DISASSEMBLY AND REASSEMBLY
1.
 Torque converter
2.
 Clamp
3.
 Input shaft speed sensor
4.
 O-ring
5.
 Output shaft speed sensor
6.
 O-ring
7.
 Manual control lever
8.
 Inhibitor switch
9.
 Snap ring
10.
 Parking gear
11.
 Oil pan
12.
 Magnet
13.
 Oil filter
14.
 O-ring
15.
 Detent spring
16.
 Valve body
17.
 O-ring
18.
 Snap ring
19.
 Solenoid valve harness
20.
 O-ring
21.
 O-ring

22.
 Oil seal
23.
 Oil seal
24.
 Oil strainer
25.
 Seal ring
26.
 Accumulator piston (for overdrive clutch)
27.
 Accumulator spring
28.
 Accumulator piston (for second brake)
29.
 Inner spring
30.
 Outer spring
31.
 Accumulator piston (for Low/reverse brake)
32.
 Inner spring
33.
 Outer spring
34.
 Accumulator piston (for underdrive clutch)
35.
 Inner spring
36.
 Outer spring
37.
 Snap ring
38.
 Accumulator cover
39.
 O-ring
40.
 Accumulator spring
41.
 Accumulator piston (for reduction brake)
42.
 Accumulator piston (for direct clutch)
43.
 Seal ring
44.
 Spring pin
45.
 Pin
46.
 Manual control shaft
47.
 O-ring
48.
 O-ring
49.
 Detent lever
50.
 Parking roller rod

51.
 Converter housing
52.
 Oil pump
53.
 Oil pump gasket
54.
 Thrust race No.1
55.
 Thrust bearing No.2
56.
 Reverse and overdrive clutch
57.
 Thrust bearing No.3
58.
 Overdrive clutch hub
59.
 Thrust bearing No.4
60.
 Reverse sun gear
61.
 Snap ring
62.
 Second brake
63.
 Return spring

64.
 Pressure plate
65.
 Brake plate
66.
 Brake disc
67.
 Low/reverse annulus gear
68.
 Thrust bearing No.7
69.
 Snap ring
70.
 Reaction plate
71.
 Snap ring
72.
 Brake plate
73.
 Brake disc
74.
 Pressure plate
75.
 Wave spring

76.
 Snap ring
77.
 Center support
78.
 Thrust race No.8
79.
 Thrust bearing No.9
80.
 Direct annulus gear
81.
 Thrust bearing No.12
82.
 Direct planetary carrier
83.
 Seal ring
84.
 Seal ring
85.
 Snap ring
86.
 Reduction brake cover
87.
 O-ring
88.
 Snap ring
89.
 Reduction brake piston nut
90.
 Reduction brake piston
91.
 Seal ring
92.
 Reduction brake piston adjusting rod
93.
 Reduction brake spring
94.
 Direct clutch
95.
 Thrust bearing No.13
96.
 Reduction brake band
97.
 Anchor plug
98.
 O-ring
99.
 Output shaft support
100.
 Output shaft support gasket
101.
 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 torque converter.
2.Remove the clamp.

3.Remove the input shaft speed sensor, and detach the O-ring from the input shaft speed sensor.

4.Remove the output shaft speed sensor, and detach the O-ring from 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.
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 remove the oil pan using the special tool Oil pan FIPG cutter (MD998727) to remove the oil pan.

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 No.1 and thrust bearing No.2.
note The thrust race No.1 may be attached to the oil pump.

24.Remove the reverse and overdrive clutch.

25.Remove the thrust bearing No.3.

26.Remove the overdrive clutch hub.

27.Remove the thrust bearing No.4.
note The thrust bearing No.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 No.7.
note The thrust bearing No.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 No.8 and thrust bearing No.9.
note The thrust race No.8 may be attached to the center support.

43.Remove the direct annulus gear.

