Disassembly And Assembly: Assembly

CAUTION: Never reuse the outer race.

Using the Special Tool Bearing outer race installer (MB991550), Install the outer race of the differential side bearing on the transaxle case.

Fig 1: Identifying Bearing Outer Race Installer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the Special Tool, install the outer race of the reduction gear bearing on the transaxle case.
- Installer cap (MD998812)
- Installer 100 (MD998813)
- Installer adapter(MD998830)
  
  Fig 2: Identifying Installer Cap And Installer Adapter
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply ATF to the bearing so that the interference can be adjusted in a smooth condition. Square bolt
- Measure the end play at more than two locations and obtain the average of the measurements.
Measure an interference (A) of the reduction gear assembly in the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the interference of the reduction gear assembly.
1. Install the reduction gear assembly on the transaxle case.
2. Set the outer race on the reduction gear bearing.
3. Measure distance L1 from the outer race to the end face of the transaxle case.
  
  Fig 3: Measuring Distance From Outer Race To End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Place a block on the end face of the converter housing and measure distance L2 to the reduction gear taper bearing shim mounting surface.
Calculate distance L3 from the end face of the converter housing to the outer race of the reduction gear assembly from the following formula.
L3 = L2 - Height of block
Calculate the thickness of the reduction gear taper bearing shim from the following formula.
Thickness of reduction gear taper bearing shim = L3 - L1 + Interference

Fig 4: Identifying Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 5: Identifying Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 6: Measuring Reduction Gear Taper Bearing Shim Mounting Surface
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 7: Measuring Reduction Gear Taper Bearing Shim Mounting Surface
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the reduction gear taper bearing shim.
Install a selected reduction gear taper bearing shim on the converter housing. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the reduction gear taper bearing shim.

Fig 8: Identifying Reduction Gear Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the Special Tool, install the outer race of the reduction gear bearing on the converter housing.
- Installer cap (MD998812)
- Installer 100 (MD998813)
- Installer adapter (MD998830)
  
  Fig 9: Identifying Special Tools
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply ATF to the bearing so that the interference can be adjusted in a smooth condition.
- Measure the end play at more than two locations and obtain the average of the measurements.
  
  Fig 10: Measuring End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure an interference (A) of the differential assembly in the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the interference of the differential assembly.
1. Install the differential assembly on the transaxle case.
2. Set the outer race on the differential side bearing.
3. Measure distance L1 from the outer race to the end face of the transaxle case.
4. Measure distance L2 from the end face of the converter housing to the differential taper bearing shim mounting surface of the converter housing.
  
  Fig 11: Identifying Differential Assembly
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Calculate the thickness of the differential taper bearing shim from the following formula.
  Thickness of differential taper bearing shim = L2 - L1 + Interference
  
  Fig 12: Locating Converter Housing End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 13: Measuring Differential Taper Bearing Shim
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 14: Measuring Differential Taper Bearing Shim
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION: Never reuse the differential taper bearing shim.
Install a selected differential taper bearing shim on the converter housing. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the differential taper bearing shim.

Fig 15: Identifying Differential Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the Special Tool Bearing outer race Installer (MB991550), Install the outer race of the differential side bearing on the converter housing.

Fig 16: Special Tool Bearing Outer Race Installer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 17: Identifying O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E18 bolts.
Install the Output gear set. Refer to the table below or the exploded view for tightening torque.
IDENTIFYING BOLTS

No. of bolts 10

Tightening torque: 38.5 N.m (28 ft-lb)

Fig 18: Identifying Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the D-rings.
- Apply ATF to the D-rings before installation.
Install D-rings on the low-reverse brake piston.

Fig 19: Identifying D-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply ATF to the low-reverse brake piston before installation.
Install the low-reverse brake piston on the transaxle case.

Fig 20: Identifying Low-Reverse Brake Piston On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the diaphragm spring.

Fig 21: Identifying Diaphragm Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the diaphragm spring retainer.

