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: Tapping Differential Bearing Outer Race In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use the special tools to tap the output shaft bearing outer race in the transaxle case.

Fig 2: Tapping Output Shaft Bearing Outer Race In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 Using Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring.

Fig 4: Installing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 Snap Ring Using Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
1. Standard value: 0 - 0.16 mm (0 - 0.0063 in.)
Fig 6: Measuring End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
Install the return spring, second brake piston and snap ring.

Fig 7: Installing Return Spring, Second Brake Piston And Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move the special tool (MB991632) to measure the end play.
1. Standard value: 1.09 - 1.55 mm (0.042 - 0.06 in.)
Fig 8: Measuring End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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.
1. Reference: Pressure Plate Thickness
  A=Special tool end play measurement determined earlier in this step.
  1. Metric values: [A+2.0 mm) - 1.55 mm] to [(A+2.0 mm) - 1.09 mm]
  2. English values: [(A+0.079 in.) - 0.061 in.] to [(A+0.079 in.) - 0.042 in.]
Turn the transaxle over.

Fig 9: Identifying Pressure Plate Thickness
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the special tool (MD998913) in a dial gauge, and then move the special tool (MB991632) to measure the axial play.
1. Standard value: 1.65 - 2.11 mm (0.065 - 0.08 in.)
  
  Fig 10: Measuring Axial Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Reference: Pressure Plate Thickness
A=Special tool end play measurement determined earlier in this step.
1. Metric values: [(A+2.0 mm) - 2.11 mm] to [(A+2.0 mm) - 1.65 mm]
2. 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: Identifying Pressure Plate Thickness
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
1. Standard value: 23 Nm (17 ft.lbs.)
Fig 12: Tightening Mounting Bolts Of Output Shaft Bearing Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
1. Standard value: 167 Nm (123 ft.lbs.)
CAUTION: The lock nut has left-handed threads.

Fig 14: Tightening Lock Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
1. A=Operating amount
2. B=Thickness of the old spacer
3. Metric values: [A+B+0.015 mm] to [A+B+0.075 MM]
4. English values: [A+B+0.0006 in.] to [A+B+0.003 in.]
Fig 15: Measuring Operating Amount Of Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Prevent the lock nut from turning by staking it in two places.

Fig 16: Staking Lock Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the cap as shown in the figure.

Fig 17: Installing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use the special tool to install the transfer drive gear.

Fig 18: Installing Transfer Drive Gear Using Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the eight mounting bolts of the transfer drive gear to the specified torque.
1. Standard value: 34 Nm (25 ft.lbs.)
Fig 19: Tightening Mounting Bolts Of Transfer Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then install the parking pawl shaft.

Fig 20: Installing Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking roller support, and then the two parking roller support shafts.

Fig 21: Installing Parking Roller Support, Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary carrier assembly.

Fig 22: Installing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

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

Fig 24: Thrust Bearings, Thrust Races, And Thrust Washers Identification Table (1 Of 3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 25: Thrust Bearings, Thrust Races, And Thrust Washers Identification Table (2 Of 3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 26: Thrust Bearings, Thrust Races, And Thrust Washers Identification Table (3 Of 3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary reverse sun gear.

Fig 27: Installing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring.

Fig 28: Installing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the pressure plate, brake disc, and brake plate.

Fig 29: Installing Pressure Plate, Brake Disc, And Brake Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
30 Install the snap ring.

Fig 30: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 31: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 32: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the brake disc, brake plate, and pressure plate.

Fig 33: Installing Brake Disc, Brake Plate, And Pressure Plate
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the thrust bearing #5.
CAUTION: Be sure to install the thrust bearing in the correct direction.

Fig 36: Installing Thrust Bearing #5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 37: Installing Overdrive Clutch Hub And Thrust Bearing #6 To Reverse And Overdrive Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reverse and overdrive clutch, and thrust bearing #7.
CAUTION: Be careful about the installation direction of the thrust bearing.

Fig 38: Installing Reverse And Overdrive Clutch, And Thrust Bearing #7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the three O-rings.

Fig 39: Installing Three O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft bearing.

