Disassembly And Reassembly: Assembly

CAUTION: Never reuse the outer race.

Using the special tool MB991550, Install the outer race of the differential side bearing on the transaxle case.

Fig 1: Installing Outer Race Of Differential Side Bearing On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the transaxle case.

Fig 2: Installing Outer Race Of Reduction Gear Bearing On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply transmission fluid to the bearing so that the interference can be adjusted in a smooth condition.
- Measure the end play at more than two locations and obtain the average of the measurements.
Measure an interference (A) of the reduction gear assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the reduction gear assembly.

Fig 3: Measuring Interference Of Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Install the reduction gear assembly on the transaxle case.
  
  Fig 4: Identifying Transaxle Case Reduction Gear Assembly
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Set the outer race on the reduction gear bearing.
  
  Fig 5: Identifying Reduction Gear Bearing Outer Race
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L1 from the outer race to the end face of the transaxle case.
  
  Fig 6: Measuring Distance L1 From Outer Race To Transaxle Case End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Place a block on the end face of the converter housing and measure distance L2 to the reduction gear taper bearing shim mounting surface.
5. Calculate distance L3 from the end face of the converter housing to the outer race of the reduction gear assembly from the following formula.
  L3 = L2 - Height of block
6. Calculate the thickness of the reduction gear taper bearing shim from the following formula.
  
  Fig 7: Measuring Reduction Gear Taper Bearing Shim Thickness
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Thickness of reduction gear taper bearing shim = L3 - L1 + Interference
  
  Standard value: 0.16 - 0.22 mm (0.006 - 0.009 in)
  
  (For reduction gear preload)
CAUTION: Never reuse the reduction gear taper bearing shim.
Install a selected reduction gear taper bearing shim on the converter housing. Refer to "SERVICE DATA" for selecting the reduction gear taper bearing shim.

Fig 8: Identifying Reduction Gear Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the converter housing.

Fig 9: Installing Outer Race Of Reduction Gear Bearing On Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply transmission fluid to the bearing so that the interference can be adjusted in a smooth condition.
- Measure the end play at more than two locations and obtain the average of the measurements.
Measure an interference (A) of the differential assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the differential assembly.

Fig 10: Measuring Interference Of Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Install the differential assembly on the transaxle case.
  
  Fig 11: Identifying Differential Assembly On Transaxle Case
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Set the outer race on the differential side bearing.
  
  Fig 12: Locating Outer Race On Differential Side Bearing
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L1 from the outer race to the end face of the transaxle case.
  
  Fig 13: Measuring Distance L1 From Outer Race To Transaxle Case End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Measure distance L2 from the end face of the converter housing to the differential taper bearing shim mounting surface of the converter housing.
5. Calculate the thickness of the differential taper bearing shim from the following formula.
  Thickness of differential taper bearing shim = L2 - L1 + Interference
  
  Standard value: 0.19 - 0.25 mm (0.008 - 0.010 in)
  
  (For differential preload)
  
  Fig 14: Measuring Distance L2 From Converter Housing End Face To Differential Taper Bearing Shim Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION: Never reuse the differential taper bearing shim.
Install a selected differential taper bearing shim on the converter housing. Refer to "SERVICE DATA" for selecting the differential taper bearing shim.

Fig 15: Identifying Differential Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the special tool MB991445, Install the outer race of the differential side bearing on the converter housing.

Fig 16: Installing Outer Race Of Differential Side Bearing On Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 17: Identifying Transaxle Case O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E18 bolts.
Install the output gear set. Refer to the following or the exploded view for the tightening torque.

No. of bolts 10

Tightening torque: 41 ± 1 N.m (30 ± 1 ft-lb)

Fig 18: Identifying Output Gear Set Torx E18 Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the D-rings.
- Apply transmission fluid to the D-rings before installation.
Install D-rings on the low-reverse brake piston.

Fig 19: Identifying Low-Reverse Brake Piston D-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply transmission fluid to the low-reverse brake piston before installation.
Install the low-reverse brake piston on the transaxle case.

Fig 20: Identifying Transaxle Case Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the diaphragm spring.

Fig 21: Identifying Diaphragm Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the diaphragm spring retainer.