Fig 22: Identifying Diaphragm Spring Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the Special Tool spring compressor (MB992195), install the snap ring.

Fig 23: Identifying Spring Compressor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.

Fig 24: Measuring End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Measure the clearance (A) of the low-reverse brake using the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the specified low-reverse brake clearance.

While compressing the drive plates, driven plates and retaining plate, measure the thickness L1 of the pack.

COMPRESSING DRIVE PLATES

Compression load [N (kg/cm² )]

7056 - 8056 (720 - 822)

Measure thickness L2 of the one-way clutch.
Measure distance L3 from the end face of the transaxle case to the low-reverse brake piston.

Fig 25: Measuring Thickness Of One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Temporarily assemble the snap ring, one-way clutch and snap ring to the transaxle case.
Measure distance L4 from the end face of the transaxle case to the one-way clutch, while pulling up the one-way clutch.
Remove the temporarily assembled snap ring, one-way clutch and snap ring from the transaxle case.

Fig 26: Identifying Snap Ring, One-Way Clutch And Snap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Calculate the clearance using the following formula. Clearance = L3 - (L1 + L2 + L4)
Select an appropriate retaining plate so that the specified clearance is obtained. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the retaining plate.

Fig 27: Measuring Distance Transaxle Case To One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 28: Measuring Distance Transaxle Case To One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION:

Apply Vaseline to the needle bearing before installation.
Ensure that the needle bearing faces the correct direction.

Install the needle bearing.

Fig 29: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply Vaseline to the bearing race before installation.
Install the bearing race on the RR sun gear on the front side.

Fig 30: Identifying Bearing Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR sun gear on the front side.

Fig 31: Identifying RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR carrier assembly.

Fig 32: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR carrier assembly.

Fig 33: Identifying RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Ensure that the various plates are installed in the correct order.
Install the low-reverse brake drive plate, driven plate and selected retaining plate on the transaxle case.

Fig 34: Identifying Low-Reverse Brake Drive Plate, Driven Plate And Selected Retaining Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, install the snap ring.

Fig 35: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the one-way clutch.

Fig 36: Identifying One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, install the snap ring.

Fig 37: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.

Fig 38: Measuring End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure the clearance (A) of the 2-6 brake using the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the specified 2-6 brake clearance.
1. While compressing the drive plates, driven plates and retaining plate, measure thickness L1 of the pack.
2. Measure distance L2 from the end face of the transaxle case to the snap ring.
  CAUTION: When measuring L3, use the same straight bar as used when L2 is measured.
3. Measure distance L3 from the end face of the side cover to the 2-6 brake piston.
4. Calculate the clearance using the following formula.
  Clearance = L2 - (L1 + L3)
5. Select an appropriate retaining plate so that the specified clearance is obtained. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the retaining plate.
  
  Fig 39: Measuring Pack Thickness
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 40: Measuring Pack Thickness
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 41: Measuring End Face Of Transaxle Case To Snap Ring
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR carrier assembly.

Fig 42: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR sun gear on the rear side.

Fig 43: Identifying RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR sun gear on the rear side.

Fig 44: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the high clutch hub.

Fig 45: Identifying High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the reduction internal gear.

Fig 46: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction internal gear on the high clutch hub.

Fig 47: Identifying Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the reduction internal gear.

Fig 48: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction carrier.

Fig 49: Identifying Reduction Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction sun gear.

Fig 50: Identifying Reduction Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the reduction sun gear end play (A) using the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the specified reduction sun gear end play (A).
1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.
2. Measure distance L2 from the reduction carrier to the reduction sun gear.
  
  Fig 51: Measuring Reduction Sun Gear End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 from the end face of the side cover to the end face of the high clutch support area.
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
5. Select an appropriate spacer so that the specified end play is obtained. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the spacer.
  
