Automatic Trans: Overhaul: Transaxle: Disassembly

CAUTION: Because the automatic transaxle is manufactured from high-precision parts, sufficient care must be taken not to scratch or damage these parts during disassembly and reassembly.

CAUTION: The working area should be covered with a rubber mat to keep it clean at all times.

CAUTION: Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth if you need to use something.

CAUTION: 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.

CAUTION: Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF) so that they do not become dirty.

CAUTION: If the transmission body has been damaged, disassemble and clean the cooler system also.

Remove the torque converter.
Use the dial gauge to measure the input shaft end play.
Remove each bracket.
Remove the oil level gauge.
Remove the oil cooler feed tube.
Remove the eye bolt and gasket.

Fig 1: Measuring Input Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 2: Identifying Input Shaft Speed Sensor And Output Shaft Speed Sensor
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Remove the manual control lever, and then remove the park/neutral position switch.
CAUTION: Make sure that the manual control lever installation nut is removed before removing the valve body.

Fig 3: Identifying Manual Control Lever And Park Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 4: Identifying Valve Body Cover
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Remove the manual control shaft detent.

Fig 5: Identifying Manual Control Shaft Detent
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Disconnect the harness connectors of the valve body.

Fig 6: Identifying Harness Connectors Of The Valve Body
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Remove the valve body mounting bolts (28 pieces).
Remove the fluid temperature sensor.
CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed.

Fig 7: Identifying Fluid Temperature Sensor
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Remove the valve body, gasket and the steel balls (2 pieces).
CAUTION: Do not lose the steel balls (2 pieces).

Fig 8: Removing Valve Body, Gasket And Steel Balls (2 Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring, and then remove the solenoid valve harness.

Fig 9: Removing Snap Ring And Solenoid Valve
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Remove the strainer and the second brake retainer oil seal.

Fig 10: Identifying Strainer And Second Brake Retainer Oil Seal For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring.

Fig 11: Accumulator Piston And Spring Description Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 12: Identifying Accumulator Piston And Spring
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Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 13: Identifying Manual Control Lever Shaft And Parking Pawl Rod For Removal
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Remove the torque converter housing mounting bolts (18 pieces), and then remove the torque converter housing.

Fig 14: Identifying Torque Converter Housing Mounting Bolts
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Remove the O-rings (2 pieces).

Fig 15: Identifying O-Rings (2 Pieces) For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.

Fig 16: Identifying Differential For Removal
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Remove the oil filter.

Fig 17: Removing Oil Filter
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Remove the oil pump mounting bolts (6 pieces).
Install the special tool (MD998333) in the hole A.

Fig 18: Locating Hole For Installing Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Screw the special tool to remove the oil pump.
Remove the oil pump gasket.

Fig 19: Screwing Special Tool To Remove Oil Pump
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Remove thrust washer #1.

Fig 20: Removing Thrust Washer #1
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Hold the input shaft, and then remove the underdrive clutch.

Fig 21: Removing Underdrive Clutch By Holding Input Shaft
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Remove thrust bearing #2.

Fig 22: Removing Thrust Bearing #2
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Remove the underdrive clutch hub.

Fig 23: Removing Underdrive Clutch Hub
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Remove the rear cover.

Fig 24: Identifying Rear Cover Bolts For Removing Rear Cover
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Remove the thrust race #8.
Remove the seal rings (4 pieces).
Remove the input shaft rear bearing.
Remove the O-rings (3 pieces).

Fig 25: Identifying O-Rings (3 Pieces) For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and the thrust bearing #7.

Fig 26: Removing Reverse And Overdrive Clutch And Thrust Bearing #7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the overdrive clutch hub and the thrust bearing #6.

Fig 27: Removing Overdrive Clutch Hub And Thrust Bearing #6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing #5.

Fig 28: Removing Thrust Bearing #5
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Remove the planetary reverse sun gear.

Fig 29: Removing Planetary Reverse Sun Gear
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Remove the snap ring.

Fig 30: Removing Snap Ring
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Remove the second brake piston and the return spring.

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

Fig 32: Removing Pressure Plate, Brake Discs And Brake Plates
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Remove the planetary carrier assembly.

Fig 33: Removing Planetary Carrier Assembly
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Remove the snap ring.

Fig 34: Removing Snap Ring
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Remove the reaction plate and the brake disc.

Fig 35: Removing Reaction Plate And Brake Disc
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Remove the snap ring.

Fig 36: Removing Snap Ring
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Remove the brake plates, brake discs and pressure plate.

Fig 37: Removing Brake Plates, Brake Discs And Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 38: Removing Wave Spring
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Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 39: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the two parking roller support shafts, and then remove the parking pawl case and parking roller support.

Fig 40: Removing Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use the special tool to remove the snap ring.
Remove the one-way clutch inner race and O-ring, spring retainer, return spring and the low-reverse brake piston.

Fig 41: Using Special Tool For Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear mounting bolts (8 pieces).

Fig 42: Removing Transfer Drive Gear Mounting Bolts
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Remove the transfer drive gear.

Fig 43: Removing Transfer Drive Gear
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Remove the cap.

Fig 44: Removing Cap
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Straighten the locking tab of the output shaft lock nut.

Fig 45: Straightening Locking Tab Of Output Shaft Lock Nut
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Use the special tool to remove the output shaft lock nut.
CAUTION: The lock nut has left-handed threads.

Fig 46: Using Special Tool For Removing Output Shaft Lock Nut
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Remove the bearing retainer mounting bolt.

Fig 47: Identifying Bearing Retainer Mounting Bolt For Removal
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Tap on the rear of the output shaft to remove the output shaft, taper roller bearing and the collar.

Fig 48: Tapping On Rear Of Output Shaft For Removing Output Shaft, Taper Roller Bearing And Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the spacer and the outer race.
Remove the snap ring.

Fig 49: Removing Snap Ring
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Remove the differential bearing outer race and spacer from the torque converter housing.
Remove the differential bearing outer race from the transaxle case.