Fig 22: Identifying Diaphragm Spring Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tool MB992195, install the snap ring.

Fig 23: Installing Snap Ring Using Special Tool MB992195
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.

Measure the clearance (A) of the low-reverse brake using the following procedure. Refer to "SERVICE DATA" for the specified low-reverse brake clearance.

Fig 24: Measuring Low-Reverse Brake Clearance

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

While compressing the drive plates, driven plates and retaining plate, measure the thickness L1 of the pack.

Compression load [N (kgf)]

7056 - 8056 (720 - 822)

Fig 25: Compressing Drive Plates, Driven Plates And Retaining Plate

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 26: Measuring Thickness L1

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: If there is no appropriate plate, use the special tool, MD998917

Measure thickness L2 of the one-way clutch.

Fig 27: Measuring One-Way Clutch Thickness L2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure distance L3 from the end face of the transaxle case to the low-reverse brake piston.

Fig 28: Measuring Distance L3 From Transaxle Case End Face To Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Temporarily assemble the snap ring, one-way clutch and snap ring to the transaxle case.
Measure distance L4 from the end face of the transaxle case to the one-way clutch, while pulling up the one-way clutch.
Remove the temporarily assembled snap ring, one-way clutch and snap ring from the transaxle case.
Calculate the clearance using the following formula. Clearance = L3 - (L1 + L2 + L4)
Select an appropriate retaining plate so that the specified clearance is obtained. Refer to "SERVICE DATA" for selecting the retaining plate.

Fig 29: Removing Temporarily Assembled Snap Ring, One-Way Clutch And Snap Ring From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Standard value: 1.9 - 2.2 mm (0.07 - 0.09 in)

(For low-reverse brake clearance)

CAUTION:

Apply vaseline to the needle bearing before installation.
Ensure that the needle bearing faces the correct direction.

Install the needle bearing.

Fig 30: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply vaseline to the bearing race before installation.
Install the bearing race on the RR sun gear on the front side.

Fig 31: Identifying Bearing Race And RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR sun gear on the front side.

Fig 32: Identifying Front Side RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR carrier assembly.

Fig 33: Identifying Needle Bearing And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR carrier assembly.

Fig 34: Identifying RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Ensure that the various plates are installed in the correct order.
Install the low-reverse brake drive plate, driven plate and selected retaining plate on the transaxle case.

Fig 35: Identifying Low-Reverse Brake Drive Plate, Driven Plate And Selected Retaining Plate, Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, install the snap ring.

Fig 36: Installing Snap Ring Using Flat-Head Screwdriver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the one-way clutch.

Fig 37: Identifying One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, install the snap ring.

Fig 38: Installing Snap Ring Using Flat-Head Screwdriver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.

Measure the clearance (A) of the 2-6 brake using the following procedure. Refer to "SERVICE DATA" for the specified 2-6 brake clearance.

Fig 39: Measuring End Play Of 2-6 Brake

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

While compressing the drive plates, driven plates and retaining plate, measure thickness L1 of the pack.

Compression load [N (kgf)]

800 - 1800 (82 - 184)

Fig 40: Compressing Drive Plates, Driven Plates And Retaining Plate

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 41: Measuring Thickness L1

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: If there is no appropriate plate, use the special tool, MD998917

Measure distance L2 from the end face of the transaxle case to the snap ring.

Fig 42: Measuring Distance L2 From Transaxle Case End Face To Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: When measuring L3, use the same straight bar as used when L2 is measured.
Measure distance L3 from the end face of the side cover to the 2-6 brake piston.
Calculate the clearance using the following formula.
Clearance = L2 - (L1 + L3)
Select an appropriate retaining plate so that the specified clearance is obtained. Refer to "SERVICE DATA" for selecting the retaining plate.
Standard value: 1.9 - 2.2 mm (0.07 - 0.09 in)

(For 2-6 brake clearance)

Fig 43: Measuring Distance L3 From Side Cover End Face To 2-6 Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION:

Apply vaseline to the needle bearing before installation.
Ensure that the needle bearing faces the correct direction.

Install the needle bearing on the RR carrier assembly.

Fig 44: Identifying Needle Bearing And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR sun gear on the rear side.