  Fig 52: Measuring Reduction Carrier To End Face Of Transaxle Case
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 53: Measuring Reduction Carrier To Reduction Sun Gear
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 54: Measuring End Face Of Side Cover To End Face Of High Clutch Support Area
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the side cover end play (A) in the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the specified side cover end play (A).
1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.
2. Measure distance L2 from the end face of the side cover to the needle bearing mounting surface.
  
  Fig 55: Measuring Side Cover End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 from the contact surface with the needle bearing of the high clutch drum to the snap ring of the cancel cover in the following procedure.
  1. Measure distance L4 from the high clutch drum edge to the snap ring of the cancel cover.
  2. Measure height L5 of the high clutch drum.
  3. Measure distance L6 from the underside of the high clutch drum to the contact surface with the needle bearing.
  4. Calculate L3 using the following formula.
    
    Fig 56: Measuring Reduction Carrier To End Face Of Transaxle Case
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  L3 = L5 - (L4 + L6) -Thickness of straight bar
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
5. Select an appropriate needle bearing so that the specified end play is obtained. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the needle bearing.
  
  Fig 57: Measuring End Face Of Side Cover To Needle Bearing Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 58: Measuring Side Cover End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 59: Measuring High Clutch Drum Edge To Snap Ring Of Cancel Cover
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 60: Measuring High Clutch Drum
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 61: Measuring Distance High Clutch Drum To Contact Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the high clutch assembly.

Fig 62: Identifying High Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Ensure that the various plates are installed in the correct order.
Install the 2-6 brake drive plate, driven plate and selected retaining plate on the transaxle case.

Fig 63: Identifying Brake Drive Plate, Driven Plate And Selected Retaining Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 64: Identifying Transaxle Case O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the spacer.
- Apply Vaseline to the spacer and needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install an appropriate spacer and the needle bearing on the side cover.

Fig 65: Identifying Spacer And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Before applying the sealant, thoroughly clean the mounting surface so that it is completely free of moisture, lubricant and the old sealant.
- The start and finish of the bead should be close to the middle of any pair of the adjoining bolt holes.

Apply Three Bond 1216B to the transaxle case mounting surface of the side cover (almost the center line of the surface).

SEALANT BEAD DIMENSIONS

L1 mm (in)

3 - 5 (0.1 - 0.2)

L2 mm (in)

2.3 (0.09)

Fig 66: Identifying Transaxle Case Mounting Surface

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E16 bolts.

Install the side cover on the transaxle case. Refer to the table below or the exploded view for tightening torque.
IDENTIFYING BOLTS

No. of bolts 14

Tightening torque: 27 N.m (20 ft-lb)

Fig 67: Identifying Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the drum support end play (A) using the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the specified drum support end play (A).
1. Measure distance L1 between the end face of the RR internal gear splines and the oil pump mounting surface of the transaxle case.
2. Measure distance L2 between the thrust washer mounting surface of the drum support and the oil pump mounting surface of the transaxle case.
3. Measure distance L3 using the following procedure.
  1. Install the FR carrier on the low clutch assembly.
    CAUTION:
    Apply Vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
    
    Fig 68: Measuring Drum Support End Play
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Install the needle bearing on the FR carrier.
  3. Install the FR internal gear on the FR carrier.
    CAUTION:
    Apply Vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
  4. Install the needle bearing on the FR sun gear.
  5. Install the FR sun gear.
    
    Fig 69: Measuring End Face Of RR Internal Gear Splines And Oil Pump Mounting Surface
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    Apply Vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
  6. Install the needle bearing on the FR sun gear.
  7. Install the 3-5 reverse clutch assembly.
  8. Measure distance L3 between A and B.
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thrust washer thickness
  
  Fig 70: Measuring End Face Of RR Internal Gear Splines And Oil Pump Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
5. Select an appropriate thrust washer so that the specified end play is obtained. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the thrust washer.
  
  Fig 71: Identifying FR Carrie And Low Clutch
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 72: Identifying Needle Bearing And FR Carrier
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 73: Identifying FR Internal Gear And FR Carrier
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 74: Identifying Needle Bearing
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 75: Identifying Needle Bearing And FR Carrier
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 76: Identifying FR Internal Gear And FR Carrier
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 77: Identifying FR Internal Gear And FR Carrier
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 78: Measuring Contact Surface With Needle Bearing Of High Clutch Drum To Snap Ring
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear assembly.

