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 transmission fluid to friction components, rotating parts, and sliding parts before installation. Immerse new clutch discs or brake discs in transmission fluid 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 Transfer Drive Gear Bearing & Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the mounting bolts (seven pieces) of the transfer drive gear bearing to the specified torque.
Tightening torque: 34 ± 2 N.m (25 ± 1 ft-lb)

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

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

Fig 4: O-ring & One-Way Clutch Inner Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Check where the identification notches of the one-way clutch inner race are. Install the one-way clutch inner race to the transfer drive gear bearing so that either of the identification notches can be located on the line A - A.

Fig 5: Identification Notches & Transmission Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put the snap ring on the inner race.
Set special tools MD998903 and MD998924 as shown in illustration, and then compress the one-way clutch inner race and install the snap ring.

Fig 6: Compressing One-Way Clutch Inner Race
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 MB991631 on the brake disc.
Install the reaction plate and the used snap ring.
Move special tool MB991631 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.

Fig 8: Installing Brake Discs, Brake Plates & Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Standard value: 0 - 0.16 mm (0 - 0.0063 inch)

(For brake reaction plate end play)
Install the brake discs (three pieces) and brake plates (two pieces) as shown in the illustration.
NOTE: Do not install the pressure plate at this time.
Place special tool MB991631 on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.

Fig 9: Installing Brake Discs & Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move special tool MB991631 and measure its movement.
Standard value (Reference):

0.79 - 1.25 mm (0.0311 - 0.0492 inch)

(For second brake end play)

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

Fig 10: Measuring Pressure Plate Movement Using Special Tool MB991631

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 11: Measuring Pressure Plate Movement

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR SECOND BRAKE

ID SYMBOL AND THICKNESS CHART

MOVEMENT AMOUNT mm (in)	THICKNESS mm (in)	ID SYMBOL
0.6 - 0.8 (0.024 - 0.031)	1.6 (0.063)	L
0.8 - 1.0 (0.031 - 0.039)	1.8 (0.071)	1
1.0 - 1.2 (0.039 - 0.047)	2.0 (0.079)	0
1.2 - 1.4 (0.047 - 0.055)	2.2 (0.087)	2
1.4 - 1.6 (0.055 - 0.063)	2.4 (0.094)	4
1.6 - 1.8 (0.063 - 0.071)	2.6 (0.102)	6

Turn the transaxle over so that the installation surface of the torque converter housing is facing up.
Install special tool MD998913 in a dial gauge, and then move special tool MB991631 and measure its movement.

Standard value (Reference):

1.65 - 2.11 mm (0.0649 - 0.0831 inch)

(For low-reverse brake end play)

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

Fig 12: Turning Transaxle Using Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR LOW-REVERSE BRAKE

ID SYMBOL AND THICKNESS CHART

MOVEMENT AMOUNT mm (in)	THICKNESS mm (in)	ID SYMBOL
1.3 - 1.5 (0.051 - 0.059)	1.6 (0.063)	L
1.5 - 1.7 (0.059 - 0.067)	1.8 (0.071)	1
1.7 - 1.9 (0.067 - 0.075)	2.0 (0.079)	0
1.9 - 2.1 (0.075 - 0.083)	2.2 (0.087)	2
2.1 - 2.3 (0.083 - 0.091)	2.4 (0.094)	4
2.3 - 2.5 (0.091 - 0.098)	2.6 (0.102)	6
2.5 - 2.7 (0.098 - 0.106)	2.8 (0.110)	8
2.7 - 2.9 (0.106 - 0.114)	3.0 (0.118)	D

Fig 13: Measuring Pressure Plate Movement

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 snap ring into the groove of transaxle case output shaft bore.
Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.

Fig 14: Tapping Output Shaft Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the bolt, as it has had sealant applied.
Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Tightening torque: 29 ± 2 N.m (21 ± 1 ft-lb)

Fig 15: Output Shaft Bearing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.

Fig 16: Installing Collar Using Special Tool (MD998350)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply transmission fluid to a new lock nut, and use special tools MB990607 and MB991625 to tighten the lock nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
Tightening torque: 170 ± 10 N.m (125 ± 7 ft-lb)

NOTE: The lock nut is reverse threaded.

Fig 17: Installing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move the output shaft to measure the end play and record the measurement value.
Standard value (reference):

0.01 - 0.09 mm (0.0004 - 0.0035 inch)

(For output shaft preload)

Fig 18: Measuring Output Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parts that were installed in steps 22 to 25.

