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 Transmission fluid.
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: Identifying Input Shaft Speed Sensor & 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 4: Park/Neutral Position Switch & Manual Control Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 5: Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 body by disconnecting the fluid temperature sensor and all the connectors.

Fig 7: Identifying 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 8: Locating Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 9: Identifying 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 10: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 11: Strainer & Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove each accumulator piston and spring.

PART NUMBER REFERENCE

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

Fig 12: Identifying Accumulator Pistons

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 13: Manual Control Lever Shaft Roller & Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (eighteen pieces), and then remove the torque converter housing.
Remove the differential bearing outer race and spacer from the torque converter housing.

Fig 14: Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (two pieces).

Fig 15: O-rings Location
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.

Fig 16: Identifying Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 17: Identifying Oil Filter
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Remove the oil pump mounting bolts (six pieces).

Fig 18: 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 19: Removing Oil Pump Using Special Tool (MD998333)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 20: Identifying Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 21: Holding Input Shaft
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Remove thrust bearing number 2.

Fig 22: Removing Thrust Bearing Number 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 23: Identifying Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 24: 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 25: 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 26: Rear Cover & Input Shaft Rear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 27: O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 28: Removing Overdrive Clutch & Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 29: Removing Overdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 30: Removing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 31: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 32: Removing Snap Ring
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Remove the second brake piston and the return spring.

Fig 33: Removing Second Brake Piston & Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure plate, second brake discs (three pieces) and second brake plates (two pieces).

Fig 34: Pressure Plate, Second Brake Discs & Second Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 35: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 36: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reaction plate and the brake disc.

Fig 37: Removing Reaction Plate & Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 38: 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 39: Removing Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 40: 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 41: 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 42: Removing Transfer Drive Gear Bearing Mounting Bolts (1 Of 2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 43: Removing Transfer Drive Gear Bearing Mounting Bolts (2 Of 2)
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 Screwdriver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a chisel, straighten the staked portions from the output shaft lock nut.

Fig 46: Straightening Staked Portions From Output Shaft Lock Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 47: Removing Output Shaft Lock Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolts.

Fig 48: Identifying Bearing Retainer Mounting Bolts
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Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 49: Removing Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.
Remove the snap ring.
Remove the differential bearing outer race from the transaxle case.

Fig 50: Removing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.