Fig 79: Identifying Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear lubrication tube.

Fig 80: Identifying Reduction Gear Lubrication Tube
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl.

Fig 81: Identifying Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking shaft.

Fig 82: Identifying Parking Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring.

Fig 83: Identifying Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking plate. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 7.9 N.m (70 in-lb)

Fig 84: Identifying Parking Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential gear assembly.

Fig 85: Identifying Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Ensure that the claws on the thrust washer are correctly engaged with the holes in the drum support.
- Apply Vaseline to the thrust washer before installation.
Install an appropriate thrust washer on the drum support.

Fig 86: Identifying Thrust Washer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low clutch assembly.

Fig 87: Identifying Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR carrier on the low clutch assembly.

Fig 88: Identifying FR Carrier On Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR carrier.

Fig 89: Identifying Needle Bearing On FR Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR internal gear on the FR carrier.

Fig 90: Identifying FR Internal Gear On FR Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR sun gear.

Fig 91: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR sun gear.

Fig 92: Identifying FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR sun gear.

Fig 93: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the 3-5 reverse clutch assembly.

Fig 94: Identifying Reverse Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the 3-5 reverse clutch end play (A) using the following procedure. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for the specified 3-5 reverse clutch end play (A).
1. Measure distance L1 between the oil pump assembly end face and A.
2. Measure distance L2 between A and the bearing race mounting surface.
  
  Fig 95: Measuring Reverse Clutch End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 between the oil pump mounting surface of the transaxle case and the needle bearing mounting surface of the 3-5 reverse clutch drum.
4. Measure thickness L4 of the needle bearing.
5. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - L4 - Bearing race thickness
6. Select an appropriate bearing race so that the specified end play is obtained. Refer to "ADJUSTING PLATE, SNAP RING AND SPACERS " for selecting the bearing race.
  
  Fig 96: Identifying Brake Drive Plate, Driven Plate And Selected Retaining Plate
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 97: Measuring Oil Pump Assembly End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 98: Measuring Bearing Race Mounting Surface Distance
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 99: Measuring Oil Pump Mounting Surface Of Transaxle Case Distance
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 100: Measuring Needle Bearing Thickness
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the 3-5 reverse clutch drum.

Fig 101: Identifying Needle Bearing On Reverse Clutch Drum
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft.

Fig 102: Identifying Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 103: Identifying O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the magnets on the oil strainer.

Fig 104: Identifying Magnet
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the oil strainer.
- Apply ATF to the O-ring of the oil strainer.
Install the oil strainer on the oil pump assembly. Refer to the table below or the exploded view for tightening torque.
IDENTIFYING BOLTS

No. of bolts 3

Tightening torque: 9.4 N.m (83 in-lb)

Fig 105: Identifying Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply Vaseline to the bearing race before installation.
Install an appropriate bearing race on the oil pump assembly.

Fig 106: Identifying Bearing Race On Oil Pump Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
- Apply the ATF as little as possible because too much ATF applied to the o-ring, could cause some confusion over oil leakage
Install an O-ring on the oil pump.

Fig 107: Identifying O-Ring On Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil pump assembly and oil strainer as one unit. Refer to the table below or the exploded view for tightening torque.
IDENTIFYING BOLTS

No. of bolts 7

Tightening torque: 21 N.m (15 ft-lb)

Fig 108: Identifying Oil Pump Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the input shaft.

Fig 109: Identifying Input Shaft O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Before applying the sealant, thoroughly clean the mounting surface so that it is completely free of moisture, lubricant and the old sealant.
- The start and finish of the bead should be close to the middle of any pair of the adjoining bolt holes.
- Apply a double bead of sealant in sections A.

Apply Three Bond 1216B to the transaxle case mounting surface of the converter housing (almost the center line of the surface).