44.Remove the thrust bearing No.12.
note The thrust bearing No.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 No.13.
note The thrust bearing No.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.
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 23 ± 3 N·m.
Symbol
 OD mm
 ID mm
 Thickness mm
No.1
 48.9
 37
 1.4
1.6
1.8
2.0
2.2
2.4
2.6
No.2
 59
 37
 2.8
No.3
 57
 38.5
 4.12
No.4
 57
 38.5
 4.12
No.5
 54.4
 38.5
 3.31
No.6
 57
 38.5
 4.12
No.7
 70
 48.8
 4.0
No.8
 73
 60
 1.6
1.8
2.0
2.2
No.9
 71.45
 57
 2.81
No.10
 72
 48.25
 4.6
No.11
 53
 34.7
 4.01
No.12
 57
 38.5
 4.12
No.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 98 ± 15 N·m.


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.


5.
caution Take care not to mistake the thrust bearing No.13 mounting direction.
Install the thrust bearing No.13 onto the direct clutch retainer.

6.
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.
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 (MB991635), 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) Using the special tool Wrench (MB991634), tighten the reduction brake piston nut to the specified torque 18.5 ± 3.5 N·m while fixing the special tool Socket (MB991635) 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.


16.
caution Take care not to mistake the thrust bearing No.12 mounting direction.
Apply vaseline or petrolatum jelly on the thrust bearing No.12, and then install on the front end of the direct planetary carrier.

17.
caution Confirm that the thrust bearing No.10 in the direct annulus gear is still at the specified location.
Install the direct annulus gear.


18.
caution Take care not to mistake the thrust bearing No.9 mounting direction.
Apply vaseline or petrolatum jelly to the thrust bearing No.9, and then install on the direct annulus gear.

19.
caution Measure and record the thickness of the thrust race No.8 before assembling.
Apply vaseline or blue petrolatum jelly on the thrust race No.8 removed, and then install it on the rear side of the center support.

20.
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 No.8 attached to the rear side of the center support does not fall off.
Install the center support.

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


22.Select the thrust race No.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.
  • When pushing in the direct annulus gear, use the special tool Oil seal installer (MD998304).
(3) Replace the thrust race No.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
(For direct planetary carrier end play)
(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
(For center support end play)
(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
(For brake reaction plate end play)
(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.
Standard value (reference): 1.49 - 1.95 mm
(For second brake end play)
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.
Standard value (reference): 1.65 - 2.11 mm
(For low/reverse brake end play)
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 No.7 mounting direction.
Apply vaseline or petrolatum jelly on the thrust bearing No.7, and then install the bearing on the rear side of the low/reverse annulus gear.

26.
caution Make sure that the thrust bearing No.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.
caution Take care not to mistake the brake plate (reaction plate side) installation direction.
Install the brake discs, brake plates and pressure plate selected in step 24 (9).


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 No.4 installation direction.
Apply vaseline or petrolatum jelly on the thrust bearing No.4, and then install on the reverse sun gear.


37.
caution Take care not to mistake the thrust bearing No.3 mounting direction.
Apply vaseline or petrolatum jelly on the thrust bearing No.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 No.2 mounting direction.
Apply vaseline or petrolatum jelly on the thrust bearing No.2, and then install on the reverse and overdrive clutch.

41.Apply vaseline or petrolatum jelly on the thrust race No.1, and then install on the oil pump.

42.
caution Never reuse the gasket.
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.
43.Tighten the ten oil pump mounting bolts to the specified torque 23 ± 3 N·m.

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
(For input shaft end play)
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 48 ± 6 N·m.

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.
  • 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
 Applied on all surface 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
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 11 ± 1 N·m.
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 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 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 Part No. MR166584 or equivalent

70.Install the oil pan.
71.Tighten the twenty oil pan mounting bolts to the specified torque 11 ± 1 N·m.


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.Tighten the two inhibitor switch mounting bolts to the specified torque 11 ± 1 N·m.

75.Install the manual control lever.
76.Tighten the manual control lever mounting nut to the specified torque 21.5 ± 3.5 N·m.

77.Install the O-ring to the output shaft.

78.Install the output shaft speed sensor.
79.Tighten the output shaft speed sensor mounting bolts to the specified torque 11 ± 1 N·m.

80.Install the O-ring to the input shaft.

81.Install the input shaft speed sensor.
82.Tighten the input shaft speed sensor mounting bolts to the specified torque 11 ± 1 N·m.
83.Install the Clamp.

84.
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