DISASSEMBLY AND REASSEMBLY



Disassembly steps


1.
 Torque converter


2.
 Input shaft speed sensor


3.
 Output shaft speed sensor


4.
 Manual control lever


5.
 Inhibitor switch


6.
 Snap ring


7.
 Parking gear


8.
 Oil pan


9.
 Magnet


10.
 Oil filter


11.
 O-ring


12.
 Detent spring


13.
 Valve body


14.
 O-ring


15.
 Snap ring


16.
 Solenoid valve harness




Disassembly steps


17.
 Oil seal


18.
 Oil seal


19.
 Oil strainer


20.
 Seal ring


21.
 Accumulator piston (for overdrive clutch)


22.
 Accumulator spring


23.
 Accumulator piston (for second brake)


24.
 Inner spring


25.
 Outer spring


26.
 Accumulator piston (for low/reverse brake)


27.
 Inner spring


28.
 Outer spring


29.
 Accumulator piston (for underdrive clutch)


30.
 Inner spring


31.
 Outer spring


32.
 Spring pin


33.
 Pin


34.
 Manual control shaft


35.
 O-ring


36.
 Detent lever


37.
 Parking roller rod




Disassembly steps


38.
 Converter housing


39.
 Oil pump


40.
 Oil pump gasket


41.
 Thrust race #1


42.
 Thrust bearing #2


43.
 Reverse and overdrive clutch


44.
 Thrust bearing #3


45.
 Overdrive clutch hub


46.
 Thrust bearing #4


47.
 Reverse sun gear


48.
 Snap ring


49.
 Second brake


50.
 Return spring




Disassembly steps


51.
 Pressure plate


52.
 Brake plate


53.
 Brake disc


54.
 Low/reverse annulus gear


55.
 Thrust bearing #7


56.
 Snap ring


57.
 Reaction plate


58.
 Snap ring


59.
 Brake plate


60.
 Brake disc


61.
 Pressure plate


62.
 Wave spring




Disassembly steps


63.
 Snap ring


64.
 Center support


65.
 Thrust race #8


66.
 Thrust bearing #9


67.
 Output flange


68.
 Thrust bearing #10


69.
 Underdrive clutch hub


70.
 Thrust bearing #11


71.
 Underdrive clutch


72.
 Thrust bearing #12


73.
 Output shaft


74.
 Seal ring


75.
 Seal ring


76.
 Thrust bearing #13


77.
 Bearing retainer


78.
 Output shaft support


79.
 Output shaft support gasket


80.
 Transmission case

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 input shaft speed sensor.

2.Remove the output shaft speed sensor.

3.Remove the manual control lever, and then remove the inhibitor switch.

4.Remove the snap ring, and remove the parking gear using a puller (corresponding load approximately 9,800 N).

5.
caution Carefully hammer the special tool so that the oil pan mounting surface is not damaged.
Remove the twenty oil pan mounting bolts and then use the special tool Oil pan FIPG cutter (MD998727) to remove the oil pan.

6.Remove the oil filter and O-ring.

7.Remove the detent spring.

8.Disconnect the valve body harness connectors.


9.Remove the twenty valve body mounting bolts and then remove the valve body, O-ring and oil temperature sensor.
note The twenty valve body mounting bolts are plated bolts.
note The O-ring is mounted on the transmission case side as shown in the illustration. However there may be cases when it will come off with the valve body.

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

11.Remove the oil strainer and two oil seals.

12.Remover each accumulator piston, seal ring and spring.
No.
 Name
1
 For overdrive clutch
2
 For second brake
3
 For low/reverse brake
4
 For underdrive clutch
note To make assembly easier, attach an identification tag on the removed accumulator piston.

13.Remove the detent lever spring pin.

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

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

16.Remove the ten oil pump mounting bolts.
17.Install special tool Oil pump remover (MD998333) into the bolt hole shown in the illustration.

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

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

21.Remove the reverse overdrive clutch.