Fig 45: Identifying Rear Side RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR sun gear on the rear side.

Fig 46: Identifying Needle Bearing And RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the high clutch hub.

Fig 47: Identifying High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the reduction internal gear.

Fig 48: Identifying Reduction Internal Gear Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction internal gear on the high clutch hub.

Fig 49: Identifying Reduction Internal Gear And High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the reduction internal gear.

Fig 50: Identifying Needle Bearing And Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction carrier.

Fig 51: Identifying Reduction Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction sun gear.

Fig 52: Identifying Reduction Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the reduction sun gear end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified reduction sun gear end play (A).

Fig 53: Checking Reduction Sun Gear End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.
  
  Fig 54: Checking Distance L1 From Reduction Carrier To Transaxle Case End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 from the reduction carrier to the reduction sun gear.
  
  Fig 55: Measuring Distance L2 From Reduction Carrier To Reduction Sun Gear
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 from the end face of the side cover to the end face of the high clutch support area.
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
5. Select an appropriate spacer so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the spacer.
  Standard value: 0.4 - 0.7 mm (0.02 - 0.03 in)
  
  (For reduction sun gear end play)
  
  Fig 56: Measuring End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the side cover end play (A) in the following procedure. Refer to "SERVICE DATA" for the specified side cover end play (A).

Fig 57: Checking Side Cover End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.
  
  Fig 58: Measuring Distance L1 From Reduction Carrier To Transaxle Case End Face
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 from the end face of the side cover to the needle bearing mounting surface.
  
  Fig 59: Measuring Distance L2 From Side Cover End Face To Needle Bearing Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 from the contact surface with the needle bearing of the high clutch drum to the snap ring of the cancel cover in the following procedure.
  
  Fig 60: Measuring Distance L3 From Needle Bearing Contact Surface And High Clutch Drum
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  1. Measure distance L4 from the high clutch drum edge to the snap ring of the cancel cover.
    
    Fig 61: Measuring Distance L4 From High Clutch Drum Edge To Cancel Cover Snap Ring
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Measure height L5 of the high clutch drum.
    
    Fig 62: Measuring Height L5 Of High Clutch Drum
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Measure distance L6 from the underside of the high clutch drum to the contact surface with the needle bearing.
  4. Calculate L3 using the following formula.
  L3 = L5 - (L4 + L6) + Thickness of straight bar
4. Calculate the end play using the following formula.
  End play = L2 - (L1 + L3) - Thickness of needle bearing
5. Select an appropriate needle bearing so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the needle bearing.
  
  Fig 63: Checking End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Standard value: 0.70 - 1.05 mm (0.028 - 0.041 in)
  
  (For side cover end play)
Install the high clutch assembly.

Fig 64: Identifying High Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Ensure that the various plates are installed in the correct order.
Install the 2-6 brake drive plate, driven plate and selected retaining plate on the transaxle case.

Fig 65: Identifying Brake Drive Plate, Driven Plate And Retaining Plate On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 66: Identifying Transaxle Case O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the spacer.
- Apply vaseline to the spacer and needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install an appropriate spacer and the needle bearing on the side cover.

Fig 67: Identifying Spacer And Needle Bearing
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 the sealant to the transaxle case mounting surface of the side cover (almost the center line of the surface).

SPECIFIED SEALANT (THREE BOND 1216B)

L1 mm (in)	3 - 5 (0.1 - 0.2)
L2 mm (in)	2.3 (0.09)

Fig 68: Identifying Sealant Applying Area On Transaxle Case Mounting Surface (Side Cover)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E16 bolts.

Install the side cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.

No. of bolts 14

Tightening torque: 27 ± 2 N.m (20 ± 1 ft-lb)

Fig 69: Identifying Side Cover Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the drum support end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified drum support end play (A).

Fig 70: Measuring Drum Support End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 between the end face of the RR internal gear splines and the oil pump mounting surface of the transaxle case.
  
  Fig 71: Measuring Distance L1 Between RR Internal Gear Splines End Face And Oil Pump Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 between the thrust washer mounting surface of the drum support and the oil pump mounting surface of the transaxle case.
  
