DISASSEMBLY AND REASSEMBLY



Disassembly steps


1.
 Torque converter


2.
 Cable end bracket


3.
 Clamp


4.
 Clamp


5.
 Harness bracket


6.
 Input shaft speed sensor


7.
 Output shaft speed sensor


8.
 Manual control lever


9.
 Inhibitor switch


10.
 Snap ring


11.
 Parking gear


12.
 Oil pan


13.
 Magnet


14.
 Oil filter


15.
 O-ring


16.
 Detent spring


17.
 Valve body


18.
 O-ring


19.
 Snap ring


20.
 Solenoid valve harness




Disassembly steps


21.
 Oil seal


22.
 Oil seal


23.
 Oil strainer


24.
 Seal ring


25.
 Accumulator piston (for overdrive clutch)


26.
 Accumulator spring


27.
 Accumulator piston (for second brake)


28.
 Inner spring


29.
 Outer spring


30.
 Accumulator piston (for Low/reverse brake)


31.
 Inner spring


32.
 Outer spring


33.
 Accumulator piston (for underdrive clutch)


34.
 Inner spring


35.
 Outer spring


36.
 Snap ring


37.
 Accumulator cover


38.
 O-ring


39.
 Accumulator spring


40.
 Accumulator piston (for reduction brake)


41.
 Accumulator piston (for direct clutch)


42.
 Seal ring


43.
 Spring pin


44.
 Pin


45.
 Manual control shaft


46.
 O-ring


47.
 O-ring


48.
 Detent lever


49.
 Parking roller rod




Disassembly steps


50.
 Converter housing


51.
 Oil pump


52.
 Oil pump gasket


53.
 Thrust race #1


54.
 Thrust bearing #2


55.
 Reverse and overdrive clutch


56.
 Thrust bearing #3


57.
 Overdrive clutch hub


58.
 Thrust bearing #4


59.
 Reverse sun gear


60.
 Snap ring


61.
 Second brake


62.
 Return spring




Disassembly steps


63.
 Pressure plate


64.
 Brake plate


65.
 Brake disc


66.
 Low/reverse annulus gear


67.
 Thrust bearing #7


68.
 Snap ring


69.
 Reaction plate


70.
 Snap ring


71.
 Brake plate


72.
 Brake disc


73.
 Pressure plate


74.
 Wave spring




Disassembly steps


75.
 Snap ring


76.
 Center support


77.
 Thrust race #8


78.
 Thrust bearing #9


79.
 Direct annulus gear


80.
 Thrust bearing #12


81.
 Direct planetary carrier


82.
 Seal ring


83.
 Seal ring


84.
 Snap ring


85.
 Reduction brake cover


86.
 O-ring


87.
 Snap ring


88.
 Reduction brake piston nut


89.
 Reduction brake piston


90.
 Seal ring


91.
 Reduction brake piston adjusting rod


92.
 Reduction brake spring


93.
 Direct clutch


94.
 Thrust bearing #13


95.
 Reduction brake band


96.
 Anchor plug


97.
 O-ring


98.
 Output shaft support


99.
 Output shaft support gasket


100.
 Transmission case

DISASSEMBLY
caution
  • Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not to scratch or damage these parts during disassembly and reassembly.
  • During the work, always use bare hands or vinyl gloves. Do not use cotton gloves. Use nylon cloth or paper towels when necessary. Do not use shop towel.
  • Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
  • Clutch discs, plastic thrust race and rubber parts should be cleaned with ATF automatic transmission fluid so that they do not become dirty.
  • If the transmission body has been damaged, disassemble and clean the cooler system also.

1.Remove the torque converter.


2.Remove the Cable end bracket, Clamps (two pieces), Harness bracket.

3.Remove the input shaft speed sensor.

4.Remove the output shaft speed sensor.

5.Remove the manual control lever.

6.Remove the Inhibitor switch.

7.Remove the snap ring, and remove the parking gear using a puller (corresponding load approximately 9,800 N).
note The parking gear may be removed without using a puller.

8.Remove the twenty oil pan mounting bolts and then remove the oil pan using the special tool Oil pan FIPG cutter (MD998727) to remove the oil pan.
caution Carefully hammer the special tool so that the oil pan mounting surface is not damaged.