SEALANT BEAD DIMENSIONS

L1 mm (in)	3 - 5 (0.1 - 0.2)
L2 mm (in)	2.3 (0.09)
L3 mm (in)	1.8 (0.07)

Fig 110: Identifying Center Line Of Surface

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E20 bolts.

Install the converter housing on the transaxle case. Refer to the exploded view for tightening torque.
IDENTIFYING BOLTS

No. of bolts 19

Tightening torque: 47 N.m (35 ft-lb)

Fig 111: Identifying Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the side oil seal.
- Apply ATF to the side oil seal before installation.

Using the Special Tool, install a side oil seal.

Oil seal installer (MB992197)
Handle (MB992075)

Fig 112: Identifying Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 113: Identifying Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION:

Ensure that the side oil seal is installed to the specified depth shown in the table below.
Measure the installed depth of the seal at four locations diagonally. Any difference between the measurements should be no more than 0.3 mm.

INSTALLED SEAL DIMENSIONS

On the transaxle case side (A) MB992197	Seal depth (C) from case end face: 4.0 ± 0.1 mm (0.2 ± 0.004 in) or less
On the converter housing side (B) MB992198 < F6AJ >	Seal depth (D) from housing end face: 14.0 ± 0.1 mm (0.6 ± 0.004 in) or less

Fig 114: Identifying Seal Depth

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CAUTION:

Never reuse the O-rings.
Apply ATF to the O-rings before installation.

Install an O-ring on the ATF adjusting bolt.
Install the ATF adjusting bolt on the transaxle case. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 7.4 N.m (65 in-lb)

Fig 115: Identifying O-Ring
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CAUTION:
- Never reuse the lip seals.
- Apply ATF to the lip seals before installation.
Install the lip seals on the transaxle case.

Fig 116: Identifying Lip Seals
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Install the detent spring. Refer to the figure below or the exploded view for tightening torque.
Install the bracket on the oil temperature sensor.
Tightening torque: 4.9 N.m (43 in-lb)

Fig 117: Identifying Detent Spring
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Install the oil temperature sensor on the control valve. Refer to the table below view for tightening torque.
Tightening torque: 7.8 N.m (69 in-lb)

Fig 118: Identifying Oil Temperature Sensor
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CAUTION: Check the oil pressure switch connectors (each indicated with an arrow) for correct fit.
Install the terminal assembly on the control valve.

Fig 119: Identifying Oil Pressure Switch Connectors
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CAUTION: Apply ATF to the manual valve before installation.
Install the manual valve on the control valve.

Fig 120: Identifying Manual Valve
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Press the terminal body into the transaxle case.

Fig 121: Identifying Transaxle Case
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CAUTION: Ensure that the notch in the manual valve is engaged with the lug on the manual plate.

Fig 122: Identifying Lug On Manual Plate
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Install the control valve assembly on the transaxle case.

Fig 123: Identifying Control Valve Assembly
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CAUTION:
- Mounting bolt A is a hexagon head bolt.
- Mounting bolt B is a hexagon socket head bolt.

Install the control valve assembly mounting bolts A and B. Refer to the table below or the exploded view for tightening torque.

IDENTIFYING BOLTS

Bolt code	A	B
Shank length mm (in)	70.1 (2.76)	50.8 (2.00)
No. of bolts	5	4

Tightening torque: 7.9 N.m (70 in-lb)

Fig 124: Identifying Control Valve Assembly Mounting Bolts

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CAUTION:

Never reuse the control valve cover gasket.
Thoroughly clean the control valve cover gasket mounting surface of the case so that it is completely free of moisture, lubricant and the old gasket.

Install the control valve cover gasket on the transaxle case.

Fig 125: Identifying Control Valve Cover Gasket
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Install the control valve cover on the transaxle case. Refer to the table below or the exploded view for tightening torque.
IDENTIFYING BOLTS

No. of bolts 16

Tightening torque: 7.9 N.m (70 in-lb)

Fig 126: Identifying Control Valve Cover Bolts
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CAUTION: Never reuse the snap ring.
Install a snap ring on the terminal body.