22.Remove the overdrive clutch hub and thrust bearing number 3.

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

24.Remove the reverse sun gear.

25.Remove the snap ring.

26.Remove the second brake and return spring.

27.Remove the low/reverse annulus gear.

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

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

30.Remove the snap ring.

31.Remove the reaction plate and one brake disc.

32.Remove the snap ring.

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

34.Remove the wave spring.

35.Remove the snap ring and center support.

36.Remove the thrust race #8, thrust bearing #9 and output flange.
note The thrust race #8 may be attached to the center support.

37.Remove the thrust bearing #10 and underdrive clutch hub.

38.Remove the thrust bearing #11 and underdrive clutch.
note The thrust bearing #11 may be attached to the underdrive clutch hub.

39.Remove the thrust bearing #12.
note The thrust bearing #12 may be attached to the underdrive clutch.

40.Remove the output shaft.

41.Remove the two large and two small seal rings from the output shaft.

42.Remove the thrust bearing #13 and bearing retainer.
note The thrust bearing #13 may be attached to the output shaft support.

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

REASSEMBLY
caution
  • The automatic transmission includes many high-precision parts. Handle these parts extremely carefully not to scratch or damage them during dissemble 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.
caution Never reuse a gasket.
Install a new gasket and output shaft support.
2.Tighten the eight output shaft support mounting bolts to the specified torque of 23 ±3 N·m.


3.
caution Make sure the thrust bearing is mounted in the correct direction.
Install the bearing retainer and thrust bearing #13 onto the output shaft.
Symbol
 O.D. mm
 I.D. mm
 Thickness
mm
 Symbol
 O.D. mm
 I.D. mm
 Thickness
mm
#1
 48.9
 37
 1.4
 #6
 57
 38.5
 4.12
1.6
 #7
 70
 48.8
 4.0
1.8
 #8
 73
 60
 1.6
2.0
 1.8
2.2
 2.0
2.4
 2.2
2.6
 #9
 71.45
 57
 2.81
#2
 59
 37
 2.8
 #10
 72
 48.25
 4.6
#3
 57
 38.5
 4.12
 #11
 53
 34.7
 4.01
#4
 57
 38.5
 4.12
 #12
 57
 38.5
 4.12
#5
 55.4
 38.5
 3.31
 #13
 58
 37.5
 4.8



4.Install new seal rings (two large pieces and two small pieces) onto the output shaft.

5.Install the output shaft into the output shaft support.


6.
caution Make sure thrust bearing #12 is mounted in the correct direction.
Apply Vaseline or petroleum jelly on the thrust bearing #12, and then install on the front end of the output shaft.

7.Install the underdrive clutch.


8.
caution Make sure thrust bearing #11 is mounted in the correct direction.
Apply Vaseline or petroleum jelly on the thrust bearing #11, and then install on the front end of the underdrive clutch retainer.

9.Install the underdrive clutch hub.


10.
caution Make sure thrust bearing #10 is mounted in the correct direction.
Apply Vaseline or petroleum jelly on the thrust bearing #10, and then install it on the underdrive clutch hub.

11.Install the output flange.


12.
caution Make sure thrust bearing #9 is mounted in the correct direction.
Apply Vaseline or petroleum jelly on the thrust bearing #9, and then install on the output flange.

13.
caution Measure and record the thickness of the thrust race #8 to be assembled.
Apply Vaseline or blue petroleum jelly on the thrust race #8 being used, and then install it on the rear side of the center support.

14.
caution
  • Install the center support so that the oil holes shown in the illustration face the lower side of the transmission case.
  • Make sure that the thrust race #8 attached to the rear side of the center support does not fall off.
Install the center support.

15.Remove the two output shaft support mounting bolts.
16.Using the two removed bolts, install special tool Bearing installer stopper (MB991603) to the specified torque of 23 ± 3 N·m.



