Disassembly And Reassembly: Disassembly

CAUTION: Do not disassemble parts other than those described in this volume.

Remove the transfer from the transaxle.
Remove the roll rod adapter bracket from the transaxle.
Remove the harness bracket from the transaxle.
Remove the oil filler tube and oil level gage from the transaxle.
Remove the control cable bracket and breather hose from the transaxle.
Remove the corrugate clamp bracket from the transaxle.
Remove the torque converter from the transaxle.

Fig 1: Removing Torque Converter From Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the vehicle speed sensor from the transaxle case.
Remove the O-ring from the vehicle speed sensor.

Fig 2: Identifying Transaxle Case Vehicle Speed Sensor
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Remove the turbine sensor from the transaxle case.
Remove the O-ring from the turbine sensor.

Fig 3: Identifying Transaxle Case Turbine Sensor
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Remove the manual control lever from the manual shaft.

Fig 4: Identifying Manual Shaft Control Lever
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Remove the transmission range switch.

Fig 5: Identifying Transmission Range Switch
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Remove the water-cooled transmission fluid cooler from the transaxle case.

Fig 6: Identifying Water-Cooled Transmission Fluid Cooler And Transaxle Case
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Remove the O-ring from the water-cooled transmission fluid cooler.

Fig 7: Identifying Water-Cooled Transmission Fluid Cooler O-Ring
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Remove the pressure test port bolt from the transaxle case.
Remove the O-ring from the pressure test port bolt.

Fig 8: Identifying Pressure Test Port Bolt O-Ring
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Remove the baffle plate from the converter housing.
Remove the O-ring from the baffle plate.

Fig 9: Identifying Baffle Plate O-Ring
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Remove stud bolts from the transaxle case.

Fig 10: Identifying Transaxle Case Stud Bolts
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Remove the cooler tube (IN) from the side cover.

Fig 11: Identifying Side Cover Cooler Tube (In)
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Remove the cooler tube (OUT) from the side cover.

Fig 12: Identifying Side Cover Cooler Tube (Out)
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CAUTION: Be careful not to break the terminal body.
Remove the snap ring from the terminal body and push the terminal body into the transaxle case.

Fig 13: Identifying Terminal Body Snap Ring
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Remove the control valve cover from the transaxle case.

No. of bolts 16

Fig 14: Locating Transaxle Case Bolts
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Remove the control valve cover gasket from the transaxle case.

Fig 15: Identifying Control Valve Cover Gasket And 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.

Remove control valve assembly mounting bolts A and B.

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

Fig 16: Identifying Control Valve Assembly Mounting Bolts

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CAUTION: Remove the control valve assembly by pulling it straight.

Remove the control valve assembly from the transaxle case.

Fig 17: Removing Control Valve Assembly From Transaxle Case
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CAUTION: Be careful not to drop the manual valve.
Remove the manual valve from the control valve.

Fig 18: Identifying Manual Control Valve
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Remove the oil temperature sensor and bracket from the control valve.
Remove the bracket from the oil temperature sensor.

Fig 19: Identifying Bracket And Oil Temperature Sensor
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Remove the terminal assembly from the control valve.

Fig 20: Identifying Terminal Assembly And Control Valve
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Remove the detent spring.

Fig 21: Identifying Detent Spring
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Remove lip seals from the transaxle case.

Fig 22: Identifying Transaxle Case Lip Seals
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Remove the transmission fluid adjusting bolt from the transaxle case.
Remove the O-ring from the transmission fluid adjusting bolt.

Fig 23: Identifying Transmission Fluid Adjusting Bolt
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CAUTION: Mounting bolts are Torx E20 bolts.
Remove converter housing mounting bolts.

No. of bolts 19

Fig 24: Locating Converter Housing Mounting Bolts
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Lightly tap the converter housing with a plastic hammer or equivalent to remove.

Fig 25: Tapping Converter Housing
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Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the converter housing.

Fig 26: Removing Outer Race Of Reduction Gear Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear taper bearing shim from the converter housing.

Fig 27: Identifying Converter Housing Reduction Gear Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the converter housing.

Fig 28: Removing Outer Race Of Differential Side Bearing From Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential taper bearing shim from the converter housing.

Fig 29: Identifying Converter Housing Differential Taper Bearing Shim
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Remove the O-ring from the input shaft.

Fig 30: Locating Input Shaft O-Ring
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Remove the oil pump assembly and oil strainer as one unit.

No. of bolts 7

Fig 31: Identifying Oil Pump Assembly And Oil Strainer
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Remove the oil strainer from the oil pump assembly.

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

Fig 32: Identifying Oil Strainer And Oil Pump Assembly

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the magnet from the oil strainer.

Fig 33: Identifying Oil Strainer Magnet
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Remove the O-ring from the transaxle case.

Fig 34: Removing O-Ring From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft.

Fig 35: Identifying Input Shaft
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Remove the bearing race and needle bearing from the 3-5 reverse clutch drum.