9.Remove the oil filter and O-ring.

10.Remove the detent spring.

11.Disconnect the harness connectors of the valve body.



12.Remove the twenty valve body mounting bolts and then remove the valve body, three O-rings and oil temperature sensor.
note The twenty valve body mounting bolts are plated bolts.
note The O-rings are mounted on the transmission case side as shown in the illustration. However there may be cases where they will come off with the valve body.

13.Remove the snap ring and disconnect the solenoid valve harness.

14.Remove the oil strainer and two oil seals.


15.Remove each accumulator piston, seal ring and spring.
Remove the snap ring, then remove the accumulator cover, O-ring and spring.
No.
 Name
1
 For overdrive clutch
2
 For second brake
3
 For low/reverse brake
4
 For underdrive clutch
5
 For reduction brake
6
 For direct clutch
note To make assembly easier, attach an identification tag on the removed accumulator piston.

16.Remove the detent lever spring pin.

17.Remove the pin, and then remove the manual control shaft, two O-rings, detent lever and parking roller rod.

18.Remove the eight converter housing mounting bolts, and then converter housing.

19.Remove the ten oil pump mounting bolts.
20.Install the special tool into the bolt hole shown in the illustration.

21.While screwing in special tools Oil pump remover (MD998333) evenly, remove the oil pump.
22.Remove the oil pump gasket.

23.Remove the thrust race #1 and thrust bearing #2.
note The thrust race #1 may be attached to the oil pump.

24.Remove the reverse and overdrive clutch.

25.Remove the thrust bearing #3.

26.Remove the overdrive clutch hub.

27.Remove the thrust bearing #4.
note The thrust bearing #4 may be attached to the overdrive clutch hub.

28.Remove the reverse sun gear.

29.Remove the snap ring.

30.Remove the second brake.

31.Remove the return spring.

32.Remove the pressure plate, brake plates and brake discs.

33.Remove the low/reverse annulus gear.

34.Remove the thrust bearing #7.
note The thrust bearing #7 may be attached to the low/reverse annulus gear.

35.Remove the snap ring.

36.Remove the reaction plate and one brake disc.

37.Remove the snap ring.

38.Remove the brake plates, brake discs, and pressure plate.

39.Remove the wave spring.

40.Remove the snap ring.

41.Remove the center support.

42.Remove the thrust race #8 and thrust bearing #9.
note The thrust race #8 may be attached to the center support.

43.Remove the direct annulus gear.

44.Remove the thrust bearing #12.
note The thrust bearing #12 may be attached to the direct annulus gear.

45.Remove the direct planetary carrier.


46.Remove the two large and two small seal rings from the direct planetary carrier.

47.Remove the snap ring and then the reduction brake piston cover and O-ring.

48.Remove the snap ring and then the nut, reduction brake piston, seal ring, adjusting rod and spring.

49.Remove the direct clutch.

50.Remove the thrust bearing #13.
note The thrust bearing #13 may be attached to the direct clutch.

51.Remove the reduction brake band.

52.Remove the anchor plug and the O-ring.

53.Remove the eight output shaft support mounting bolts, and then remove the output shaft support and gasket.

RESASSEMBLY
caution
  • Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
  • Never use grease other than blue petrolatum jelly and white Vaseline.
  • Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
  • Never apply sealant or adhesive to gaskets.
  • When replacing a bushing, replace the reassembly which it belongs to.
  • During the work, always use bare hands or vinyl gloves. Do not use cotton gloves. Use nylon cloth or paper towels when necessary. Do not use shop towel.
  • Change the oil in the cooler system.

1.Install a new gasket and output shaft support.
caution Never reuse a gasket.
2.Tighten the eight output shaft support mounting bolts to the specified torque.
Symbol
 OD mm
 ID mm
 Thickness mm
#1
 48.9
 37
 1.4
1.6
1.8
2.0
2.2
2.4
2.6
#2
 59
 37
 2.8
#3
 57
 38.5
 4.12
#4
 57
 38.5
 4.12
#5
 54.4
 38.5
 3.31
#6
 57
 38.5
 4.12
#7
 70
 48.8
 4.0
#8
 73
 60
 1.6
1.8
2.0
2.2
#9
 71.45
 57
 2.81
#10
 72
 48.25
 4.6
#11
 53
 34.7
 4.01
#12
 57
 38.5
 4.12
#13
 58
 37.5
 4.8
Identification of thrust bearings and thrust races

3.Install a new O-ring on the anchor plug and tighten the anchor plug to the specified torque.


