DISASSEMBLY AND REASSEMBLY
1.
 Torque converter
2.
 Front roll stopper bracket
3.
 Harness bracket
4.
 Rear roll stopper bracket
5.
 Corrugate clamp bracket
6.
 Control cable bracket
7.
 Oil level gauge
8.
 Oil filler tube
9.
 Eye bolt
10.
 Oil cooler feed tube
11.
 Air breather
12.
 Input shaft speed sensor
13.
 Output shaft speed sensor
14.
 Manual control lever
15.
 Inhibitor switch
16.
 Sealing cap

17.
 Valve body cover
18.
 Manual control shaft detent
19.
 Valve body
20.
 Gasket
21.
 Snap ring
22.
 Solenoid valve harness
23.
 Strainer
24.
 Second brake retainer oil seal
25.
 Accumulator piston
26.
 Accumulator spring
27.
 Accumulator spring

28.
 Manual control lever shaft roller
29.
 Manual control lever shaft
30.
 Parking pawl rod
31.
 Converter housing
32.
 Outer race
33.
 Spacer
34.
 Differential
35.
 Oil filter
36.
 Oil pump
37.
 Gasket
38.
 Thrust washer #1
39.
 Underdrive clutch and input shaft
40.
 Thrust bearing #2
41.
 Underdrive clutch hub
42.
 Parking pawl shaft
43.
 Spacer
44.
 Parking pawl spring
45.
 Parking roller support shaft
46.
 Parking pawl
47.
 Parking roller support

48.
 Rear cover
49.
 Thrust race #8
50.
 Seal ring
51.
 Input shaft rear bearing
52.
 Thrust bearing #7
53.
 Reverse and overdrive clutch
54.
 Thrust bearing #6
55.
 Overdrive clutch hub
56.
 Thrust bearing #5
57.
 Planetary reverse sun gear
58.
 Snap ring
59.
 Second brake
60.
 Return spring
61.
 Pressure plate
62.
 Second brake disc
63.
 Second brake plate
64.
 Planetary carrier
65.
 Snap ring
66
 Reaction plate
67.
 Snap ring
68.
 Low-reverse brake disc
69.
 Low-reverse brake plate
70.
 Pressure plate

71.
 Wave spring
72.
 Snap ring
73.
 One-way clutch inner race
74.
 O-ring
75.
 Spring retainer
76.
 Return spring
77.
 Low-reverse brake
78.
 Transfer drive gear
79.
 Cap
80.
 Lock nut
81.
 Output shaft
82.
 Taper roller bearing
83.
 Collar
84.
 Outer race
85.
 Spacer
86.
 Snap ring
87.
 Outer race

DISASSEMBLY


caution
  • The automatic transmission includes many high-precision parts. Handle these parts extremely carefully not to scratch or damage them during disassembly and reassembly.
  • Work bench should be covered with a rubber mat and keep it clean at all times.
  • Do not wear any cloth gloves and do not use any rags during disassembly. Use only nylon cloth or paper towels if necessary.
  • All removed parts must be washed clean. Metal parts may be washed in an ordinary solvent, but they should be dried completely using compressed air.
  • Clutch discs, plastic thrust plates and rubber parts should be washed in automatic transmission fluid (ATF) and keep them free of dirt after washing.
  • If the transmission has been found damaged and repaired, also disassemble and clean the ATF cooler system.
1.Remove the torque converter.

2.Use a dial gauge to measure the input shaft end play.
3.Remove each bracket.
4.Remove the oil level gauge.
5.Remove the oil filler tube.
6.Remove the oil cooler feed tube.

7.Remove the air breather.

8.Remove the input shaft speed sensor and output shaft speed sensor.

9.
caution Be sure to remove the manual control lever mounting nut before removing the valve body. If the removal sequence is reversed, the inhibitor switch could be broken.
Remove the manual control lever, then remove the inhibitor switch.

10.Remove the sealing cap.

11.Remove the valve body cover.

12.Remove the manual control shaft detent.

13.Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.

14.
caution Do not remove the bolts (four pieces) shown in the illustration.
Remove the valve body mounting bolts (twenty seven pieces).

15.
caution Be careful not to lose the steel balls (2 pieces).
Remove the valve body, gasket and the steel balls (2 pieces).

16.Remove the snap ring from the connector, then push the connector into the transmission case to remove the solenoid valve harness.

17.Remove the strainer and second brake retainer oil seal.

