Disassembly And Assembly: Assembly

CAUTION:

Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
Do not use grease. Use petroleum jelly (i.e. Vaseline).
Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse new clutch discs or brake discs in ATF for at least two hours before assembling them.
When replacing a bushing, replace the assembly which it belongs to.
Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.

Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case. Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.

Fig 1: Installing Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the mounting bolts (eight pieces) of the transfer drive gear bearing to the specified torque.
Tightening torque: 34 ± 2 N.m (25 ± 1 ft-lb)

Fig 2: Tightening Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.

Fig 3: Installing Low-Reverse Brake Piston, Return Spring, And Spring Retainer Into Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Fit a new O-ring into the groove of one-way clutch inner race.

Fig 4: O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.

Fig 5: Identification Notches In One-Way Clutch Inner Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put the snap ring on the inner race.
Set special tools MD999577 and MD998924 as shown in the illustration, and then compress the one-way clutch inner race and install the snap ring.

Fig 6: Compressing One-Way Clutch Inner Race Using Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring onto the low-reverse brake piston.

Fig 7: Installing Wave Spring Onto Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the brake discs (six pieces), brake plates (five pieces) and snap ring as shown in the illustration.
NOTE: Do not install the pressure plate at this time.
Install special tool MB991632 on the brake disc.
Install the reaction plate and the used snap ring.
Move special tool MB991632 to measure the end play of reaction plate. Then replace the snap ring installed in step 11 to adjust the end play to standard value.
Standard value of end play:

0 - 0.16 mm (0 - 0.006 inch)
Install the brake discs (four pieces) and brake plates (three pieces) as shown in the illustration.
NOTE: Do not install the pressure plate at this time.

Fig 8: Measuring End Play Of Reaction Plate By Moving Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 9: Installing Return Spring, Second Brake Piston And Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Place special tool MB991632 on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.
Move special tool MB991632 and measure its movement.
Standard value of end play (Reference):

1.09 - 1.55 mm (0.043 - 0.061 inch)

Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

PRESSURE PLATE FOR SECOND BRAKE

THICKNESS SPECIFICATION

MOVEMENT AMOUNT mm (in)	THICKNESS mm (in)	ID SYMBOL
1.1 - 1.3 (0.043 - 0.051)	1.8 (0.071)	E
1.3 - 1.5 (0.051 - 0.059)	2.0 (0.079)	D
1.5 - 1.7 (0.059 - 0.067)	2.2 (0.087)	C
1.7 - 1.9 (0.067 - 0.075)	2.4 (0.094)	B
1.9 - 2.1 (0.075 - 0.083)	2.6 (0.102)	A
2.1 - 2.3 (0.083 - 0.091)	2.8 (0.110)	0

Turn the transaxle over so that the installation surface of the torque converter housing is facing up.

Fig 10: Measuring Special Tool Movements Using Dial Indicator
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 11: Checking Standard Value Of End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998913 in a dial gauge, and then move special tool MB991632 and measure its movement.
Standard value of end play (Reference):

1.65 - 2.11 mm (0.065 - 0.083 inch)

Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

PRESSURE PLATE FOR LOW-REVERSE BRAKE

THICKNESS SPECIFICATION

MOVEMENT AMOUNT mm (in)	THICKNESS mm (in)	ID SYMBOL
1.0 - 1.2 (0.039 - 0.047)	1.6 (0.063)	F
1.2 - 1.4 (0.047 - 0.055)	1.8 (0.071)	E
1.4 - 1.6 (0.055 - 0.063)	2.0 (0.079)	D
1.6 - 1.8 (0.063 - 0.071)	2.2 (0.087)	C
1.8 - 2.0 (0.071 - 0.079)	2.4 (0.094)	B
2.0 - 2.2 (0.079 - 0.087)	2.6 (0.102)	A
2.2 - 2.4 (0.087 - 0.094)	2.8 (0.110)	0
2.4 - 2.6 (0.094 - 0.102)	3.0 (0.118)	1

Fig 12: Special Tool Installation Position

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 13: Checking Standard Value Of End Play Using Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.

Remove all parts and special tools that were installed to take the measurements in steps 9 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.
Install the needle bearing as shown in the illustration.
Install the two seal rings.

Fig 14: Installing Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring into the groove of transaxle case output shaft bore.

Fig 15: Locating Identification Mark
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 16: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary carrier assembly.

Fig 17: Installing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary reverse sun gear.

Fig 18: Installing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring on the low-reverse brake piston.