4.Install the reduction brake band.
Fit the anchor bracket hole of the brake band onto the anchor plug tip, and then insert the apply bracket part into the hole for reduction brake piston adjusting rod.
caution Take care not to mistake the thrust bearing #13 mounting direction.


5.Install the thrust bearing #13 onto the direct clutch retainer.
caution Take care that the reduction brake band does not come off the anchor plug and the hole for the reduction brake piston adjusting rod.

6.Install the direct clutch.

7.Install the reduction brake spring.

8.Screw the reduction brake piston adjusting rod into the reduction brake piston manually to the full.
9.Install new seal ring on the piston.

10.Press the reduction brake piston into the transmission case, and then install the snap ring.
note Set the open of the snap ring at indicated location.

11.Tighten the reduction brake piston adjusting rod manually to the full.




12.Adjust the reduction brake piston by the following procedure.
(1) Mount the special tool Reduction brake stopper (MB991693) so that the reduction brake piston does not rotate.
(2) Mount the torque wrench to the special tool (Socket), and after repeating tightening and turning back with a torque of 10 N·m twice, tighten the reduction brake piston adjusting rod to the specified torque of 5 N·m. Then turn the reduction brake piston adjusting rod 5 1/2 to 5 3/4 turns back.
(3) Remove the special tool and tighten the reduction brake piston nut manually.
(4) Tighten the reduction brake piston nut to the specified torque of 19 ± 3 N·m using the special tool (Wrench) while fixing the special tool (Socket) so as not to rotate.

13.Install a new O-ring on the reduction brake piston cover, and then install the cover and the snap ring on the transmission case.


14.Install new seal rings (two large pieces) onto the front end of the direct planetary carrier, and new seal rings (two small pieces) onto the shaft of the direct planetary carrier.

15.Insert the direct planetary carrier into the output shaft support.
caution Take care not to mistake the thrust bearing #12 mounting direction.


16.Apply Vaseline or petrolatum jelly on the thrust bearing #12, and then install on the front end of the direct planetary carrier.
caution Confirm that the thrust bearing #10 in the direct annulus gear is still at the specified location.

17.Install the direct annulus gear.
caution Take care not to mistake the thrust bearing #9 mounting direction.


18.Apply Vaseline or petrolatum jelly to the thrust bearing #9, and then install on the direct annulus gear.
caution Measure and record the thickness of the thrust race #8 before assembling.

19.Apply Vaseline or blue petrolatum jelly on the thrust race #8 removed, and then install it on the rear side of the center support.
caution
  • Install the center support so that the oil hole shown in the illustration faces the lower side of the transmission case.
  • Use care that the thrust race #8 attached to the rear side of the center support does not fall off.

20.Install the center support.

21.Using the transfer case adapter bolt, install special tool Bearing installer stopper (MB991603).


22.Select the thrust race #8 with the following procedure.
(1) Fix a dial gauge to the special tool Bearing installer stopper (MB991603).
(2) Push the direct planetary carrier and direct annulus gear in alternately, and measure the end play of the direct planetary carrier.
note When pushing in the direct planetary carrier, make sure that the center support does not move.
note When pushing in the direct annulus gear, use the special tool Oil seal installer (MD998304).
(3) Replace the thrust race #8 installed in step 19 with a suitable one which can bring the end play of the direct planetary carrier to the standard value. Then, reassemble.
note Refer to the thickness recorded in step 19.
Standard value: 0.25 - 0.71 mm
(4) Measure the end play again, and confirm that it is within the standard value.
note Carry this step out with the special tool and dial gauge installed.



23.Using the following steps, select a suitable snap ring for fixing the center support.
(1) Install the snap ring which has been used for fixing the center support.
(2) Alternately push in the direct planetary carrier and center support, and measure the end play of the center support.
note Be sure to push the direct planetary carrier in fully until the center support contacts the snap ring.
(3) Replace the snap ring for fixing the center support installed in step 23 (1) with a suitable one so that the end play of the center support is at the standard value. Then, reassemble.
Standard value: 0 - 0.16 mm
(4) Measure the end play again, and confirm that it is within the standard value.






