545RFE - Service Information: Installation

NOTE: Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free of any debris. The hub must be smooth to avoid damaging pump seal at installation.

Fig 1: Identifying Gearshift Cable, Gearshift Cable Bracket And Manual Shift Lever

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

1. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever (3) and shift cable bracket (2), from the original transmission onto the replacement transmission.
   Fig 2: Identifying Straightedge And Scale

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2. Lubricate oil pump seal lip with transmission fluid.
3. Align converter and oil pump.
4. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
5. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13 mm (1/2 in.) (1) to rear of straightedge (2) when converter is fully seated.
6. Temporarily secure converter with C-clamp.
   Fig 3: Identifying Engine And Transmission

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7. Position transmission on jack and secure it with chains.
8. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment. 
9. Apply a light coating of high temperature grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
10. Raise transmission and align the torque converter with the drive plate and transmission converter housing with the engine block.
11. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.
12. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
13. Install two bolts to attach the transmission to the engine.
14. Install remaining torque converter housing to engine bolts. Tighten to 68 N.m (50 ft. lbs.).
15. Install transfer case, if equipped. Tighten transfer case nuts to 35 N.m (26 ft. lbs.).
    Fig 4: Identifying Rear Transmission Mount And Crossmember

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16. Install rear transmission crossmember (1). Tighten crossmember to frame bolts to 68 N.m (50 ft. lbs.).
17. Install rear support to transmission (2). Tighten bolts to 47 N.m (35 ft. lbs.).
18. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 N.m (35 ft. lbs.). Tighten the clevis bracket to rear support bolt to 68 N.m (50 ft. lbs.).
19. Remove engine support fixture.
    Fig 5: Identifying Gearshift Cable, Gearshift Cable Bracket And Manual Shift Lever

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20. Connect gearshift cable (1) to transmission.
    Fig 6: Identifying Transmission Solenoid/TRS Assembly And Transmission

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21. Connect the wiring harness connector to the solenoid and pressure switch assembly (2) connector. Be sure transmission harnesses are properly routed.
Fig 7: Identifying Input Speed Sensor And Transmission
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22. Connect the wiring harness connector to the input speed sensor (2).
    Fig 8: Identifying Output Speed Sensor And Transmission

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23. Connect the wiring harness connector to the output speed sensor (2).
    Fig 9: Identifying Line Pressure Sensor And Transmission

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24. Connect the wiring harness connector to the line pressure sensor (2).
    Fig 10: Identifying Cooler Line Fittings And Clips

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    CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.
25. Install torque converter-to-driveplate bolts.

    Tighten bolts to 31 N.m (270 in. lbs.).

26. Install starter motor and cooler line bracket.
27. Connect cooler lines to transmission.
    Fig 11: Identifying Engine Transmission Collar, Engine And Transmission

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28. Install transmission fill tube.
29. Install exhaust components.
30. Install the structural dust cover (2) onto the transmission and the engine. For 3.7L, refer to INSTALLATION or for 4.7L, refer to INSTALLATION .
    Fig 12: Identifying Skid Plate, Transmission Crossmember And Frame Rails

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31. Align and install the front propeller shaft, if necessary. (Refer to PROPELLER SHAFT/SHAFT - PROPELLER FRONT/INSTALLATION )
32. Align and install the rear propeller shaft. (Refer to PROPELLER SHAFT/SHAFT - PROPELLER REAR/INSTALLATION )
33. Adjust gearshift cable if necessary.
34. Install any skid plates (1) removed previously.
35. Lower vehicle.
36. Fill transmission with Mitsubishi ATF +4, Automatic Transmission Fluid.