Fig 40: Installing Input Shaft Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 41: Identifying Seal Ring Identification Color
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 the chart on OIL PUMP for the appropriate parts number.
1. 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 42: Measuring End Play Of Underdrive Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Squeeze out the liquid gasket and apply it to the shown points of the rear cover.
1. 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 43: Identifying Points Of Rear Cover For Applying Liquid Gasket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the rear cover, and tighten its mounting bolts to the specified torque.

Fig 44: Installing Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub.

Fig 45: Installing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install thrust bearing #2.
CAUTION: Be sure to install the thrust bearing in the correct direction.

Fig 46: Installing Thrust Bearing #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.
Install the used thrust washer #1.

Fig 48: Installing Used Thrust Washer #1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use the special tool to install a new oil pump gasket and oil pump.

Fig 49: Installing New Oil Pump Gasket And Oil Pump Using Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the old gasket.
Tighten the oil pump mounting bolts to the specified torque.
1. 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 the chart on OIL PUMP for the appropriate parts number.
1. Standard value: 0.70 - 1.45 mm (0.0276 - 0.0569 in.)
Fig 50: Measuring End Play Of Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 51: Installing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential.

Fig 52: Installing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 53: Placing Solder On 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.
1. Standard value: 47 Nm (35 ft.lbs.)
Loosen the bolts, and remove the solder.

Fig 54: Installing Torque Converter Housing To Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use a micrometer to measure the thickness of the pressed solder. Select a spacer which thickness is within the following value. Refer to the chart on OIL PUMP for the appropriate parts number.
1. [T + 0.045 mm (0.0018 in.)] to [T + 0.105 mm (0.0041 in.)]
Fig 55: Measuring Thickness Of Pressed Solder
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the spacer selected in the above step.

Fig 56: Installing Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Assemble the spacer selected in step (60) to the torque converter housing. Use the special tool to press in the outer race.

Fig 57: Pressing Spacer With Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Squeeze out the liquid gasket and apply it to the shown area of torque converter.
1. 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 58: Identifying Area For Applying Liquid Gasket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the two O-rings.

Fig 59: Installing Two O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the torque converter, and then tighten its 18 mounting bolts to the specified torque.
1. Standard value: 47 Nm (35 ft.lbs.)
Fig 60: Installing Torque Converter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the manual control lever shaft and parking pawl rod.
Install the manual control lever shaft roller.

Fig 61: Installing Manual Control Lever Shaft And Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the accumulator pistons, new seal rings, and springs.
NOTE: The accumulator springs are identified as shown in the figure.

Fig 62: Identifying Accumulator Springs
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 63: Accumulator Springs Identification Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 64: Installing Accumulator Pistons, New Seal Rings, And Springs
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the strainer and second brake retainer oil seal.

Fig 65: Installing Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the solenoid valve harness, and then secure the snap ring to the connector groove.

Fig 66: Installing Solenoid Valve Harness And Securing Snap Ring To Connector Groove
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body, gasket, and two steel balls.

Fig 67: Installing Valve Body, Gasket, And Two Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the fluid temperature sensor.
Install the 28 valve body mounting bolts.

Fig 68: Installing Fluid Temperature Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Connect the valve body connectors.

Fig 69: Valve Body Connectors Description Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 70: Identifying Valve Body Connectors
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the manual control shaft detent.

Fig 71: Installing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply the liquid gasket to the valve body cover.
1. 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 72: Applying Liquid Gasket 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.
1. Standard value: 11 Nm (8.0 ft.lbs.)
Fig 73: Installing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the park/neutral position switch and manual control lever.

Fig 74: Installing Park/Neutral Position Switch And Manual Control Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft speed sensor and output shaft speed sensor.

Fig 75: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the eye bolt with a new gasket.
Install the oil cooler feed tube.
Install the oil dipstick.
Install the bracket.

Fig 76: Installing Torque Converter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the torque converter, and secure it so that the shown dimension (A) meets the reference value.
1. Reference value: approx. 9.4 mm (0.37 in.)
CAUTION: Apply ATF to the oil pump drive hub before installing the toque converter. Be careful not to damage the oil seal lip when installing the torque converter.