in a dial gauge, and then move special tool MB991632 and measure its movement.

Standard value of end play (Reference): 1.65 - 2.11 mm (0.050 - 0.0831 inch)

Fig 11: Installing Special Tool In A Dial Gauge
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

Fig 12: Measuring Amount Of Movement For Pressure Plate Thickness
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 13: Using Special Tools And To Tap Output Shaft Bearing Outer Race In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove all parts and special tools that were installed to take the measurements in steps 8 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.
Install the snap ring into the groove of transaxle case output shaft bore.
Install the thinnest output shaft preload adjustment spacer [thickness 1.88 mm (0.0740 in); part number MD756579].
Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.

Fig 14: Pressure Plate Thickness Moving Amount Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the bolt, as it has had sealant applied.
Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Tightening torque: 54 +/- 5 N.m (40 +/- 4 ft-lb)

Fig 15: Identifying Output Shaft Bearing Retainer Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.

Fig 16: Using Special Tool To Installing Collar And Taper Roller Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
Tightening torque: 170 +/- 10 N.m (126 +/- 7 ft-lb)

NOTE: The jam nut is reverse threaded.

Fig 17: Using Special Tools And Tightening Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move the output shaft to measure the end play and record the measurement value.
Remove the parts that were installed in steps 21 to 25.
Add 1.88 mm (0.074 inch)* and 0.01 to 0.09 mm (0.0004 to 0.0035 inch)** to the measured value in step 26 and select a spacer of the same thickness. Adjustment spacer sizes are all listed on SERVICE SPECIFICATIONS . Select the most suitable one from among those listed.
NOTE: *is the thickness of the spacer installed in step 21. **is the preload of the output shaft.
Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 27.
Stake the jam nut with a punch (two places).

Fig 18: Measuring Output Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 19: Staking Jam Nut With Punch
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Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.

Fig 20: Using Special Tools And Installing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 21: Identifying Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking roller support, and then insert the two parking roller support shafts.

Fig 22: Identifying Parking Roller Support Shaft
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IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS mm (in)

Fig 23: Identifying Thrust Bearing, Thrust Races, And Thrust Washers
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 24: Thrust Bearing, Thrust Races, And Thrust Washers Thickness Table( 1 Of 2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 25: Thrust Bearing, Thrust Races, And Thrust Washers Thickness Table(2 Of 2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary carrier assembly.

Fig 26: Installing Planetary Carrier Assembly
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Install the planetary reverse sun gear.

Fig 27: Installing Planetary Reverse Sun Gear
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Install the wave spring on the low-reverse brake piston.

Fig 28: Installing Wave Spring On Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the pressure plate that was selected in step 18. Next, install six brake discs and five brake plates, one on top of the other.

Fig 29: Installing Brake Discs And Five Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 30: Installing Snap Ring
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Install the reaction plate.

Fig 31: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.

Fig 32: Installing Snap Ring
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Install four brake discs and three brake plates, one on top of the other. Next, install the pressure plate that was selected in step 16.

Fig 33: Installing Four Brake Discs And Three Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring and second brake piston.

Fig 34: Installing Return Spring And Second Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 35: Installing Snap Ring
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CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.

Fig 36: Installing Thrust Bearing Number 5 In Direction
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Use care to install the thrust bearing in the proper direction.
Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.

Fig 37: Attaching Thrust Bearing Number 6 To Inside Of Overdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reverse and overdrive clutch.
CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
Check the installation direction of thrust bearing number 7 and install it on the reverse clutch retainer.

Fig 38: Checking Installation Direction Of Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
Install the four seal rings in the grooves of the rear cover.

Fig 39: Using Special Tool To Taping Input Shaft Rear Bearing In Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure the end play of the under drive sun gear by the following procedures:
1. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7.
2. Install the rear cover on the transaxle case and tighten the bolts to the specified torque.
  Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
3. Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.
4. Install the under drive clutch hub on the under drive sun gear.
5. Measure end play of the underdrive sun gear and record the measurement value.
  Standard value (Reference): 0.25 - 0.45 mm (0.0098 - 0.0177 inch)
6. After taking the measurements in steps (1) to (4), take out the installed parts.
  
  Fig 40: Measuring End Play Of Under Drive Sun Gear
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the three O-rings.
Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 50 from the table below. Install it on thrust bearing number 7.

Fig 41: Installing Three O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 42: Thrust Race Thickness Measurement Values Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the illustrated position of the rear cover.
NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes).

Fig 43: Applying Bead Of Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the rear cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

Fig 44: Installing Rear Cover Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub to the underdrive sun gear.

Fig 45: Installing Underdrive Clutch Hub To Underdrive Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.

Fig 46: Installing Thrust Bearing Number 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch.

Fig 47: Installing Underdrive Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14 inch) in diameter] on the underdrive clutch retainer as shown in the illustration.

