Automatic Trans: Overhaul: Transaxle: Reassembly

CAUTION: Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.

CAUTION: Never use grease other than blue petrolatum jelly and white Vaseline.

CAUTION: 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.

CAUTION: Never apply sealant or adhesive to gaskets.

CAUTION: When replacing a bushing, replace the assembly which it belongs to.

CAUTION: Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something.

CAUTION: Change the oil in the cooler system.

Use the special tools to tap the differential bearing outer race in the transaxle case.

Fig 1: Installing Differential Bearing Outer Race
Use the special tools to tap the output shaft bearing outer race in the transaxle case.

Fig 2: Installing Output Shaft Bearing Outer Race
Install the used spacer and snap ring.
Install the transfer gear, low-reverse brake piston, return spring, and spring retainer, one-way clutch and O-ring.
Use the special tools to install the snap ring.

Fig 3: Installing Snap Ring
Install the wave spring.

Fig 4: Installing Wave Spring
Replace the pressure plate of the low-reverse brake with the special tool, and then install the (6) brake discs, (5) brake plates and snap ring as shown in the figure.

Fig 5: Installing Brake Discs, Brake Plates And Snap Ring
Install the reaction plate and the used snap ring.
Move the special tool to measure the end play, and then replace the snap ring installed in step (8) to adjust the end play to standard value.
Standard value: 0 - 0.16 mm (0 - 0.0063 in.)

Fig 6: Measuring End Play
Replace the pressure plate of the second brake with the special tool, and then install the brake disc and brake plate as shown in the figure.

Fig 7: Installing Brake Disc And Brake Plate
Install the return spring, second brake piston and snap ring.
Move the special tool (MB991632) to measure the end play.

Fig 8: Measuring End Play (1 Of 2)

Standard value:
1. 1.09 - 1.55 mm (0.042 - 0.06 in.)
Remove the special tool. Use the following formula to determine the proper thickness range for the pressure plate. Install the correct size pressure plate based on your calculations.

Reference: Pressure Plate Thickness

Fig 9: Measuring End Play (2 Of 2)
1. A=Special tool end play measurement determined earlier in this step.
Metric values: [(A+2.0 mm) - 1.55 mm] to [(A+2.0 mm) - 1.09 mm]

English values: [(A+0.079 in.) - 0.061 in.] to [(A+0.079 in.) - 0.042 in.]
Turn the transaxle over.
Install the special tool (MD998913) in a dial gauge, and then move the special tool (MB991632) to measure the axial play.

Fig 10: Measuring Axial Play (1 Of 2)

Standard value:
1. 1.65 - 2.11 mm (0.065 - 0.08 in.)
Reference: Pressure Plate Thickness
1. A=Special tool end play measurement determined earlier in this step.
Metric values: [(A+2.0 mm) - 2.11 mm] to [(A+2.0 mm) - 1.65 mm]

English values: [(A+0.079 in.) - 0.08 in.] to [(A+0.079 in.) - 0.065 in.]
Remove the parts installed from steps (6) to (14).

Fig 11: Measuring Axial Play (2 Of 2)
Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Standard value: 23 Nm (17 ft.lbs.)

Fig 12: Tightening Output Shaft Bearing Retainer Bolts
Install the output shaft in the transaxle case, and then use the special tool to install the collar and taper roller bearing in the output shaft.

Fig 13: Installing Collar And Taper Roller Bearing In Output Shaft
Apply ATF to a new lock nut, and use the special tool to tighten the lock nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
Standard value: 167 Nm (123 ft.lbs.)

CAUTION: The lock nut has left-handed threads.

Fig 14: Tightening Lock Nut
Move the output shaft to measure operating amount (A), and then replace the spacer installed in step (3) with a new one which thickness is within the following value.
A=Operating amount

B=Thickness of the old spacer

Metric values: [A+B+0.015 mm] to [A+B+0.075 mm]

English values: [A+B+0.0006 in.] to [A+B+0.003 in.]

Fig 15: Measuring Operating Amount
Prevent the lock nut from turning by staking it in two places.

Fig 16: Staking Lock Nut
Install the cap as shown in the figure.

Fig 17: Installing Cap
Use the special tool to install the transfer drive gear.

Fig 18: Installing Transfer Drive Gear
Tighten the eight mounting bolts of the transfer drive gear to the specified torque.
Standard value: 34 Nm (25 ft.lbs.)

Fig 19: Tightening Transfer Drive Gear Mounting Bolts
Install the parking pawl, spacer, and spring. Then install the parking pawl shaft.

Fig 20: Installing Parking Pawl Shaft
Install the parking roller support, and then the two parking roller support shafts.

Fig 21: Installing Parking Roller Support Shafts

Install the planetary carrier assembly.