24.Using the following steps, select a snap ring for adjusting the brake reaction plate end play and second brake end play, and a pressure plate for adjusting the low/reverse brake end play.
(1) Install the wave spring onto the low/reverse brake piston.
(2) Install the special tool (MB991632) in the position shown in the illustration instead of the pressure plate for the low/reverse brake. Install the brake discs, brake plates and snap ring.
(3) Install the reaction plate and snap ring that was used.
caution Take care to the assembly direction of the reaction plate.
(4) Install a dial gauge onto special tool (MD998913) so that the tool end contacts the brake reaction plate. Measure the end play by moving special tool (MB991632).
(5) Replace the snap ring installed in step 24 (3) with a suitable one so that the end play may fall within the standard value. Then, reassemble.
Standard value: 0 - 0.16 mm
(6) Measure the end play again, and confirm that it is within the standard value.
(7)
caution Take care to the shape and assembly direction of the brake plates installed at section "A" shown in the illustration.
Next, install the special tool instead of the pressure plate for the second brake. Install the four brake discs and three brake plates.
(8) Install the return spring, second brake and snap ring.
(9) Install a dial gauge onto special tool (MD998913) so that the end contacts the special tool (MB991632). Move special tool (MB991632) and measure the moving amount.
Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
End play standard value (reference):
    1.49 - 1.95 mm
Moving amount mm
 Pressure plate
Thickness mm
 ID Symbol
1.2 or more - less than 1.4
 1.6
 F
1.4 or more - less than 1.6
 1.8
 E
1.6 or more - less than 1.8
 2.0
 D
1.8 or more - less than 2.0
 2.2
 C
2.0 or more - less than 2.2
 2.4
 B
2.2 or more - less than 2.4
 2.6
 A
2.4 or more - less than 2.6
 2.8
 0
2.6 or more - less than 2.8
 3.0
 1
(10) Remove the snap ring, second brake, return spring and special tool installed in step (8).
(11) Install the pressure plate selected in step (9), and install the return spring, second brake and snap ring again.
(12) Install a dial gauge onto special tool (MD998913) so that the end contacts the special tool (MB991632). Move special tool (MB991632) and measure the moving amount.
Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
End play standard value (reference):
    1.65 - 2.11 mm
Moving amount mm
 Pressure plate
Thickness mm
 ID Symbol
1.5 or more - less than 1.7
 1.8
 E
1.7 or more - less than 1.9
 2.0
 D
1.9 or more - less than 2.1
 2.2
 C
2.1 or more - less than 2.3
 2.4
 B
2.3 or more - less than 2.5
 2.6
 A
2.5 or more - less than 2.7
 2.8
 0
2.7 or more - less than 2.9
 3.0
 1
(13) Remove the parts installed in steps 24 (1) to (12).


25.
caution Take care not to mistake the thrust bearing #7 mounting direction.
Apply Vaseline or petrolatum jelly on the thrust bearing #7, and then install the bearing on the rear side of the low/reverse annulus gear.

26.
caution Make sure that the thrust bearing #7 attached to the rear side of the low/reverse annulus gear does not fall off.
Install the low/reverse annulus gear.

27.Install the reverse sun gear.

28.Install the wave spring onto the low/reverse brake piston.

29.Install the pressure plate selected in step 24 (12), brake discs and brake plates.

30.Install the snap ring.

31.
caution Take care not to mistake the reaction plate installation direction.
Install the reaction plate.

32.Install the snap ring selected in step 24 (5).

33.Install the brake discs, brake plates and pressure plate selected in step 24 (9).
caution Take care not to mistake the brake plate (reaction plate side) installation direction.


34.
caution Install the return spring so that the flat side faces the back of the transmission.
Install the return spring and second brake.

35.Install the snap ring.


36.
caution Take care not to mistake the thrust bearing #4 installation direction.
Apply Vaseline or petrolatum jelly on the thrust bearing #4, and then install on the reverse sun gear.


