Disassembly And Reassembly: Disassembly

CAUTION: Do not disassemble parts other than those described in this volume.

Remove the transfer from the transaxle.
Remove the roll rod adapter bracket from the transaxle.
Remove the harness bracket from the transaxle.
Remove the oil filler tube and oil level gage from the transaxle.
Remove the control cable bracket and breather hose from the transaxle.
Remove the corrugate clamp bracket from the transaxle.
Remove the torque converter from the transaxle.

Fig 1: Removing Torque Converter From Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the vehicle speed sensor from the transaxle case.
Remove the O-ring from the vehicle speed sensor.

Fig 2: Removing O-Ring From Vehicle Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the turbine sensor from the transaxle case.
Remove the O-ring from the turbine sensor.

Fig 3: Removing O-Ring From Turbine Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever from the manual shaft.

Fig 4: Removing Manual Control Lever From Manual Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transmission range switch.

Fig 5: Removing Transmission Range Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the water-cooled transmission fluid cooler from the transaxle case.

Fig 6: Removing Water-Cooled Transmission Fluid Cooler From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the water-cooled transmission fluid cooler.

Fig 7: Removing O-Ring From Water-Cooled Transmission Fluid Cooler
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure test port bolt from the transaxle case.
Remove the O-ring from the pressure test port bolt.

Fig 8: Removing O-Ring From Pressure Test Port Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the baffle plate from the converter housing.
Remove the O-ring from the baffle plate.

Fig 9: Removing O-Ring From Baffle Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove stud bolts from the transaxle case.

Fig 10: Removing Stud Bolts From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cooler tube (IN) from the side cover.

Fig 11: Removing Cooler Tube (In) From Side Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cooler tube (OUT) from the side cover.

Fig 12: Removing Cooler Tube (Out) From Side Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful not to break the terminal body.
Remove the snap ring from the terminal body and push the terminal body into the transaxle case.

Fig 13: Removing Snap Ring From Terminal Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the control valve cover from the transaxle case.

No. of bolts 16

Fig 14: Locating Control Valve Cover From Transaxle Case Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the control valve cover gasket from the transaxle case.

Fig 15: Removing Control Valve Cover Gasket From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Mounting bolt A is a hexagon head bolt.
- Mounting bolt B is a hexagon socket head bolt.

Remove control valve assembly mounting bolts A and B.

Fig 16: Locating Control Valve Assembly Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Bolt code	A	B
Shank length mm (in)	71.5 (2.82)	58.0 (2.28)
No. of bolts	5	4

CAUTION: Remove the control valve assembly by pulling it straight.

Remove the control valve assembly from the transaxle case.

Fig 17: Removing Control Valve Assembly From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful not to drop the manual valve.
Remove the manual valve from the control valve.

Fig 18: Removing Manual Valve From Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil temperature sensor and bracket from the control valve.
Remove the bracket from the oil temperature sensor.

Fig 19: Removing Bracket From Oil Temperature Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the terminal assembly from the control valve.

Fig 20: Removing Terminal Assembly From Control Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring.

Fig 21: Removing Detent Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove lip seals from the transaxle case.

Fig 22: Removing Lip Seals From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transmission fluid adjusting bolt from the transaxle case.
Remove the O-ring from the transmission fluid adjusting bolt.

Fig 23: Removing O-Ring From Transmission Fluid Adjusting Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E20 bolts.
Remove converter housing mounting bolts.

No. of bolts 19

Fig 24: Locating Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Lightly tap the converter housing with a plastic hammer or equivalent to remove.

Fig 25: Tapping Converter Housing With Plastic Hammer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the converter housing.

Fig 26: Removing Outer Race Of Reduction Gear Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear taper bearing shim from the converter housing.

Fig 27: Removing Reduction Gear Taper Bearing Shim From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the converter housing.

Fig 28: Removing Outer Race Of Differential Side Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential taper bearing shim from the converter housing.

Fig 29: Removing Differential Taper Bearing Shim From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the input shaft.

Fig 30: Removing O-Ring From Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump assembly and oil strainer as one unit.

No. of bolts 7

Fig 31: Removing Oil Pump Assembly And Oil Strainer Unit
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the oil strainer from the oil pump assembly.