18.Remove the accumulator pistons and their springs.
No.
 Accumulator
1
 For low-reverse brake
2
 For underdrive clutch
3
 For second brake
4
 For overdrive clutch
note Put tags to the removed accumulator pistons and springs so that you will be able to reinstall them in the correct positions.
19.Remove the manual control lever shaft roller.

20.Remove the manual control lever shaft and the parking pawl rod.

21.Remove the converter housing mounting bolts, then remove the converter housing.
22.Remove the differential bearing outer race and spacer from the converter housing.

23.Remove the O-rings (2 pieces).

24.Remove the differential.

25.Remove the oil filter.

26.Remove the oil pump mounting bolts.

27.Install the special tools Oil pump remover as shown in the drawing.
28.Screw the special tools evenly to remove the oil pump.
29.Remove the oil pump gasket.

30.Remove the thrust washer #1.

31.Holding the input shaft, remove the underdrive clutch.

32.Remove the thrust bearing #2.

33.Remove the underdrive clutch hub.

34.Pull out the parking pawl shaft, then remove the spacer and spring.

35.Remove the parking roller support shafts (2 pieces), then remove the parking pawl and parking roller support.

36.Remove the rear cover.
37.Remove the thrust race #8.
38.Remove the seal rings (4 pieces).
39.Remove the input shaft rear bearing.

40.Remove the O-rings (three pieces).

41.Remove the reverse and overdrive clutch and the thrust bearing #7.

42.Remove the overdrive clutch hub and thrust bearing #6.

43.Remove the thrust bearing #5.

44.Remove the planetary reverse sun gear.

45.Remove the snap ring.

46.Remove the second brake piston and return spring.

47.Remove the pressure plate, brake discs (three pieces) and brake plates (two pieces).

48.Remove the planetary carrier.

49.Remove the snap ring.

50.Remove the reaction plate and brake discs.

51.Remove the snap ring.

52.Remove the brake plates (five pieces), brake discs (six* pieces) and pressure plate.
note *Includes the brake discs removed in step 50.

53.Remove the wave spring.

54.Use the special tools to press down the one-way clutch inner race, then remove the snap ring.

  • Spring compressor (MD998903)
  • Spring compressor retainer (MD998924)
55.Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.

56.Remove the four or three of the transfer drive gear mounting bolts. Then turn the gear 1/8 of a turn (45°) and remove the remaining three or four bolts.

57.Remove the transfer drive gear.

58.Remove the cap.

59.Unbend the locking tab of the output shaft lock nut.

60.
caution The lock nut thread is left-handed.
Use the special tools to remove the output shaft lock nut.

  • Torque wrench socket (MB990607)
  • Special socket (MB991625)

61.Remove the bearing retainer mounting bolts.

62.Remove the output shaft, taper roller bearing and collar by striking the rear end of the output shaft.

63.Remove the spacer and outer race.
64.Remove the differential bearing outer race from the transmission case.

REASSEMBLY
caution
  • Never reuse any gasket, O-ring, and oil seal. Always replace them with new ones.
  • Never use any product other than blue petrolatum jelly or white Vaseline to lubricate or hold parts during assembly.
  • Apply ATF to friction elements, rotating parts, and sliding parts before installation.
    Soak new clutch discs or brake discs in ATF for at least two hours before installing them.
  • Never apply sealant or adhesive to gaskets.
  • When a bushing requires replacement, replace the assembly of which the bushing forms a part.
  • Never use any cloth gloves or any rags during reassembly. Use only nylon cloth or paper towels if necessary.
  • Change also the ATF in the cooler circuit.

1.Use the special tool Guide (MD998412) to install the transfer drive gear.

2.Tighten the transfer drive gear mounting bolts to the specified torque of 34 ± 2 N·m.
3.Install the low-reverse brake piston, return spring and spring retainer.
4.Fit a new O-ring in the groove in the one-way clutch inner race.

5.Locate the identification notches on the one-way clutch inner race, then install the one-way clutch inner race in the transfer drive gear bearing with the notches aligned with the A-A line as shown in the drawing.

6.Use the special tools to hold down the one-way clutch inner race, then fit the snap ring in position.

  • Spring compressor (MD998903)
  • Spring compressor retainer (MD998924)

7.Install the wave spring on the low-reverse brake piston.