37.
caution Take care not to mistake the thrust bearing #3 mounting direction.
Apply Vaseline or petrolatum jelly on the thrust bearing #3, and then install on the overdrive clutch hub.
38.Install the overdrive clutch hub.

39.Install the reverse and overdrive clutch.


40.
caution Take care not to mistake the thrust bearing #2 mounting direction.
Apply Vaseline or petrolatum jelly on the thrust bearing #2, and then install on the reverse and overdrive clutch.

41.Apply Vaseline or petrolatum jelly on the thrust race #1, and then install on the oil pump.

42.Install the special tool Guide (MD998412) at the position shown in the illustration, and using this as a guide, install the oil pump and gasket.
caution Never reuse the gasket.
43.Tighten the ten oil pump mounting bolts to the specified torque.

44.Using the special tool Dial gauge support (MD998316), set a dial gauge as shown in the illustration. Measure the end play of the input shaft, and replace the thrust race installed in step 41 with a suitable one so that the end play may meet the standard value. Then, reassemble.
Standard value: 0.25 - 0.81 mm
45.Measure the end play again, and confirm that it is within the standard value.

46.
caution Evenly squeeze out the sealant so that it is not insufficient or excessive.
Apply sealant on the converter housing.
Specified sealant:
    Mitsubishi Part No. MR166584 or equivalent

47.Install the converter housing.
48.Tighten the eight converter housing mounting bolts to the specified torque.

49.Install the parking roller rod to the detent lever.

50.Install two new O-rings to the manual control shaft.

51.Install the assemble into the transmission case together with the detent lever and parking roller rod.

52.Install the pin.

53.Hammer in the spring pin so that its slit is perpendicular to the axial direction of the manual control shaft.
54.Install a new seal ring onto each accumulator piston.




55.Install each accumulator piston and spring, then install accumulator cover with O-ring and snap ring.
note Install the accumulator pistons to the original positions following the identification tags attached when they were removed.
note The springs are identified by paint application position as shown below. Assemble following this table.
No.
 Name
 Identification paint application position
1
 For overdrive clutch
 None
2
 For second brake
 Inner
 None
Outer
 Applied on all surface including both ends
3
 For low/reverse brake
 Inner
 None
Outer
 None
4
 For underdrive clutch
 Inner
 Applied on half of surface including both ends
Outer
 Applied on half of surface including both ends
5
 For reduction brake
 None
6
 For direct clutch
 None

56.
caution Take care to the installation direction of the oil seal.
Install the oil strainer and two new oil seals. Install the oil seals so that the notched section is oriented as shown in the illustration.

57.Install the solenoid valve harness, and then secure the snap ring to connector groove.
note Install the harness so that it is oriented as shown in the illustration.

58.Install new three O-rings onto the transmission case at the positions shown in the illustration.

59.Install the valve body while inserting the manual valve pin into the detent lever groove.

60.Install the oil temperature sensor.

61.Tighten the twenty valve body mounting bolts to the specified torque.
Bolt
 Length mm
A
 25
B
 30
C
 40
D
 45
E
 55

62.Connect the connector to the valve body.

63.Install the detent spring.
64.Tighten the detent spring mounting bolt to the specified torque.
Specified torque: 6.0 ± 1.0 N·m

65.Install the new O-ring to the oil filter.

66.Install the oil filter.
67.Tighten the oil filter mounting bolt to the specified torque.
Specified torque: 6.0 ± 1.0 N·m

68.Install three magnets.
69.
caution Evenly squeeze out the sealant so that it is not insufficient or excessive.
Apply sealant on the oil pan.
Specified sealant:
    MITSUBISHI genuine sealant part No. MR166584 or equivalent

70.Install the oil pan.
71.Tighten the oil pan mounting bolts to the specified torque.


72.
caution
  • Install the parking gear so that the side without the spline cut faces the transmission side.
  • Heat the parking gear to 160 - 180°C, and shrink fit up to the stepped section of the output shaft.
Install the parking gear and snap ring.

73.Install the Inhibitor switch.

74.Install the manual control lever.

75.Install the output shaft speed sensor.

76.Install the input shaft speed sensor.


77.Install the Cable end bracket, Clamps (two pieces), Harness bracket.

78.Install the torque converter.