Bolt code	A	B
Shank length mm (in)	25 (1.0)	16 (0.6)
No. of bolts	2	1

Fig 32: Removing Oil Strainer From Oil Pump Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the magnet from the oil strainer.

Fig 33: Removing Magnet From Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 34: Removing O-Ring From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft.

Fig 35: Removing Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing race and needle bearing from the 3-5 reverse clutch drum.

Fig 36: Removing Bearing Race And Needle Bearing From 3-5 Reverse Clutch Drum
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the 3-5 reverse clutch assembly.

Fig 37: Removing 3-5 Reverse Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the FR sun gear.

Fig 38: Removing Needle Bearing From FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the FR sun gear.

Fig 39: Removing FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the FR sun gear.

Fig 40: Removing Needle Bearing From FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the FR internal gear and FR carrier as one unit.

Fig 41: Removing FR Internal Gear And FR Carrier Unit
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the FR internal gear and needle bearing from the FR carrier.

Fig 42: Removing FR Internal Gear And Needle Bearing From FR Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the low clutch assembly.

Fig 43: Removing Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the thrust washer from the drum support.

Fig 44: Removing Thrust Washer From Drum Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential assembly.

Fig 45: Removing Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pawl shaft plate.

Fig 46: Removing Pawl Shaft Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the return spring.

Fig 47: Removing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft.

Fig 48: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl.

Fig 49: Removing Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear lubrication tube.

Fig 50: Removing Reduction Gear Lubrication Tube
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear assembly.

Fig 51: Removing Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E16 bolts.
Remove the side cover.

No. of bolts 14

Fig 52: Removing Side Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the spacer and needle bearing from the side cover.

Fig 53: Removing Spacer And Needle Bearing From Side Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 54: Removing O-Ring From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the high clutch assembly.

Fig 55: Removing High Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction sun gear.

Fig 56: Removing Reduction Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction carrier.

Fig 57: Removing Reduction Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the reduction internal gear.

Fig 58: Removing Needle Bearing From Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction internal gear from the high clutch hub.

Fig 59: Removing Reduction Internal Gear From High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the reduction internal gear.

Fig 60: Removing Needle Bearing From Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the high clutch hub.

Fig 61: Removing High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR sun gear on the rear side.

Fig 62: Removing Needle Bearing From RR Sun Gear On Rear Side
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the RR sun gear on the rear side.

Fig 63: Removing RR Sun Gear On Rear Side
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR carrier assembly.

Fig 64: Removing Needle Bearing From RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.

Fig 65: Removing 2-6 Brake Retaining Plate, Drive Plate And Driven Plate From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, remove the snap ring.

Fig 66: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch and RR carrier assembly as one unit.

Fig 67: Removing One-Way Clutch And RR Carrier Assembly Unit
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Separate the one-way clutch and RR carrier assembly.

Fig 68: Separating One-Way Clutch And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR carrier assembly.

Fig 69: Removing Needle Bearing From RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, remove the snap ring.

Fig 70: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
Remove the low-reverse brake retaining plate, drive plate and driven plate.

Fig 71: Removing Low-Reverse Brake Retaining Plate, Drive Plate And Driven Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the RR sun gear on the front side.

Fig 72: Removing RR Sun Gear On Front Side
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing race from the RR sun gear on the front side.

Fig 73: Removing Bearing Race From RR Sun Gear On Front Side
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing.

Fig 74: Removing Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tool MB992195, remove the snap ring.

Fig 75: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the diaphragm spring retainer.

Fig 76: Removing Diaphragm Spring Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the diaphragm spring.

Fig 77: Removing Diaphragm Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.
Feed air through the oil hole as indicated in the illustration to remove the low-reverse brake piston from the transaxle case.

Fig 78: Removing Low-Reverse Brake Piston From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove D-rings from the low-reverse brake piston.

Fig 79: Removing D-Rings From Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E18 bolts.
Remove the Output gear set.

No. of bolts 10

Fig 80: Removing Output Gear Set
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 81: Removing O-Ring From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not damage the transaxle case when removing the side oil seal.
Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.

Fig 82: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the transaxle case equivalent.

Fig 83: Removing Outer Race Of Reduction Gear Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the transaxle case.

Fig 84: Removing Outer Race Of Differential Side Bearing From Transaxle Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.