Fig 22: Installing Planetary Carrier Assembly

Fig 23: Identifying Thrust Bearings, Thrust Races & Thrust Washers

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

SYMBOL	O.D. - mm (in.)	I.D. - mm (in.)	THICKNESS	PART NUMBER
#1	59(2.32)	47(1.85)	1.8(0.071)	MD754509
#1	59 (2.32)	47 (1.85)	2.0 (0.079)	MD754508
#1	59 (2.32)	47 (1.85)	2.2 (0.087)	MD754507
#1	59 (2.32)	47 (1.85)	2.4 (0.094)	MD753793
#1	59(2.32)	47(1.85)	2.6(0.102)	MD753794
#1	59(2.32)	47(1.85)	2.8(0.110)	MD753795
#2	49(1.93)	36(1.42)	3.6(0.142)	MD756846
#3	49(1.93)	36(1.42)	3.6(0.142)	MD756846
#4	55.4(2.18)	38.5(1.51)	3.3(0.130)	MD757847
#5	57(2.24)	38.5(1.51)	4.1(0.16)	MD756846
#6	57(2.24)	38.5(1.51)	4.1(0.16)	MD756846
#7	59(2.32)	37(1.46)	2.8(0.110)	MD754595
#8	48.9 (1.925)	37 (1.46)	1.6 (0.063)	MD707267
#8	48.9 (1.925)	37 (1.46)	1.7 (0.067)	MD759681
#8	48.9(1.925)	37(1.46)	1.8(0.071)	MD723064
#8	48.9 (1.925)	37 (1.46)	1.9 (0.075)	MD754794
#8	48.9(1.925)	37(1.46)	2.0(0.079)	MD707268
#8	48.9(1.925)	37(1.46)	2.1(0.083)	MD754795
#8	48.9(1.925)	37(1.46)	2.2(0.087)	MD723065
#8	48.9(1.925)	37(1.46)	2.3(0.091)	MD754796
#8	48.9(1.925)	37(1.46)	2.4(0.094)	MD724358
#8	48.9 (1.925)	37 (1.46)	2.5 (0.098)	MD754797
#8	48.9(1.925)	37(1.46)	2.6(0.102)	MD754798

Install the planetary reverse sun gear.

Fig 24: Installing Planetary Reverse Sun Gear
Install the wave spring.

Fig 25: Installing Wave Spring
Install the pressure plate, brake disc, and brake plate.

Fig 26: Installing Pressure Plate, Brake Disc, And Brake Plate
Install the snap ring.

Fig 27: Installing Snap Ring
Install the reaction plate.

Fig 28: Installing Reaction Plate
Install the snap ring.

Fig 29: Installing Snap Ring
Install the brake disc, brake plate, and pressure plate.

Fig 30: Installing Brake Disc, Brake Plate, And Pressure Plate
Install the return spring and second brake piston.

Fig 31: Installing Return Spring And Second Brake Piston
Install the snap ring.

Fig 32: Installing Snap Ring
Install thrust bearing #5.
CAUTION: Be sure to install the thrust bearing in the correct direction.

Fig 33: Installing Thrust Bearing #5
Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.
CAUTION: Be careful about the installation direction of the thrust bearing.

Fig 34: Installing Overdrive Clutch Hub & Thrust Bearing #6
Install the reverse and overdrive clutch, and thrust bearing #7.
CAUTION: Be careful about the installation direction of the thrust bearing.

Fig 35: Installing Reverse And Overdrive Clutch, And Thrust Bearing #7
Install the three O-rings.

Fig 36: Installing O-Rings
Install the input shaft bearing.

Fig 37: Installing Input Shaft Bearing
Install the four seal rings.
CAUTION: There are two types of seal rings, with and without identification color. Be sure to install them to their correct positions.

Fig 38: Installing Seal Rings
Install used thrust race #8, and then the rear cover.
Measure end play of the underdrive sun gear. Replace the thrust race installed in step (44) to adjust the play to the standard value. Refer to IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS for the appropriate parts number.
Standard value: 0.25 - 0.45 mm (0.0098 - 0.0177 in.)

NOTE: Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.

Fig 39: Measuring End Play Of Underdrive Sun Gear
Squeeze out the liquid gasket and apply it to the shown points of the rear cover.
Liquid gasket:

MITSUBISHI genuine sealant Part No. MD974421 or equivalent

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 approx. 1 hour.

Fig 40: Applying Liquid Gasket To Rear Cover
Install the rear cover, and tighten its mounting bolts to the specified torque.

Fig 41: Installing Rear Cover
Install the underdrive clutch hub.

Fig 42: Installing Underdrive Clutch Hub
Install thrust bearing #2.
CAUTION: Be sure to install the thrust bearing in the correct direction.

Fig 43: Installing Thrust Bearing #2
Hold the input shaft, and install the underdrive clutch.

Fig 44: Installing Underdrive Clutch
Install the used thrust washer #1.

Fig 45: Installing Used Thrust Washer #1
Use the special tool to install a new oil pump gasket and oil pump.