17.Select the thrust race #8 with the following procedure:
(1) Fix a dial gauge to special tool Bearing installer stopper (MB991603).
(2) Push the output shaft, and the output flange in alternately, and then measure the end play of output shaft.
note
  • When pushing the output shaft in, take care that the center support does not move.
  • When pushing the output flange in, use the special tool Oil seal installer (MD998029).
(3) Reinstall by selecting the thrust race #8 installed by the procedure (13) so that the end play of output shaft becomes the standard value.
note Refer to the thickness recorded in step 13.
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 special tool Bearing installer stopper (MB991603) and dial gauge installed.




18.Using the following steps, select the snap ring for fixing the center support.
(1) Install the snap ring used for fixing the center support used.
(2) After pushing the output shaft, and the center support in alternately, and then measure the end play of center support.
note When pushing the output shaft in, be sure to push them in to the point where the center support touches the snap ring.
(3) Select the snap ring for fixing the center support installed in step 18 (1) 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.






19.Using the following steps, select the snap ring for adjusting the brake reaction plate end play and second brake end play, and the pressure plate for adjusting the low/reverse brake end play.
(1) Install the wave spring onto the low/reverse brake piston.
(2) Install special tool Clearance dummy plate (MB991632) onto the position shown in the illustration instead of the pressure plate for the low/reverse brake. Install the six brake disc, five brake plate and snap ring.
(3)
caution Pay close attention to the assembly direction of the reaction plate.
Install the reaction plate and snap ring that was used.
(4) Install a dial gauge onto special tool Dial gauge extension (MD998913) so that the end contacts the brake reaction plate. Measure the end play by moving special tool Clearance dummy plate (MB991632).
(5) Select the snap ring installed in step 19 (3) so that the end play is 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 Pay close attention to the shape and assembly direction of the brake plate A installation.
Next, install special tool Clearance dummy plate (MB991632) 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 Dial gauge extension (MD998913) so the end contacts the special tool. Move special tool Clearance dummy plate (MB991632) and measure the moving amount. Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
Standard value (reference): 1.49 - 1.95 mm
PRESSURE PLATE FOR SECOND BRAKE
Moving amount mm
 Pressure plate
Thickness
mm
 identification 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 Clearance dummy plate (MB991632) 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 Dial gauge extension (MD998913) so the end contacts the special tool. Move special tool Clearance dummy plate (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 <4M40>
PRESSURE PLATE FOR LOW/REVERSE BRAKE
Moving amount mm
 Pressure plate
Thickness mm
 Identification 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
End play standard value (reference): 1.35 - 1.81 mm <6G72>
PRESSURE PLATE FOR LOW/REVERSE BRAKE
Moving amount mm
 Pressure plate
Thickness mm
 Identification symbol
1.2 or more - less than 1.4
 1.8
 E
1.4or more - less than 1.6
 2.0
 D
1.6 or more - less than 1.8
 2.2
 C
1.8 or more - less than 2.0
 2.4
 B
2.0 or more - less than 2.2
 2.6
 A
2.2 or more - less than 2.4
 2.8
 0
2.4 or more - less than 2.6
 3.0
 1
(13) Remove the parts installed in steps 19 (1) to (12).


20.
caution Make sure thrust bearing #7 is mounted in the correct direction.
Apply Vaseline or petroleum jelly on the thrust bearing #7, and then install on the rear side of the low/reverse annulus gear.

21.
caution Make sure that thrust bearing #7 attached to the rear side of the low/reverse annulus gear does not fall off.
Install the low/reverse annulus gear.

22.Install the reverse sun gear.

23.Install the wave spring to the low/reverse brake piston.

24.Install the pressure plate, six brake disc and five brake plate selected in step 19 (12).

25.Install the snap ring.

26.
caution Make sure the reaction plate in the proper direction.
Install the reaction plate.

27.Install the snap ring selected in step 19 (5).