Fig 19: Installing Wave Spring On Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the pressure plate that was selected in step 19. Next, install brake discs (six pieces) and brake plates (five pieces), one on top of the other.

Fig 20: Installing Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 21: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 22: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.

Fig 23: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install second brake discs (four pieces) and second brake plates (three pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.

Fig 24: Installing Second Brake Discs, Second Brake Plates And Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring and second brake piston.

Fig 25: Installing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the snap ring.

Fig 26: Installing Snap Ring

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IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

Fig 27: Identification Of Thrust Bearing, Thrust Races, And Thrust Washers

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

THICKNESS SPECIFICATION

SYMBOL	OD mm (in)	ID mm (in)	THICKNESS mm (in)	SYMBOL	OD mm (in)	ID mm (in)	THICKNESS mm (in)
NO. 1	59 (2.32)	47 (1.85)	1.8 (0.071)	NO. 8	48.9 (1.925)	37 (1.46)	1.8 (0.071)
	59 (2.32)	47 (1.85)	2.0 (0.079)		48.9 (1.925)	37 (1.46)	1.9 (0.075)
	59 (2.32)	47 (1.85)	2.2 (0.087)		48.9 (1.925)	37 (1.46)	2.0 (0.079)
	59 (2.32)	47 (1.85)	2.4 (0.094)		48.9 (1.925)	37 (1.46)	2.1 (0.083)
	59 (2.32)	47 (1.85)	2.6 (0.102)		48.9 (1.925)	37 (1.46)	2.2 (0.087)
	59 (2.32)	47 (1.85)	2.8 (0.110)		48.9 (1.925)	37 (1.46)	2.3 (0.091)
NO. 2	49 (1.93)	34 (1.34)	3.6 (0.142)		48.9 (1.925)	37 (1.46)	2.4 (0.094)
NO. 3	57 (2.24)	38.5 (1.52)	4.1 (0.161)		48.9 (1.925)	37 (1.46)	2.5 (0.098)
NO. 4	55.4 (2.18)	38.5 (1.52)	3.3 (0.130)		48.9 (1.925)	37 (1.46)	2.6 (0.102)
NO. 5	57 (2.24)	38.5 (1.52)	4.1 (0.161)	NO. 9	80 (3.15)	60 (2.36)	2.5 (0.098)
NO. 6	57 (2.24)	38.5 (1.52)	4.1 (0.161)	NO. 10	80 (3.15)	60 (2.36)	2.5 (0.098)
NO. 7	59 (2.32)	37 (1.46)	2.8 (0.110)	NO. 11	58 (2.28)	40.7 (1.60)	4.2 (0.165)
NO. 8	48.9 (1.925)	37 (1.46)	1.6 (0.063)	NO. 12	54.6 (2.15)	43(1.69)	3.0 (0.118)
NO. 8	48.9 (1.925)	37 (1.46)	1.7 (0.067)

CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.

Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.

Fig 28: Installing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Use care to install the thrust bearing in the proper direction.
Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.
Install the reverse and overdrive clutch.

Fig 29: Thrust Bearing Number 6 Installation Direction
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.

Fig 30: Installing Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
Install the seal rings (four pieces) in the grooves of the rear cover.

Fig 31: Tapping Input Shaft Rear Bearing In Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure the end play of the under drive sun gear by the following procedures:
1. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7.
2. Install the rear cover on the transaxle case and tighten the bolts to the specified torque.
  Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
3. Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.
4. Install the under drive clutch hub on the under drive sun gear.
5. Measure end play of the underdrive sun gear and record the measurement value.
  Standard value of end play (Reference):
  
  0.25 - 0.45 mm (0.010 - 0.017 inch)
6. After taking the measurement in steps (5), take out the installed parts in steps (1) through (4).
Fig 32: Measuring End Play Of Under Drive Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (six pieces).

Fig 33: Removing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the direct clutch accumulator piston and spring and then install the O-ring.
NOTE: Accumulator spring is identified as shown in the illustration.

Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 40 from the table below. Install it on thrust bearing number 7.

Fig 34: Clutch Accumulator Piston And Spring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

THICKNESS SPECIFICATION

MEASUREMENT VALUE mm (in)	THICKNESS mm (in)
0.3 - 0.4 (0.012 - 0.016)	1.6 (0.063)
0.4 - 0.5 (0.016 - 0.020)	1.7 (0.067)
0.5 - 0.6 (0.020 - 0.024)	1.8 (0.071)
0.6 - 0.7 (0.024 - 0.028)	1.9 (0.075)
0.7 - 0.8 (0.028 - 0.031)	2.0 (0.079)
0.8 - 0.9 (0.031 - 0.035)	2.1 (0.083)
0.9 - 1.0 (0.035 - 0.039)	2.2 (0.087)
1.0 - 1.1 (0.039 - 0.043)	2.3 (0.091)
1.1 - 1.2 (0.043 - 0.047)	2.4 (0.094)
1.2 - 1.3 (0.047 - 0.051)	2.5 (0.098)
1.3 - 1.4 (0.051 - 0.055)	2.6 (0.102)

CAUTION:

Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
Make sure the starting point and the ending point are about the middle between the bolts.

