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.

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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.

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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.

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Install the reduction gear assembly on the transaxle case.

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Set the outer race on the reduction gear bearing.

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Measure distance L1 from the outer race to the end face of the transaxle case.

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Place a block on the end face of the converter housing and measure distance L2 to the reduction gear taper bearing shim mounting surface.
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
Calculate the thickness of the reduction gear taper bearing shim from the following formula.
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)

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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.

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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.

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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.

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Install the differential assembly on the transaxle case.

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Set the outer race on the differential side bearing.

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Measure distance L1 from the outer race to the end face of the transaxle case.

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Measure distance L2 from the end face of the converter housing to the differential taper bearing shim mounting surface of the converter housing.
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)

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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.

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

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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 transaxle case.

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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)

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CAUTION:
- Never reuse the D-rings.
- Apply transmission fluid to the D-rings before installation.
Install D-rings on the low-reverse brake piston.

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

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Install the diaphragm spring.

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Install the diaphragm spring retainer.

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Using the special tool MB992195, install the snap ring.

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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.

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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)

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

Measure thickness L2 of the one-way clutch.

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Measure distance L3 from the end face of the transaxle case to the low-reverse brake piston.

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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.

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

(For low-reverse brake clearance)

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CAUTION:

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

Install the needle bearing.

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

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Install the RR sun gear on the front side.

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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.

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Install the RR carrier assembly.

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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.

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Using a flat-head screwdriver or equivalent, install the snap ring.

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Install the one-way clutch.

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Using a flat-head screwdriver or equivalent, install the snap ring.

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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.

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

Compression load (N (kgf)

800 - 1800 (82 - 184)

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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.

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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)

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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.

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Install the RR sun gear on the rear side.

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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.

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Install the high clutch hub.

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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.

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Install the reduction internal gear on the high clutch hub.

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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.

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Install the reduction carrier.

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Install the reduction sun gear.

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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).

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Measure distance L1 from the reduction carrier to the end face of the transaxle case.

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Measure distance L2 from the reduction carrier to the reduction sun gear.

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Measure distance L3 from the end face of the side cover to the end face of the high clutch support area.
Calculate the end play using the following formula.
End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
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)

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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).

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Measure distance L1 from the reduction carrier to the end face of the transaxle case.

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Measure distance L2 from the end face of the side cover to the needle bearing mounting surface.

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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.

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Measure distance L4 from the high clutch drum edge to the snap ring of the cancel cover.

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Measure height L5 of the high clutch drum.

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Measure distance L6 from the underside of the high clutch drum to the contact surface with the needle bearing.
Calculate L3 using the following formula.

L3 = L5 - (L4 + L6) + Thickness of straight bar

Calculate the end play using the following formula.
End play = L2 - (L1 + L3) - Thickness of needle bearing
Select an appropriate needle bearing so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the needle bearing.
Standard value: 0.70 - 1.05 mm (0.028 - 0.041 in)

(For side cover end play)

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Install the high clutch assembly.

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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.

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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 transaxle case.

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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.

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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)

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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)

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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).

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Measure distance L1 between the end face of the RR internal gear splines and the oil pump mounting surface of the transaxle case.

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Measure distance L2 between the thrust washer mounting surface of the drum support and the oil pump mounting surface of the transaxle case.

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Measure distance L3 using the following procedure.

Install the FR carrier on the low clutch assembly.

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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.

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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.

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Install the needle bearing on the FR sun gear.

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Install the FR sun gear.

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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.

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Install the 3-5 reverse clutch assembly.

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Measure distance L3 between A and B.

Calculate the end play using the following formula.
End play = L3 - (L1 - L2) - Thrust washer thickness
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)

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Install the reduction gear assembly.

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Install the reduction gear lubrication tube.

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Install the parking pawl.

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Install the parking pawl shaft.

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Install the return spring.

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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)

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Install the differential gear assembly.

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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.

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Install the low clutch assembly.

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Install the FR carrier on the low clutch assembly.

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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.

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Install the FR internal gear on the FR carrier.

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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.

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Install the FR sun gear.

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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.

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Install the 3-5 reverse clutch assembly.

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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).

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Measure distance L1 between the oil pump assembly end face and A.

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Measure distance L2 between A and the bearing race mounting surface.

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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.

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Measure thickness L4 of the needle bearing.
Calculate the end play using the following formula.
End play = L3 - (L1 - L2) - L4 - Bearing race thickness
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)

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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.

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Install the input shaft.

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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 transaxle case.

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Install the magnets on the oil strainer.

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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)

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CAUTION: Apply vaseline to the bearing race before installation.

Install an appropriate bearing race on the oil pump assembly.

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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.

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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)

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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 input shaft.

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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

SEALANT SPECIFICATION

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

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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)

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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.

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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

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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)

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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.

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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)

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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)

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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.

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CAUTION: Apply transmission fluid to the manual valve before installation.
Install the manual valve on the control valve.

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Press the terminal body into the transaxle case.

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CAUTION: Ensure that the notch in the manual valve is engaged with the lug on the manual plate.

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Install the control valve assembly on the transaxle case.

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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)

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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.

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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)

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CAUTION: Never reuse the snap ring.
Install a snap ring on the terminal body.

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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)

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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)

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

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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.

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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)

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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)

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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.

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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)

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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.

Loosely install an transmission range switch on the manual shaft.

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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)

Set the manual shaft to Range N.

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Align the hole in the transmission range switch with the hole in the shift plate. With the holes aligned, insert a pin ( 5 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)

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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 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)

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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)

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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)
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)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.