  Fig 72: Measuring Distance L2 Between Drum Support Thrust Washer Mounting Surface And Oil Pump Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 using the following procedure.
  1. Install the FR carrier on the low clutch assembly.
    
    Fig 73: Identifying FR Carrier And Low Clutch Assembly
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    Apply vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
  2. Install the needle bearing on the FR carrier.
    
    Fig 74: Identifying Needle Bearing And FR Carrier
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the FR internal gear on the FR carrier.
    CAUTION:
    Apply vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
    Fig 75: Identifying FR Internal Gear And FR Carrier
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Install the needle bearing on the FR sun gear.
    
    Fig 76: Identifying Needle Bearing And FR Sun Gear
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  5. Install the FR sun gear.
    
    Fig 77: Identifying FR Sun Gear
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    Apply vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
  6. Install the needle bearing on the FR sun gear.
    
    Fig 78: Identifying FR Sun Gear Needle Bearing
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  7. Install the 3-5 reverse clutch assembly.
    
    Fig 79: Identifying Reverse Clutch Assembly
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Measure distance L3 between A and B.
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thrust washer thickness
5. Select an appropriate thrust washer so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the thrust washer.
  Standard value: 0 - 0.35 mm (0 - 0.014 in)
  
  (For drum support end play)
  
  Fig 80: Measuring Thrust Washer Thickness
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear assembly.

Fig 81: Identifying Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear lubrication tube.

Fig 82: Identifying Reduction Gear Lubrication Tube
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl.

Fig 83: Identifying Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl shaft.

Fig 84: Locating Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring.

Fig 85: Identifying Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the pawl shaft plate. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.9 N.m (70 in-lb)

Fig 86: Identifying Pawl Shaft Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential gear assembly.

Fig 87: Identifying Differential Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Ensure that the claws on the thrust washer are correctly engaged with the holes in the drum support.
- Apply vaseline to the thrust washer before installation.
Install an appropriate thrust washer on the drum support.

Fig 88: Identifying Drum Support Thrust Washer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low clutch assembly.

Fig 89: Identifying Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR carrier on the low clutch assembly.

Fig 90: Identifying Low Clutch Assembly FR Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR carrier.

Fig 91: Identifying FR Carrier And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR internal gear on the FR carrier.

Fig 92: Identifying FR Carrier And FR Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR sun gear.

Fig 93: Identifying Needle Bearing And FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR sun gear.

Fig 94: Identifying FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR sun gear.

Fig 95: Identifying Needle Bearing And FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the 3-5 reverse clutch assembly.

Fig 96: Identifying Reverse Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the 3-5 reverse clutch end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified 3-5 reverse clutch end play (A).

Fig 97: Measuring Reverse Clutch End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 between the oil pump assembly end face and A.
  
  Fig 98: Checking Distance L1 Between Oil Pump Assembly End Face And A
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 between A and the bearing race mounting surface.
  
  Fig 99: Measuring Distance L2 Between A And Bearing Race Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 between the oil pump mounting surface of the transaxle case and the needle bearing mounting surface of the 3-5 reverse clutch drum.
  
  Fig 100: Measuring Distance L3 Between Transaxle Case Oil Pump Mounting Surface And Needle Bearing Mounting Surface
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Measure thickness L4 of the needle bearing.
5. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - L4 - Bearing race thickness
6. Select an appropriate bearing race so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the bearing race.
  Standard value: 0.55 - 0.85 mm (0.022 - 0.034 in)
  
  (For 3-5 reverse clutch end play)
  
  Fig 101: Measuring Needle Bearing Thickness L4
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the 3-5 reverse clutch drum.

Fig 102: Identifying Reverse Clutch Drum Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft.

Fig 103: Identifying Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 104: Installing O-Ring On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the magnets on the oil strainer.

Fig 105: Identifying Oil Strainer Magnet
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the oil strainer.
- Apply transmission fluid to the O-ring of the oil strainer.

Install the oil strainer on the oil pump assembly. Refer to the following or the exploded view for the tightening torque.

Bolt code	A	B
Shank length mm (in)	25 (1.0)	16 (0.6)
No. of bolts	2	1

Tightening torque: 9.4 N.m (83 in-lb)

Fig 106: Identifying Oil Strainer And Oil Pump Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply vaseline to the bearing race before installation.