Apply a 1.6 mm (0.06 inch) diameter bead of sealant to the illustrated position of the rear cover.
Specified sealant:

Mitsubishi Part No. MD974421 or equivalent

NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes). Leaks will occur if the rear cover is installed after the sealant dries.

Fig 35: Grease Application Portion
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the rear cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)

NOTE: After installation, keep the sealed area away from ATF for approximately one hour.

Fig 36: Installing Rear Cover Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Install the thrust bearing with the indicated side facing down.
Install the thrust race number 12 and thrust bearing number 11.

Fig 37: Directions For Installing Thrust Race Number 12 And Thrust Bearing Number 11
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Finger-tighten the anchor plug and a new O-ring, then install the reduction brake band and direct clutch simultaneously.

Fig 38: Tightening Anchor Plug
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the direct clutch can be rotated only in the direction indicated in the illustration.
NOTE: If the clutch can be rotated in the other direction, remove and reinstall it correctly.

Fig 39: Direct Clutch Rotation Direction
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
51. Tighten the anchor plug to the specified torque.
Tightening torque: 98 ± 15 N.m (72 ± 11 ft-lb)

Fig 40: Tightening Anchor Plug To Specified Torque
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the direct planetary carrier assembly.

Fig 41: Installing Direct Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction brake spring and piston in position in the transmission case, then install the snap ring.

Fig 42: Installing Reduction Brake Spring, Piston And Snap Ring In Position In Transmission Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Adjust the reduction brake piston using the following procedure:
1. Remove the nut from the reduction brake piston.
2. Install the stopper of the special tool MB991633 to hold the reduction brake piston against rotation.
  
  Fig 43: Installing Stopper Of Special Tool
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Using a torque wrench fitted with the socket of the special tool MB991633, tighten the adjusting rod to 10 N.m (89 in-lb), then loosen it. Repeat this operation twice. Tighten the adjusting rod to 5 N.m (43 in-lb), then turn it back 5-1/2 (180 degrees) to 5-3/4 (270 degrees) turns.
  
  Fig 44: Tightening And Loosening Adjusting Rod Using Torque Wrench Fitted With Socket
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Install the nut on the adjusting rod and tighten the nut to 19 ± 3 N.m (14 ± 2 ft-lb) using the wrench of the special tool MB991633.
Fig 45: Installing Nut On Adjusting Rod Using Wrench Of Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction brake piston cover and snap ring.

Fig 46: Locating Reduction Brake Piston Cover Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 47: Installing Parking Pawl, Spacer, And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking roller support, and then insert the parking roller support shafts (two pieces).

Fig 48: Installing Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub to the underdrive sun gear.

Fig 49: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.

Fig 50: Installing Thrust Bearing In Correct Direction
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch.
Adjustment of input shaft end play and select the thrust washer number 1. (Refer to adjustment of transaxle - THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY .

Fig 51: Holding Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown in the illustration.
Install the new oil pump gasket on the transaxle case.
Install the oil pump and tighten the six mounting bolts to the specified torque.
Tightening torque: 29 ± 2 N.m (21 ± 1 ft-lb)

Fig 52: Installing Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the input shaft end play meets the standard value.
Standard value of end play:

0.70 - 1.45 mm (0.028 - 0.057 inch)

Fig 53: Checking Input Shaft End Play Values
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the pipe clamp bolts (two places), and tighten to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)

Fig 54: Locating Pipe Clamp Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 55: Installing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.

Fig 56: Tapping Differential Bearing Outer Race In Transaxle Case Using Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential.
Adjustment of differential case preload and select the spacer. (Refer to ADJUSTMENT OF TRANSAXLE .

Fig 57: Differential Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the selected spacer to the torque converter housing.

Fig 58: Locating Selected Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.

Fig 59: Tapping Differential Bearing Outer Race In Transaxle Case Using Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB991445 to press the outer race into housing.