Fig 46: Installing Oil Pump

CAUTION: Never reuse the old gasket.
Tighten the oil pump mounting bolts to the specified torque.
Standard value: 23 Nm (17 ft.lbs.)
Measure end play of the input shaft. Replace the thrust washer installed in step (51) to adjust the play to the standard value. Refer to IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS for the appropriate parts number.
Standard value: 0.70 - 1.45 mm (0.0276 - 0.0569 in.)

Fig 47: Measuring End Play Of The Input Shaft
Install the oil filter.

Fig 48: Installing Oil Filter
Install the differential.

Fig 49: Installing Differential
Place solder (approx. 10 mm (0.39 in.) in length, 3 mm (0.12 in.) in diameter) on the torque converter housing as shown in the figure.

Fig 50: Placing Solder On Torque Converter Housing
Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.
Standard value: 47 Nm (35 ft.lbs.)
Loosen the bolts, and remove the solder.

Fig 51: Installing Torque Converter Housing To The Transaxle Case
Use a micrometer to measure the thickness of the pressed solder. Select a spacer which thickness is within the following value. Refer to IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS for the appropriate parts number.
[T + 0.045 mm (0.0018 in.)] to [T + 0.105 mm (0.0041 in.)]

Fig 52: Measuring Thickness Of The Pressed Solder
Install the spacer selected in the above step.

Fig 53: Installing Spacer
Assemble the spacer selected in step (60) to the torque converter housing. Use the special tool to press in the outer race.

Fig 54: Installing Outer Race
Squeeze out the liquid gasket and apply it to the shown area of torque converter housing.
Liquid gasket:

MITSUBISHI genuine sealant Part No. MD974421 or equivalent

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 approx. 1 hour.

Fig 55: Applying Liquid Gasket To Torque Converter Housing
Install the two O-rings.

Fig 56: Installing O-Rings
Install the torque converter housing, and then tighten its 18 mounting bolts to the specified torque.
Standard value: 47 Nm (35 fl.lbs.)

Fig 57: Installing Torque Converter Housing
Install the manual control lever shaft and parking pawl rod.
Install the manual control lever shaft roller.

Fig 58: Installing Manual Control Lever Shaft Roller

Install the accumulator pistons, new seal rings, and springs.

NOTE: The accumulator springs are identified as shown in the figure.

Fig 59: Identifying Accumulator Springs

ACCUMULATOR PISTON IDENTIFICATION

Accumulator Piston No. ⁽¹⁾

Accumulator Piston Function

For low-reverse brake

For underdrive clutch

For second brake

For overdrive clutch

⁽¹⁾	See Fig 60.

Fig 60: Identifying Accumulator Pistons

Install the strainer and second brake retainer oil seal.

Fig 61: Installing Strainer And Second Brake Retainer Oil Seal
Install the solenoid valve harness, and then secure the snap ring to the connector groove.

Fig 62: Installing Solenoid Valve Harness
Install the valve body, gasket, and two steel balls.

Fig 63: Locating Steel Balls
Install the fluid temperature sensor.
Install the 28 valve body mounting bolts.

Fig 64: Installing Fluid Temperature Sensor & Valve Body Mounting Bolts

Connect the valve body connectors.

Fig 65: Identifying Valve Body Connectors

VALVE BODY CONNECTOR IDENTIFICATION

No. ⁽¹⁾

PARTS TO BE CONNECTED

CABLE COLOR

CONNECTOR HOUSING COLOR

Underdrive solenoid valve

White, red, red

Black

Overdrive solenoid valve

Orange, red

Black

Low-reverse solenoid valve

Brown, yellow

Milky white

Second solenoid valve

Green, red, red

Milky white

Damper clutch control solenoid valve

Blue, yellow, yellow

Black

Fluid temperature sensor

Black, red

Black

⁽¹⁾	See Fig 65.

Install the manual control shaft detent.

Fig 66: Installing Manual Control Shaft Detent
Apply the liquid gasket to the valve body cover.

Fig 67: Applying Liquid Gasket To Valve Body Cover

Liquid gasket:

MITSUBISHI genuine sealant Part No. MD974421 or equivalent

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 approx. 1 hour.
Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Standard value: 11 Nm (8.0 ft.lbs.)

Fig 68: Installing Valve Body Cover
Install the speedometer gear.

Fig 69: Installing Speedometer Gear
Install the park/neutral position switch and manual control lever.

Fig 70: Installing Park/Neutral Position Switch And Manual Control Lever
Install the input shaft speed sensor and output shaft speed sensor.

Fig 71: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
Install the eye bolt with a new gasket.
Install the oil cooler feed tube.
Install the oil dipstick.
Install the brackets.
Install the torque converter, and secure it so that the shown dimension (A) meets the reference value.

Fig 72: Installing Torque Converter

Reference value: approx. 9.4 mm (0.37 in.)

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.