8.Install the brake discs (six pieces), brake plates (five pieces) and snap ring for the low-reverse brake as shown in the drawing.
note Do not install the pressure plate yet.
9.Install the special tool Clearance dummy plate (MB991631) on the stack of the brake discs.
10.Install the reaction plate and the snap ring that was removed during disassembly.
11.Move up the special tool to check whether the end play of the reaction plate is within the standard value range. If necessary, remove the snap ring that has been installed in step 10 and install another appropriate snap ring.
Standard value: 0 - 0.16 mm

12.Install the brake discs (three pieces) and brake plates (two pieces) for the second brake as shown in the drawing.
note Do not install the pressure plate yet.
13.Install the special tool Clearance dummy plate (MB991631).
14.Install the return spring, second brake piston, and snap ring.


15.Move the special tool Clearance dummy plate (MB991631) to measure the amount of movement. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

Available pressure plates
Amount of movement mm
 Thickness mm
 Identification mark
0.6 - 0.8
 1.6
 L
0.8 - 1.0
1.8
 1
1.0 - 1.2
2.0
 0
1.2 - 1.4
2.2
 2
1.4 - 1.6
2.4
 4
1.6 - 1.8
2.6
 6
Standard value (reference): 0.79 - 1.25 mm
16.Turn the transmission upside down.

17.Move the special tool Clearance dummy plate (MB991631) and measure the amount of movement using a dial gauge fitted with the special tool Dial gauge extension (MD998913). Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
Standard value of low-reverse brake end play (reference): 1.65 - 2.11 mm

Available pressure plates
Amount of movement mm
 Thickness mm
 Identification mark
1.3 - 1.5
 1.6
 L
1.5 - 1.7
 1.8
 1
1.7 - 1.9
 2.0
 0
1.9 - 2.1
 2.2
 2
2.1 - 2.3
 2.4
 4
2.3 - 2.5
 2.6
 6
2.5 - 2.7
 2.8
 8
2.7 - 2.9
 3.0
 D
18.Remove all the parts has been installed in steps 7. through 17.
19.Install the snap ring in the groove formed in the output shaft hole in the transmission case.

20.Use the special tool to drive the output shaft bearing outer race into the transmission case.

  • Installer adapter (MB990930)
  • Handle (MB990938)

21.
caution Do not reuse the output shaft bearing retainer mounting bolts as they are pre-coated with a sealant.
Install the output shaft bearing retainer mounting bolts and tighten them to the specified torque of 29 ± 2 N·m.

22.Use the special tool Bearing installer (MD998350) to install the collar and taper roller bearing on the output shaft.

23.
caution The lock nut thread is left-handed.
Apply ATF to a new lock nut, and use the special tool to tighten the lock nut to the specified torque of 170 ± 10 N·m. Then loosen the nut one turn, then tighten it again to the specified torque.

  • Torque wrench socket (MB990607)
  • Special socket (MB991625)

24.Move the output shaft and to measure the amount of movement; record the measurement.
25.Remove all the parts having installed in steps 20. through 23.
26.Select a spacer whose thickness corresponds to the measurement recorded in step 24. from the table below and install the spacer.

Available spacer
Amount of movement mm
 Thickness mm
 Identification mark
1.81 - 1.85
 1.88
 88
1.85 - 1.89
 1.92
 92
1.89 - 1.93
 1.96
 96
1.93 - 1.97
 2.00
 00
1.97 - 2.01
 2.04
 04
2.01 - 2.05
 2.08
 08
2.05 - 2.09
 2.12
 12
2.09 - 2.13
 2.16
 16
2.13 - 2.17
 2.20
 20
2.17 - 2.21
 2.24
 24
2.21 - 2.25
 2.28
 28
2.25 - 2.29
 2.32
 32
2.29 - 2.33
 2.36
 36
2.33 - 2.37
 2.40
 40
2.37 - 2.41
 2.44
 44
2.41 - 2.45
 2.48
 48
2.45 - 2.49
 2.52
 52
2.49 - 2.53
 2.56
 56
2.53 - 2.57
 2.60
 60
2.57 - 2.61
 2.64
 64
2.61 - 2.65
 2.68
 68
2.65 - 2.69
 2.72
 72
2.69 - 2.73
 2.76
 76
27.Repeat steps 20. through 23. to reinstall the parts.

28.Stake the lock nut (at two places).

29.Use the special tools to install the cap as shown in the drawing.

  • Installer adapter (MB990931)
  • Handle (MB990938)

30.Install the planetary carrier assembly.

31.Install the planetary reverse sun gear.

32.Install the wave spring on the low-reverse brake piston.

33.Install the pressure plate that has been selected in step 17. Then install the brake discs (five pieces) and brake plates (five pieces).