Fig 60: Pressing Differential Bearing Outer Race Into Torque Converter Housing Using Special Tools
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.
Apply a 1.6 mm (0.06 inch) diameter bead of sealant to the torque converter housing in the area shown in the illustration.
Specified sealant:

Mitsubishi Part No. MD974421 or equivalent

Fig 61: Sealant Applying Area
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes). Leaks will occur if the rear cover is installed after the sealant dries.

NOTE: After installation, keep the sealed area away from ATF for approximately one hour.

Fig 62: Differential Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (two pieces).
Install the torque converter housing and then tighten its mounting bolts (twenty pieces) to the specified torque.
Tightening torque: 48 ± 6 N.m (35 ± 4 ft-lb)
Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
Install the manual control lever shaft and parking pawl rod.

Fig 63: Torque Converter Housing Mounting Bolts Tightening Sequence
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".
Insert the new seal rings in the grooves of the accumulator pistons.
NOTE: The piston and seal ring are common parts.

Fig 64: Inserting Manual Control Lever Shaft Roller
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the piston and spring of the reduction brake accumulator, then install the accumulator cover.

Fig 65: Snap Ring Location
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Identify the accumulator spring and insert it and the accumulator piston into each hole of the transaxle case.

NOTE: Accumulator springs are identified as shown in the illustration.

ACCUMULATOR SPRINGS REFERENCE

NO.	NAME	IDENTIFICATION "BLUEING"
1	For low-reverse brake	None
2	For underdrive clutch	Half
3	For second brake	Whole surface
4	For overdrive clutch	None

Fig 66: Inserting Seal Rings In Grooves Of Accumulator Pistons

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 67: Accumulator Piston

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the strainer and second brake retainer oil seal.

Fig 68: Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert a new O-ring to the groove of the solenoid valve harness connector.
Insert the solenoid valve harness connector into the hole from the inside of the transaxle case so it is oriented as shown in the illustration. Then secure the snap ring to the connector groove.

Fig 69: Inserting Solenoid Valve Harness Connector Into Hole From Inside Of Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
Install the valve body to the transaxle case.
Make sure that the manual valve's pin is in the groove in the detent plate of the manual control lever.

Fig 70: Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body mounting bolts (twenty seven pieces), and tighten to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)

Fig 71: Locating Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Attach the solenoid valve harness to the valve body by connecting all the connectors.

Install the fluid temperature sensor to the specified torque.

Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)

Fig 72: Fluid Temperature Sensor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CABLE COLOR REFERENCE

NO.	PARTS TO BE CONNECTED	SOLENOID VALVE HARNESS
NO.	PARTS TO BE CONNECTED	CABLE COLOR	CONNECTOR HOUSING COLOR
1	Underdrive solenoid valve	White, Red, Red	Black
2	Overdrive solenoid valve	Orange, Red	Black
3	Low-reverse solenoid valve	Brown, Yellow	Milky white
4	Second solenoid valve	Blue, Red, Red	Milky white
5	Damper clutch control solenoid valve	Blue, Yellow, Yellow	Black
6	Reduction solenoid valve	Green, Yellow, Yellow	Black

Fig 73: Manual Control Shaft Detent

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6.0 ± 1.0 N.m (53 ± 9 in-lb)
CAUTION:
- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.
Apply a 2.4 - 2.6 mm (0.09 - 0.10 inch) diameter bead of sealant or equivalent) to the valve body cover in the area shown in the illustration.
Specified sealant:

Mitsubishi Part No. MD974421 or equivalent

NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.

NOTE: After installation, keep the sealed area away from ATF for approximately one hour.

Fig 74: Sealant Applying Area
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)

Fig 75: Valve Body Cover Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Press Face "A" of the air breather to be on the same plane as the Face "B" of the transaxle case as shown in the illustration.

Fig 76: Pressing Face Of Air Breather
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Install the park/neutral position switch and tighten the bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the manual control lever and tighten the nut to the specified torque.
Tightening torque: 22 ± 3 N.m (16 ± 2 ft-lb)

Fig 77: Manual Control Lever And Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Apply ATF on the both sides of the new gasket and threads of the eyebolts, and then tighten to the specified torque.
Tightening torque: 24 ± 3 N.m (18 ± 2 ft-lb)
Tighten the oil cooler feed tube clamp bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the oil dipstick.
Install the control cable support brackets to the specified torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the roll stopper brackets.
Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)

Fig 78: Input And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.
Install the torque converter, and align it with the oil pump so that the shown in the illustration dimension "A" meets the reference value.
Reference value: Approximately 9.4 mm (0.37 inch)

Fig 79: Torque Converter Dimension
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.