28.
caution Make sure the brake plate (reaction plate side) is installed in the proper direction.
Install the brake disc, brake plate and pressure plate selected in step 19 (9).


29.
caution Install the return spring end coil side so that it faces the back of the transmission. (Only for one side end coil type)
Install the return spring and second brake.

30.Install the snap ring.


31.
caution Make sure thrust bearing #4 is installed in the proper direction.
Apply Vaseline or petroleum jelly on the thrust bearing #4, and then install on the reverse sun gear.


32.
caution Make sure thrust bearing #3 is mounted in the correct direction.
Apply Vaseline or petroleum jelly on the thrust bearing #3, and then install on the overdrive clutch hub.
33.Install the overdrive clutch hub.


34.
caution Make sure thrust bearing #2 is mounted in the correct direction.
Install the reverse and overdrive clutch.

35.Apply Vaseline or petroleum jelly on the thrust bearing #2, and then install on the reverse and overdrive clutch.

36.Apply Vaseline or petroleum jelly on the thrust race #1 being used, and then install on the oil pump.

37.
caution Never reuse a gasket.
Install special tools Guide (MD998412) at the position shown in the illustration, and using this as a guide, install the oil pump and gasket.
38.Tighten the ten oil pump mounting bolts to the specified torque of 23 ± 3 N·m.

39.Use 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 select the thrust race installed in step 36 so that the end play is at the standard value. Then, reassemble.
Standard value: 0.25 - 0.81 mm
40.Measure the end play again, and confirm that it is within the standard value.

41.
caution Evenly squeeze out the sealant so that it is not insufficient or excessive.
Apply the sealant on the converter housing.
Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

42.Install the converter housing.
43.Tighten the eight converter housing mounting bolts to the specified torque of 48 ± 6 N·m.

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

45.Install two new O-rings to the manual control shaft, and assemble onto the transmission case together with the detent lever and parking roller rod.

46.Install the pin.

47.Hammer in so that the slit section of the spring valve is perpendicular to the axial direction of the manual control shaft.


48.Install a new seal ring onto each accumulator piston.
49.Install each accumulator piston and spring.
note Identification colors are applied on the spring as shown below. Assemble following this table.
note Install the accumulator pistons to the original positions following the identification tags attached when removed.
No.
 Name
 Identification paint application position
1
 For overdrive clutch
 None
2
 For second brake
 Inner
 Applied on all surfaces including both ends
Outer
 Applied on half of surface including both ends
3
 For low/reverse brake
 Inner
 Applied on half of surface including both ends
Outer
 Applied on entire surface of one side
4
 For underdrive clutch
 Inner
 Applied on half of surface including both ends
Outer
 Applied on half of surface including both ends

50.
caution Pay close attention 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.

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

52.Install the new O-ring into the transmission case at the position shown in the illustration.

53.Install the valve body while inserting of Control shaft into the detent lever groove.

54.Tighten the twenty valve body mounting bolts to the specified torque of 11 ± 1 N·m.
Bolt
 Length mm
A
 25
B
 30
C
 40
D
 45
E
 55

55.Install the oil temperature sensor.

56.Connect the connector to the valve body.

57.Install the detent spring.
58.Tighten the detent spring mounting bolt to the specified torque of 6.0 ± 1.0 N·m.

59.Install the oil filter and a new O-ring.

60.Install the magnet.
61.
caution Evenly squeeze out the sealant so that it is not insufficient or excessive.
Apply the sealant or equivalent on the oil pan.
Specified sealant:
Mitsubishi Part No. MD997740 or equivalent

62.Install the oil pan.
63.Tighten the oil pan mounting bolts to the specified torque of 11 ± 1 N·m.


64.
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. Do not heat for longer than necessary at this time.
Install the parking gear and snap ring.

65.Install the inhibitor switch and manual control lever.

66.Install the output shaft speed sensor.

67.Install the input shaft speed sensor.

68.
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 illustration meets the reference value.
Reference value: 20.9 mm