34.Install the snap ring.

35.Install the brake disc and the reaction plate.

36.Install the snap ring that has been selected in step 11.

37.Install the brake discs (three pieces), brake plates (two pieces), and the pressure plate that has been selected in step 15.

38.Install the return spring and second brake.

39.Install the snap ring.

40.
caution Be sure to install the thrust bearing with the indicated side facing down.
Install the thrust bearing #5.
O.D. mm
 I.D. mm
 Thickness mm
 Marking
 O.D. mm
 I.D. mm
 Thickness mm
 Marking
59
 47
 1.8
 #1
 48.9
 37
 1.6
 #8
2.0
 1.7
2.2
 1.8
2.4
 1.9
2.6
 2.0
2.8
 2.1
49
 34
 3.6
 #2
 2.2
49
 34
 3.6
 #3
 2.3
45.3
 31
 3.3
 #4
 2.4
49
 34
 3.6
 #5
 2.5
49
 34
 3.6
 #6
 2.6
59
 37
 2.8
 #7



IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

41.
caution Be sure to install the thrust bearing with the indicated side facing down.
Install the overdrive clutch hub and thrust bearing #6 in the reverse and overdrive clutch.

42.
caution Be sure to install the thrust bearing with the indicated side facing down.
Install the reverse and overdrive clutch and thrust bearing #7.

43.Use the special tool Handle (MB990938) to press-fit the input shaft rear bearing into the rear cover.
44.Install the seal rings (four places).

45.Measure the end play of the underdrive sun gear using the following procedure to select a thrust race #8 of proper thickness.
(1) Install the thinnest thrust race #8 (thickness: 1.6mm) on the thrust bearing #7.
(2) Install the rear cover on the transmission and tighten the bolts to the specified torque of 23 ± 3 N·m.
(3) Turn the transmission upside down, thus making the torque converter housing mounting end face up.
(4) Install the underdrive clutch hub on the underdrive sun gear.
(5) Measure the end play of the underdrive sun gear and record the measurement.
Standard value (reference): 0.25 - 0.45 mm
(6) Remove all the parts installed in substeps (1) through (4).

46.Install the O-rings (three places).
47.Select a thrust race #8 whose thickness corresponds to the measurement recorded in substep (5) of step 46. from the table below and install the thrust race on the thrust bearing #7.
Measurement mm
 Thickness mm
0.3 - 0.4
 1.6
0.4 - 0.5
 1.7
0.5 - 0.6
 1.8
0.6 - 0.7
 1.9
0.7 - 0.8
 2.0
0.8 - 0.9
 2.1
0.9 - 1.0
 2.2
1.0 - 1.1
 2.3
1.1 - 1.2
 2.4
1.2 - 1.3
 2.5
1.3 - 1.4
 2.6

48.Apply an approx. 1.6 mm diameter bead of form-in-place gasket (FIPG) to the rear cover along its circumference as shown in the drawing.
Specified sealant:
    Mitsubishi genuine sealant Part No. MD974421 or equivalent

49.Install the rear cover and tighten its mounting bolts to the specified torque of 23 ± 3 N·m.

50.Install the parting pawl, spacer and spring in position, then install the parking pawl shaft.

51.Install the parking roller support, then install the parking roller support shafts (two pieces).

52.Install the underdrive clutch hub.

53.
caution Install the thrust bearing with the indicated side facing down.
Install the thrust bearing #2.

54.Install the underdrive clutch holding the input shaft.

55.Install the thinnest thrust washer #1 for adjusting the input shaft end play (thickness: 1.8mm) on the underdrive clutch retainer.

56.
caution Never use a gasket that has been tightened.
Use the special tool Guide (MD998412) to install a new oil pump gasket and the oil pump.
57.Tighten the oil pump mounting bolts to the specified torque of 29 ± 2 N·m.

58.Measure the end play of the input shaft. Choose a thrust washer #1 of a thickness corresponding to the measurement, referring to the following table. Replace the thrust washer installed in step 55 with the thrust washer #1 thus chosen.

Available thrust washer
Amount of movement mm
 Thickness mm
 Identification mark
2.25 - 2.45
 1.8
 18
2.45 - 2.65
 2.0
 20
2.65 - 2.85
 2.2
 22
2.85 - 3.05
 2.4
 24
3.05 - 3.25
 2.6
 26
3.25 - 3.45
 2.8
 28
Make sure that the end play of the input shaft is within the standard value range with the thrust washer #1 in place.
Standard value (reference): 0.70 - 1.45mm

59.Install the oil filter.