Install an appropriate bearing race on the oil pump assembly.

Fig 107: Identifying Oil Pump Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
- Apply the transmission fluid as little as possible because too much transmission fluid applied to the O-ring, could cause some confusion over oil leakage.
Install an O-ring on the oil pump.

Fig 108: Identifying Oil Pump O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil pump assembly and oil strainer as one unit. Refer to the following or the exploded view for the tightening torque.

No. of bolts 7

Tightening torque: 21 N.m (15 ft-lb)

Fig 109: Identifying Oil Pump Assembly And Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the input shaft.

Fig 110: Locating Input Shaft O-Ring
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 double bead of sealant in sections A.

Apply the sealant to the transaxle case mounting surface of the converter housing (almost the center line of the surface).

SPECIFIED SEALANT (THREE BOND 1216B)

L1 mm (in)	3 - 5 (0.1 - 0.2)
L2 mm (in)	2.3 (0.09)
L3 mm (in)	1.8 (0.07)

Fig 111: Identifying Sealant Applying Area On Transaxle Case Mounting Surface

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E20 bolts.

Install the converter housing on the transaxle case. Refer to the following or the exploded view for the tightening torque.

No. of bolts 19

Tightening torque: 47 ± 2 N.m (35 ± 1 ft-lb)

Fig 112: Locating Transaxle Case Converter Housing
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CAUTION:
- Never reuse the side oil seal.
- Apply transmission fluid to the side oil seal before installation.

Using the special tools MB992197 and MB992075, install a side oil seal.

Fig 113: Identifying Special Tools MB992197 And MB992075

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CAUTION:

Ensure that the side oil seal is installed to the specified depth shown in the table below.
Measure the installed depth of the seal at four locations diagonally. Any difference between the measurements should be no more than 0.3 mm (0.01 in).

On the transaxle case side

Seal depth (A) from case end face: 4.0 ± 0.5 mm (0.2 ± 0.02 in) or less

Fig 114: Identifying Seal Depth

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CAUTION:

Never reuse the O-rings.
Apply transmission fluid to the O-rings before installation.

Install an O-ring on the ATF adjusting bolt.
Install the ATF adjusting bolt on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.4 ± 2.4 N.m (65 ± 21 in-lb)

Fig 115: Identifying O-Ring And ATF Adjusting Bolt
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CAUTION:
- Never reuse the lip seals.
- Apply transmission fluid to the lip seals before installation.
Install the lip seals on the transaxle case.

Fig 116: Identifying Transaxle Case Lip Seals
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Install the detent spring. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 4.9 N.m (43 in-lb)

Fig 117: Identifying Detent Spring
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Install the bracket on the oil temperature sensor.
Install the oil temperature sensor on the control valve. Refer to the following view for the tightening torque.
Tightening torque: 7.9 N.m (70 in-lb)

Fig 118: Identifying Bracket And Oil Temperature Sensor
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CAUTION: Check the oil pressure switch connectors (each indicated with an arrow) for correct fit.
Install the terminal assembly on the control valve.

Fig 119: Locating Terminal Assembly Control Valve
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CAUTION: Apply transmission fluid to the manual valve before installation.
Install the manual valve on the control valve.

Fig 120: Identifying Manual Control Valve
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Press the terminal body into the transaxle case.

Fig 121: Identifying Transaxle Case Terminal Body
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CAUTION: Ensure that the notch in the manual valve is engaged with the lug on the manual plate.

Fig 122: Identifying Transaxle Case Terminal Body
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Install the control valve assembly on the transaxle case.

Fig 123: Installing Control Valve Assembly On Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Mounting bolt A is a hexagon head bolt.
- Mounting bolt B is a hexagon socket head bolt.

Install the control valve assembly mounting bolts A and B. Refer to the following or the exploded view for tightening torque.

Bolt code	A	B
Shank length mm (in)	71.5 (2.82)	58.0 (2.28)
No. of bolts	5	4

Tightening torque: 7.9 N.m (70 in-lb)

Fig 124: Identifying Control Valve Assembly Mounting Bolts

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CAUTION:

Never reuse the control valve cover gasket.
Thoroughly clean the control valve cover gasket mounting surface of the transaxle case so that it is completely free of moisture, lubricant and the old gasket.