Fig 48: Placing Two Beads Of Solder On Underdrive Clutch Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown.
Install the oil pump to the transaxle case.
NOTE: Do not install the oil pump gasket at this time.
Tighten the oil pump mounting bolts (six pieces) to the specified torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)

Fig 49: Installing Special Tool MD998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump mounting bolts.
Using special tools MD998333, remove the oil pump and the crushed solders.

Fig 50: Using Special Tools And Removing Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.

Fig 51: Measuring Thickness Of Crushed Solder Beads
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 52: Thrust Washer Thickness Measurement Value Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install thrust washer number 1 that was selected in step 65 on the underdrive clutch retainer.

Fig 53: Installing Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown.
Install the new oil pump gasket on the transaxle case.
Install the oil pump and tighten the mounting bolts (six pieces) to the specified torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)

Fig 54: Installing Oil Pump Using Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the input shaft end play meets the standard value.
Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch)

Fig 55: Measuring Input Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 56: Installing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.

Fig 57: Using Special Tools And Taping Differential Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential

Fig 58: Installing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter] on the torque converter housing as shown in the illustration

Fig 59: Placing Two Beads Of Solder On Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990936 and MB990938 to press in the differential bearing outer race into the torque converter housing.

Fig 60: Using Special Tools And Pressing In Differential Bearing Outer Race Into Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.
Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.

Fig 61: Identifying Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to the measured value and select a spacer with the corresponding thickness. Adjustment spacer sizes are all listed on SERVICE SPECIFICATIONS . Select the most suitable one from among those listed.
NOTE: *is the thickness for the differential case preload.

Fig 62: Measuring Thickness Of Crushed Solder Beads
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the spacer selected in step 79 to the torque converter housing.
Use special tools MB990936 and MB990938 to press the outer race into housing.

Fig 63: Using Special Tools And Pressing Outer Race Into Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the torque converter housing in the area shown.
NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes).

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

Fig 64: Applying Bead Of Sealant On Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the two O-rings.

Fig 65: Installing Two O-Rings
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Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque.
Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)

Fig 66: Installing Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert the two O-rings into the grooves of the manual control lever shaft.
Install the manual control lever shaft and parking pawl rod.
Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".

Fig 67: Aligning Hole With Groove In Manual Control Lever Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 68: Identifying Accumulator Spring
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Insert the new seal rings in the grooves of the accumulator pistons.
NOTE: The piston and seal ring are common parts.
Identify the accumulator spring and insert it and the accumulator piston into each hole of the transaxle case.
NOTE: Accumulator springs are identified as shown in the illustration.

Fig 69: Identification "BLUEING" Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 70: Inserting New Seal Rings In Grooves Of Accumulator Pistons
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the strainer and second brake retainer oil seal.

Fig 71: Installing Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert a new O-ring to the groove of the solenoid valve harness connector.
Insert the solenoid valve harness connector into the hole from the inside of the transaxle case so it is oriented as shown in the illustration. Then secure the snap ring to the connector groove.

Fig 72: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
Install the valve body and gasket to the transaxle case. Make sure that the manual valve's pin is in the groove in the detent plate of the manual control lever.

Fig 73: Installing Valve Body And Gasket To Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the 27 valve body mounting bolts, and tighten to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb)

Fig 74: Installing Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.

Fig 75: Attaching Solenoid Valve Harness To Valve Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 76: Solenoid Valve Harness Cable Color Identification Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6.0 +/- 1.0 N.m (52 +/- 8 in-lb)

Fig 77: Installing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown.
NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes).

NOTE: After installation, keep the sealed area away from the oil for approximately one hour.

Fig 78: Applying Bead Of Sealant To Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb)

Fig 79: Installing Valve Body Cover Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the Sealing cap and tighten the bolt to the specified torque.
Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 8 in-lb)

Fig 80: Identifying Sealing Cap
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Install the park/neutral position switch and tighten the bolt to specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb)
Install the manual control lever and tighten the nut to specified torque.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

Fig 81: Identifying Manual Control Lever And Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb)

Fig 82: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Press Face "A" of the air breather to be even with Face "B" of the transmission case as shown in the drawing.
Apply ATF on the both sides of the new gasket and threads of the eyebolts, and then tighten to the specified torque.
Tightening torque: 24 +/- 3 N.m (18 +/- 2 ft-lb)
Tighten the oil cooler feed pipe clamp bolt to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb)
Install the oil dipstick.
Install the cable support bracket.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
Install the roll stopper brackets.
Tightening torque: 70 +/- 10 N.m (51 +/- 7 ft-lb)

Fig 83: Identifying Air Breather
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CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.
Install the torque converter, and secure it so that the shown dimension "A" meets the reference value.
Reference value:

Approximately 9.4 mm (0.37 inch)
Install the transfer together with new o-ring and tighten the bolts to the specified torque < W4A5A >
Tightening torque: 69 +/- 9 N.m (51 +/- 6 ft-lb)

Fig 84: Identifying Dimension Of Meets Reference Value
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