60.Use the special tools to drive the differential bearing outer race into the transmission case.

  • Installer adapter (MB990935)
  • Handle (MB990938)

61.Install the differential.

62.Place two pieces of about 10mm long, 3mm diameter solder on the converter housing at the locations indicated in the drawing.

63.Use the special tools to drive the outer race into position.

  • Installer adapter (MB990935)
  • Handle (MB990938)

64.Install the converter housing on the transmission case without applying FIPG. Tighten the mounting bolts to the specified torque of 48 ± 6 N·m.
65.Remove the bolts and converter housing, and take out the solder pieces.

66.Use a micrometer to measure the thickness of the crashed solder.
67.Select a spacer of the thickness equivalent to the micrometer reading plus the standard preload value.
Standard preload value: 0.045 - 0.105mm

68.Install the spacer selected in step 67. into the converter housing and drive the outer race into position using the special tools.

  • Installer adapter (MB990935)
  • Handle (MB990938)

69.Apply an approx. 1.6 mm diameter bead of from-in-place gasket (FIPG) to the converter housing along its circumference as shown in the drawing.
Specified sealant:
    Mitsubishi genuine sealant Part No. MD974421 or equivalent

70.Install the O-rings (two pieces).

71.Install the converter housing and tighten the mounting bolts to the specified torque of 48 ± 6 N·m.
72.Install the manual control lever shaft and parking pawl rod.

73.Install the manual control lever shaft roller.
74.Fit a new seal ring to each accumulator piston.
note All the four accumulator pistons and seal rings are identical.


75.Identify the accumulator spring for each accumulator and install it in the correct hole in the transmission case together with the piston.
note The accumulator springs are identified as shown in the table below.
No.
 Accumulator spring
 Blue ink marking
1
 For low-reverse brake
 No marking
2
 For underdrive clutch
 Half of surface
3
 For second brake
 Entire surface
4
 For overdrive clutch
 No marking

76.Install the strainer and second brake retainer oil seal as shown in the drawing.
77.Fit a new O-ring into the groove in the solenoid valve harness connector.

78.Insert the solenoid valve harness connector into the hole in the transmission case from inside the case. After making sure that the connector is positioned as shown in the drawing, fit the snap ring snugly into the connector groove.

79.Install the steel balls one each in the two holes on the top of the valve body (outside valve body).
80.Install the valve body and gasket. Make sure that the pin of the manual valve is in place in the detent plate groove in the manual control lever shaft.

81.Install the valve body mounting bolts and tighten them to the specified torque of 11 ± 1 N·m.

82.Install the oil temperature sensor and them connect the connector to the valve body.
No.
 Solenoid valve
 Wire colour
 Connector housing colour
1
 Underdrive solenoid valve
 White/red/red
 Black
2
 Overdrive solenoid valve
 Orange/red
 Black
3
 Low-reverse solenoid valve
 Brown/yellow
 Milky white
4
 Second solenoid valve
 Blue/red/red
 Milky white
5
 Damper clutch control solenoid valve
 Blue/yellow/yellow
 Black

83.Install the manual control shaft detent and tighten its mounting bolt to the specified torque of 6.0 ± 1.0 N·m.

84.Apply an approx. 2.5 mm diameter bead of from-in-place gasket (FIPG) to the valve body cover along its circumference as shown in the drawing.
Specified sealant:
    Mitsubishi genuine sealant Part No. MD974421 or equivalent

85.Install the valve body cover and tighten its mounting bolts to the specified torque of 11 ± 1 N·m.

86.Install the sealing cap.

87.Install the inhibitor switch and the manual control lever, and tighten its mounting bolts to the specified torque of 23 ± 3 N·m.

88.Install the input shaft speed sensor and output shaft speed sensor.

89.Press Face "A" of the air breather to be on the same plane as the Face "B" of the transmission case as shown in the drawing.
90.Coat both sides of the four new gaskets and the screw threads of the eyebolt with ATF, install the oil cooler feed tube, and then tighten the eyebolt to 24 ± 3 N·m.
91.Install a new O-ring on the oil filter tube and connect the tube to the valve body cover.
92.Install the oil level gauge.
93.Install the brackets.

94.
caution Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil seal lip when installing the torque converter.
Install the torque converter, and secure it so that the dimension (A) indicated in the drawing meets the reference value.
Reference value: 12.2 mm