Fig 127: Identifying Snap Ring
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CAUTION: Never reuse the copper washers.
Refer to the table below or the exploded view for the tightening torque to install the cooler tube (OUT) onto the side cover.
Eye bolt Tightening torque: 39.2 N.m (29 ft-lb)

Bracket Tightening torque: 21.6 N.m (16 ft-lb)

Fig 128: Identifying Cooler Tube (OUT)
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CAUTION: Never reuse the copper washers.

Refer to the table below or the exploded view for the tightening torque to install the cooler tube (IN) on the side cover.

Tightening torque: 39.2 N.m (29 ft-lb)

Fig 129: Identifying Cooler Tube

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CAUTION: Ensure that the cooler tube (IN) is against the stop on the side cover.

Fig 130: Identifying Cooler Tube

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CAUTION: Ensure that the stud bolts protrude from the case as much as indicated in the table below.

STUD MEASUREMENTS

Stud bolt 1 mm (in)	40 (1.6)
Stud bolt 2 mm (in)	61.5 (2.4)

Install stud bolt 1 and 2 on the transaxle case.

Fig 131: Identifying Stud Bolts On Transaxle Case
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CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the baffle plate.
Install the baffle plate on the converter housing. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 132: Identifying Baffle Plate O-Ring
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CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the pressure test port bolt.
Install the pressure test port bolt on the transaxle case. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 7.4 N.m (65 in-lb)

Fig 133: Identifying Pressure Test Port Bolt
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CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the water-cooled fluid cooler.

Fig 134: Identifying Fluid Water-Cooled Cooler O-Ring
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Install the water-cooled fluid cooler on the transaxle case. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 4.2 N.m (37 in-lb)

Fig 135: Identifying Fluid Water Cooled Cooler
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CAUTION:
- Never reuse the Park/neutral position switch.
- l When loosely installing the switch, insert it squarely onto the manual shaft. (Do not hold the switch at an angle.)
Install an Park/neutral position switch using the following procedure.
1. Loosely install an Park/neutral position switch on the manual shaft.
2. Install the shift plate on the manual shaft.
  Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
3. Set the manual shaft to Range N.
4. Align the hole in the Park/neutral position switch with the hole in the shift plate. With the holes aligned, insert a pin (ø5 mm) or equivalent through the holes. Now, tighten the bolt to the specified torque shown in the table below or in the exploded view. Refer to the figure below or the exploded view for tightening torque.
  Tightening torque: 5.9 N.m (52 in-lb)
  
  Fig 136: Identifying Park / Neutral Position Switch
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  Fig 137: Identifying Park / Neutral Position Switch
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  Fig 138: Identifying Park / Neutral Position Switch
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CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the turbine sensor.
Install the turbine sensor on the transaxle case. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 139: Identifying Turbine Sensor O-Ring
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CAUTION:
- Never reuse the O-rings.
- Apply ATF to the O-rings before installation.
Install an O-ring on the vehicle speed sensor.
Install the vehicle speed sensor on the transaxle case. Refer to the figure below or the exploded view for tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 140: Identifying O-Ring And Vehicle Speed Sensor
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CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Install the torque converter on the transaxle. Ensure that the dimension A is to the specification.
TORQUE CONVERTER DEPTH

Dimension A mm (in) 11.6 (0.46)
Install the control cable bracket and breather hose on the transaxle.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
Install the oil filler tube and oil level gage on the transaxle.
Tightening torque: 11 ±1 Nm (97 ± 9 in-lb)

Fig 141: Measuring Torque Converter Depth
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Install the harness bracket on the transaxle.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle.
Tightening torque: 90 ± 10 Nm (66 ± 7 ft-lb)
Install the transfer on the transaxle. < W6AJ >
Tightening torque: 68 ± 9 Nm (50 ± 7 ft-lb)