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

SPACER FOR OUTPUT SHAFT

ID SYMBOL AND THICKNESS CHART

MOVEMENT AMOUNT mm (in)	THICKNESS mm (in)	ID SYMBOL
1.81 - 1.85 (0.0713 - 0.0728)	1.88 (0.0740)	88
1.85 - 1.89 (0.0728 - 0.0744)	1.92 (0.0756)	92
1.89 - 1.93 (0.0744 - 0.0760)	1.96 (0.0772)	96
1.93 - 1.97 (0.0760 - 0.0776)	2.00 (0.0787)	00
1.97 - 2.01 (0.0776 - 0.0791)	2.04 (0.0803)	04
2.01 - 2.05 (0.0791 - 0.0807)	2.08 (0.0819)	08
2.05 - 2.09 (0.0807 - 0.0823)	2.12 (0.0835)	12
2.09 - 2.13 (0.0823 - 0.0839)	2.16 (0.0850)	16
2.13 - 2.17 (0.0839 - 0.0854)	2.20 (0.0866)	20
2.17 - 2.21 (0.0854 - 0.0870)	2.24 (0.0882)	24
2.21 - 2.25 (0.0870 - 0.0886)	2.28 (0.0898)	28
2.25 - 2.29 (0.0886 - 0.0902)	2.32 (0.0913)	32
2.29 - 2.33 (0.0902 - 0.0917)	2.36 (0.0929)	36
2.33 - 2.37 (0.0917 - 0.0933)	2.40 (0.0945)	40
2.37 - 2.41 (0.0933 - 0.0949)	2.44 (0.0961)	44
2.41 - 2.45 (0.0949 - 0.0965)	2.48 (0.0976)	48
2.45 - 2.49 (0.0965 - 0.0980)	2.52 (0.0992)	52
2.49 - 2.53 (0.0980 - 0.0996)	2.56 (0.1008)	56
2.53 - 2.57 (0.0996 - 0.1012)	2.60 (0.1024)	60
2.57 - 2.61 (0.1012 - 0.1028)	2.64 (0.1039)	64
2.61 - 2.65 (0.1028 - 0.1043)	2.68 (0.1055)	68
2.65 - 2.69 (0.1043 - 0.1059)	2.72 (0.1071)	72
2.69 - 2.73 (0.1059 - 0.1075)	2.76 (0.1087)	76

Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 28.
Stake the lock nut with a punch (two places).

Fig 19: Staking Lock Nut With Punch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.

Fig 20: Installing Cap Using Special Tools MB990931 & MB990938 (1 Of 2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 21: Installing Cap Using Special Tools MB990931 & MB990938 (2 Of 2)
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.
Install the planetary reverse sun gear.

Fig 23: Installing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring on the low-reverse brake piston.

Fig 24: 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 25: Installing Brake Discs & Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 26: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 27: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.

Fig 28: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install second brake discs (three pieces) and second brake plates (two pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.

Fig 29: Installing Brake Discs
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring and second brake piston.

Fig 30: Installing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 31: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SYMBOL AND THICKNESS CHART

SYMBOL	OD mm (in)	ID mm (in)	THICKNESS mm (in)
NO. 1	59 (2.32)	47 (1.85)	1.8 (0.071)
	59 (2.32)	47 (1.85)	2.0 (0.079)
	59 (2.32)	47 (1.85)	2.2 (0.087)
	59 (2.32)	47 (1.85)	2.4 (0.094)
	59 (2.32)	47 (1.85)	2.6 (0.102)
	59 (2.32)	47 (1.85)	2.8 (0.110)
NO. 2	49 (1.93)	34 (1.34)	3.6 (0.142)
NO. 3	49 (1.93)	34 (1.34)	3.6 (0.142)
NO. 4	46 (1.81)	31 (1.22)	3.3 (0.130)
NO. 5	49 (1.93)	34 (1.34)	3.6 (0.142)
NO. 6	49 (1.93)	34 (1.34)	3.6 (0.142)
NO. 7	59 (2.32)	37 (1.46)	2.8 (0.110)
NO. 8	48.9 (1.925)	37 (1.46)	1.6 (0.063)
	48.9 (1.925)	37 (1.46)	1.7 (0.067)
	48.9 (1.925)	37 (1.46)	1.8 (0.071)
	48.9 (1.925)	37 (1.46)	1.9 (0.075)
	48.9 (1.925)	37 (1.46)	2.0 (0.079)
	48.9 (1.925)	37 (1.46)	2.1 (0.083)
	48.9 (1.925)	37 (1.46)	2.2 (0.087)
	48.9 (1.925)	37 (1.46)	2.3 (0.091)
	48.9 (1.925)	37 (1.46)	2.4 (0.094)
	48.9 (1.925)	37 (1.46)	2.5 (0.098)
	48.9 (1.925)	37 (1.46)	2.6 (0.102)