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.
Work on a rubber mat and 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 torque converter
Use a dial gauge to measure the input shaft end play
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 air breather by inserting a screwdriver into the air breather and prying it up.

Fig 2: Removing Air Breather
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 3: Removing Input 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 4: Removing Manual Control Lever Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the Sealing cap and o-ring.

Fig 5: Identifying Sealing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 6: Removing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control shaft detent.

Fig 7: Removing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disconnect the solenoid valve harness from the valve body by disconnecting the fluid temperature sensor and all the connectors.

Fig 8: Disconnecting Fluid Temperature Sensor
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 bolts (twenty seven pieces).

Fig 9: Removing Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 10: Removing Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.

Fig 11: Identifying Connector Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 12: Identifying Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove each accumulator piston and spring.

Fig 13: Identifying Accumulator Pistons

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

ITEM NUMBER SPECIFICATION

NUMBER	NAME
1	For low-reverse brake
2	For underdrive clutch
3	For second brake
4	For overdrive clutch

Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 14: Removing Manual Control Lever Shaft Roller
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (eighteen pieces), and then remove the torque converter housing.

Fig 15: Removing Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential bearing outer race and spacer from the torque converter housing.
Remove the O-rings (two pieces).

Fig 16: Differential Bearing Outer Race & Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.

Fig 17: Removing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 18: Identifying Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump mounting bolts (six pieces).

Fig 19: Identifying Oil Pump Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998333 in the position shown in the illustration.
Turn special tool MD998333 to remove the oil pump.
Remove the oil pump gasket

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

Fig 21: Identifying 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/Installing Underdrive Clutch & Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 23: Removing Thrust Bearing No. 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 24: Identifying Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 25: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking roller support shafts (two pieces), and then remove the parking pawl and parking roller support.

Fig 26: Removing Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the rear cover and input shaft rear bearing.
Remove thrust race number 8.
Remove the seal rings (four pieces).

Fig 27: Removing Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 28: Removing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 29: Removing Reverse & Overdrive Clutch & Thrust Bearing No. 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 30: Removing Overdrive Clutch Hub & Thrust Bearing No. 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 31: Removing Thrust Bearing No. 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 32: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring

Fig 33: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 34: Removing Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (two pieces), brake discs (three pieces) and pressure plate.

Fig 35: Removing Brake Plates, Brake Disc & Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 36: Removing Planetary Carrier Assembly
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 reaction plate and the brake disc.

Fig 38: Removing Reaction Plate & Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 39: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.
NOTE: *Includes the brake discs removed in Step 48.

Fig 40: Removing Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring

Fig 41: Removing Wave Spring
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 MD998903 and MD998924, compress the one-way clutch inner race
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
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear bearing mounting bolts (three or four pieces).
Then, turn the gear 1/8 turn (45 degrees) and remove the remaining bolts.

Fig 43: Removing Transfer Drive Gear Bearing Mounting 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 screwdriver into the center of the cap and prying it up.

Fig 45: Removing Cap Using Inserting Screwdriver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a chisel, straighten the staked portions from the output shaft jam nut.

Fig 46: Straightening Staked Portions
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: 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 & Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.

Fig 50: Removing Outer Race & Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.
Remove the differential bearing outer race from the transaxle case.