Install the control valve cover gasket on the transaxle case.

Fig 125: Identifying Transaxle Case Control Valve Cover Gasket
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Install the control valve cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.

No. of bolts 16

Tightening torque: 9.0 ± 0.9 N.m (80 ± 8 in-lb)

Fig 126: Locating Transaxle Case Bolts
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CAUTION: Never reuse the snap ring.
Install a snap ring on the terminal body.

Fig 127: Identifying Terminal Body Snap Ring
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CAUTION: Never reuse the copper washers.
Refer to the following or the exploded view for the tightening torque to install the cooler tube (OUT) onto the side cover.
Eye bolt tightening torque: 33 ± 3 N.m (29 ± 2 ft-lb)

Bracket tightening torque: 22 ± 1 N.m (16 ± 1 ft-lb)

Fig 128: Identifying Cooler Tube (Out) Onto Side Cover
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CAUTION: Never reuse the copper washers.

Refer to the following or the exploded view for the tightening torque to install the cooler tube (IN) on the side cover.

Tightening torque: 33 ± 3 N.m (29 ± 2 ft-lb)

Fig 129: Identifying Side Cover Cooler Tube (IN)

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CAUTION: Ensure that the cooler tube (IN) is against the stop on the side cover.

Fig 130: Identifying Cooler Tube (IN)

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CAUTION: Ensure that the stud bolts protrude from the case as much as indicated in the table below.

Stud bolt code	1	2
Projection amount mm (in)	39.9 (1.57)	61.4 (2.42)

Install stud bolt 1 and 2 on the transaxle case.

Fig 131: Identifying Transaxle Case Stud Bolts
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the baffle plate.
Install the baffle plate on the converter housing. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 6.6 ± 1.0 N.m (58 ± 9 in-lb)

Fig 132: Identifying Baffle Plate O-Ring
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the pressure test port bolt.
Install the pressure test port bolt on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.4 N.m (65 in-lb)

Fig 133: Identifying Pressure Test Port Bolt O-Ring
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the water-cooled transmission fluid cooler.

Fig 134: Identifying Water-Cooled Transmission Fluid Cooler O-Ring
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Install the water-cooled transmission fluid cooler on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 4.3 ± 0.6 N.m (38 ± 16 in-lb)

Fig 135: Identifying Water-Cooled Transmission Fluid Cooler And Transaxle Case
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CAUTION:
- Never reuse the transmission range switch.
- When loosely installing the switch, insert it squarely onto the manual shaft. (Do not hold the switch at an angle.)
Install an transmission range switch using the following procedure.
1. Loosely install an transmission range switch on the manual shaft.
  
  Fig 136: Identifying Transmission Range Switch
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Install the manual control lever on the manual shaft. Install the spring washer and jam nut on the manual shaft. Refer to the following or the exploded view for the tightening torque.
  Tightening torque: 22 ± 3 N.m (17 ± 2 ft-lb)
3. Set the manual shaft to Range N.
  
  Fig 137: Installing Manual Control Lever On Manual Shaft
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Align the hole in the transmission range switch with the hole in the shift plate. With the holes aligned, insert a pin (ø5 mm) or equivalent through the holes. Now, tighten the bolt to the specified torque shown in the following or in the exploded view. Refer to the following or the exploded view for the tightening torque.
  Tightening torque: 5.9 N.m (52 in-lb)
  
  Fig 138: Aligning Hole In Transmission Range Switch
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the turbine sensor.
Install the turbine sensor on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 139: Identifying Turbine Sensor O-Ring
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the vehicle speed sensor.
Install the vehicle speed sensor on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 140: Identifying Transaxle Case Vehicle Speed Sensor
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CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Install the torque converter on the transaxle. Ensure that the dimension A is to the specification.

Dimension A mm (in) 11.6 (0.46)
Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)

Fig 141: Measuring Torque Converter End Play
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Install the oil filler tube and oil level gage on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 11 ± 1 N.m (97 ± 8 in-lb)
Install the harness bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the corrugate clamp bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the roll rod adapter bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)
Install the transfer on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 69 ± 9 N.m (51 ± 6 ft-lb)