Fig 36: Identifying Bearing Race And Needle Bearing
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Remove the 3-5 reverse clutch assembly.

Fig 37: Identifying Reverse Clutch Assembly
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Remove the needle bearing from the FR sun gear.

Fig 38: Identifying Needle Bearing And FR Sun Gear
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Remove the FR sun gear.

Fig 39: Identifying FR Sun Gear
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Remove the needle bearing from the FR sun gear.

Fig 40: Identifying Needle Bearing And FR Sun Gear
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Remove the FR internal gear and FR carrier as one unit.

Fig 41: Identifying FR Internal Gear And FR Carrier
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Remove the FR internal gear and needle bearing from the FR carrier.

Fig 42: Identifying FR Internal Gear And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the low clutch assembly.

Fig 43: Identifying Low Clutch Assembly
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Remove the thrust washer from the drum support.

Fig 44: Identifying Drum Support Thrust Washer
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Remove the differential assembly.

Fig 45: Identifying Differential Assembly
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Remove the pawl shaft plate.

Fig 46: Identifying Pawl Shaft Plate
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Remove the return spring.

Fig 47: Identifying Return Spring
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Remove the parking pawl shaft.

Fig 48: Locating Parking Pawl Shaft
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Remove the parking pawl.

Fig 49: Identifying Parking Pawl
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Remove the reduction gear lubrication tube.

Fig 50: Identifying Reduction Gear Lubrication Tube
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Remove the reduction gear assembly.

Fig 51: Identifying Reduction Gear Assembly
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CAUTION: Mounting bolts are Torx E16 bolts.
Remove the side cover.

No. of bolts 14

Fig 52: Identifying Side Cover Mounting Bolts
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Remove the spacer and needle bearing from the side cover.

Fig 53: Identifying Spacer And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 54: Identifying Transaxle Case O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the high clutch assembly.

Fig 55: Identifying High Clutch Assembly
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Remove the reduction sun gear.

Fig 56: Identifying Reduction Sun Gear
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Remove the reduction carrier.

Fig 57: Identifying Reduction Carrier
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Remove the needle bearing from the reduction internal gear.

Fig 58: Identifying Needle Bearing And Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction internal gear from the high clutch hub.

Fig 59: Identifying Reduction Internal Gear And High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the reduction internal gear.

Fig 60: Identifying Needle Bearing And Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the high clutch hub.

Fig 61: Identifying High Clutch Hub
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Remove the needle bearing from the RR sun gear on the rear side.

Fig 62: Identifying Needle Bearing And RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the RR sun gear on the rear side.

Fig 63: Identifying Rear Side RR Sun Gear
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Remove the needle bearing from the RR carrier assembly.

Fig 64: Identifying Needle Bearing And RR Carrier Assembly
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CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.

Fig 65: Identifying 2-6 Brake Retaining Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, remove the snap ring.

Fig 66: Removing Snap Ring Using Flat-Head Screwdriver
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch and RR carrier assembly as one unit.

Fig 67: Identifying One-Way Clutch And RR Carrier Assembly
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Separate the one-way clutch and RR carrier assembly.

Fig 68: Identifying One-Way Clutch And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR carrier assembly.

Fig 69: Identifying Needle Bearing And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, remove the snap ring.

Fig 70: Removing Snap Ring Using Flat-Head Screwdriver
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CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
Remove the low-reverse brake retaining plate, drive plate and driven plate.

Fig 71: Identifying Low-Reverse Brake Retaining Plate, Drive And Driven Plate
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Remove the RR sun gear on the front side.

Fig 72: Identifying Front Side RR Sun Gear
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Remove the bearing race from the RR sun gear on the front side.

Fig 73: Identifying Bearing Race And RR Sun Gear
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Remove the needle bearing.

Fig 74: Identifying Needle Bearing
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Using the special tool MB992195, remove the snap ring.

Fig 75: Removing Snap Ring Using Special Tool MB992195
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Remove the diaphragm spring retainer.

Fig 76: Identifying Diaphragm Spring Retainer
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Remove the diaphragm spring.

Fig 77: Identifying Diaphragm Spring
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CAUTION: Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.
Feed air through the oil hole as indicated in the illustration to remove the low-reverse brake piston from the transaxle case.

Fig 78: Identifying Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove D-rings from the low-reverse brake piston.

Fig 79: Identifying Low-Reverse Brake Piston D-Rings
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CAUTION: Mounting bolts are Torx E18 bolts.
Remove the Output gear set.

No. of bolts 10

Fig 80: Identifying Output Gear Set
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Remove the O-ring from the transaxle case.

Fig 81: Identifying Transaxle Case O-Ring
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CAUTION: Do not damage the transaxle case when removing the side oil seal.
Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.

Fig 82: Removing Side Oil Seal From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the transaxle case equivalent.

Fig 83: Removing Outer Race Of Reduction Gear Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the transaxle case.

Fig 84: Removing Outer Race Of Differential Side Bearing From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.