Disassembly And Assembly: Disassembly

CAUTION:

Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
The working area should be covered with a rubber mat to keep it clean at all times.
Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
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.
Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
If the transaxle body has been damaged, disassemble and clean the cooler system.

Remove the transfer and O-ring < W4A5A >
Use a dial gauge to measure the input shaft end play.
Remove the torque converter.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt, gaskets and the oil cooler feed tube.

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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.
Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.

Fig 3: Identifying Manual Control Lever And Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sealing cap and o-ring.

Fig 4: Identifying Sealing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 5: Identifying Valve Body Cover
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Remove the manual control shaft detent.

Fig 6: Identifying Manual Control Shaft Detent
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Disconnect the solenoid valve harness from the valve by undoing the fluid temperature sensor and all the connectors.

Fig 7: Identifying Solenoid Valve Harness From Valve Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Make sure that the manual control lever and the park/neutral position switch are removed. See step 8.
- Do not remove the bolts (four pieces) shown in the illustration.
Remove the valve body mounting blots(twenty seven places).

Fig 8: Locating Valve Body Mounting Blots
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket and the two steel balls.

Fig 9: Removing Valve Body Gasket And Two Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector and then push the connector into the transaxle case and remove the solenoid valve harness.

Fig 10: Identifying Snap Ring From Connector
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 11: Identifying Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring

Fig 12: Identifying Accumulator Piston And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 13: Identifying Manual Control Lever Shaft And Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 14: Identifying Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (18 pieces), and then remove the torque converter housing.
Remove the differential bearing outer race and spacer from the torque converter housing.

Fig 15: Identifying O-rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (two pieces).

Fig 16: Number Name Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.
Remove the differential bearing outer race from the transaxle case.

Fig 17: Removing Differential Bearing Outer Race From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 18: Removing Oil Filter
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Remove the oil pump mounting bolts (six pieces).
Install special tool MD998333 in hole "A".

Fig 19: Removing Oil Pump Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 20: Turning Special Tools MD998333 To Removing Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 21: Removing Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 22: Removing Underdrive Clutch And Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 23: Removing Thrust Bearing Number 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 24: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the rear cover.
Remove thrust race number 8.
Remove the seal rings (four pieces).
Remove the input shaft rear bearing.

Fig 25: Removing Input Shaft Rear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 26: Identifying O-Rings (Three Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 27: Removing Reverse And Overdrive Clutch And Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 28: Removing Overdrive Clutch Hub And Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 29: Removing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 30: Removing Planetary Reverse Sun Gear
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Remove the snap ring.

Fig 31: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 32: Removing Second Brake Piston And Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure plate, brake discs and brake plates.

Fig 33: Removing Pressure Plate Brake Discs And Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 34: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 35: Removing Snap Ring
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Remove the reaction plate and the brake disc.

Fig 36: Removing Reaction Plate And Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 37: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.

Fig 38: Removing Brake Plates Brake Discs And Pressure plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 39: Removing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 40: Removing Spacer And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the two parking roller support shafts, and then remove the parking roller support.

Fig 41: Removing Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998338 and MD998924, compress the one-way clutch inner race.
  NOTE: This illustration shows F4A5A.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
  
  Fig 42: Removing One-Way Clutch Inner Race Using Special Tools
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the four transfer drive gear bearing mounting bolts. Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

Fig 43: Removing Remaining Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 44: Removing Transfer Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cap by inserting a screw driver into the center of the cap and prying it up.

Fig 45: Removing Cap By Inserting A Screw Driver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a chisel, remove the staked nut from the output shaft.

Fig 46: Using Chisel And Removing Staked Nut From Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 47: Using Special Tools And Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolts.

Fig 48: Removing Bearing Retainer Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 49: Removing Output Shaft Taper Roller Bearing And Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the outer race and the spacer.
Remove the snap ring.

Fig 50: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.