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Transaxle Reassembly

  1. Handle all parts carefully to avoid damaging bearing and mating surfaces. Lubricate all parts with Dexron II before reassembly. Gaskets and thrust washers may be held in place with petroleum jelly.
  2. Place transaxle on bench with oil pan mounting surface up. Install annulus gear and output flange assembly with bearings and transfer drive gear attached. Install snap ring on output flange rear bearing.
  3. Install bearing outer races, inner races and spacer (in correct direction) to transfer idle gear. See Fig 1 . Install NEW "O" ring in groove of transfer idler gear shaft.
    Fig 1: Installing Transfer Gear, Bearings & Spacer
    G96A15156Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Install transfer idle gear assembly in transaxle case. Insert idler shaft from outside of case. Screw in and tighten idler shaft to transaxle case using wrench adapter.
  5. Using torque wrench and Torque Wrench Adapter, measure output flange preload. See Fig 2 . Preload should be 13 INCH lbs. (1.5 N.m) on KM175 transaxle, 7 INCH lbs. (0.8 N.m) on all other transaxles.
    Fig 2: Measuring Output Flange Preload
    G96B15157Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. If preload is incorrect, tighten or loosen transfer idler shaft until correct reading is obtained. Install idler shaft lock plate and tighten bolt. On KM 175 transaxle, install NEW "O" rings on oil pipe and install in side of case.
  7. On all transaxles, install NEW "O" ring in groove around output flange and install bearing retainer. On KM175 transaxle, apply sealant to top of bearing retainer screws. Ensure sealant does not ooze out of screw heads.
  8. On all transaxles, install transfer shaft, governor, and tapered bearing into case. Install Transfer Shaft Retainer on converter housing. See Fig 3 .
  9. Install transfer shaft bearing inner race, outer race and snap ring to transfer shaft (end opposite retainer plate). Install transfer driven gear onto transfer shaft. Install snap ring on end of transfer shaft. Turn transaxle case so engine mating side is up.
    Fig 3: KM170 Transaxle Transfer Shaft Retainer Plate
    G96C15158Courtesy of HYUNDAI MOTOR CO.
  10. Install thrust race No. 12 and thrust bearing No. 11 to output flange (thrust race No. 13 and thrust bearing No. 12 on KM175 transaxle). Ensure thrust bearing No. 10 is installed in planetary gear carrier (thrust bearing No. 11 on KM 175 transaxle). See Fig 5 and Fig 6 .
  11. Install planetary gear carrier on internal gear. Attach thrust race No. 10 (KM175 transaxle only) and bearing No. 9 to forward sun gear. Assemble forward sun gear with reverse sun gear and install assembly into planetary gear carrier. On KM175 transaxle, install "O" ring into pressure plug port of center support assembly.
  12. On all transaxles, attach Handle and Center Support Remover to center support. Lubricate overrunning clutch of low-reverse brake in center support with Dexron II. Insert center support with low-reverse brake assembly into case.
  13. Press center support with 22 lbs. (10 kg) of pressure and tighten center support bolts. Install Sun Gear Holder so that, when transaxle in placed upside down, sun gear assembly will stay in place.
    Fig 4: Installing Set Screw, Detent Ball & Spring to Manual Control Shaft
    G96D15159Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Insert manual control shaft into case, pushing it fully toward manual control lever. With shaft fully seated against inner part of case, install a NEW "O" ring. See Fig 4 .
  15. With "O" ring installed, pull manual control shaft back until set screw groove is aligned with set screw hole. Install set screw with gasket, detent ball, and spring as shaft is pulled back into place.
  16. Install parking sprag rod to detent plate of manual control shaft. Install parking sprag rod support and tighten bolts. See Fig. 23. Install accumulator piston and spring (if equipped).
  17. Install "O" ring at top center of valve body (brake oil pressure passage). Install valve body in transaxle, fitting detent plate pin (for manual control shaft) in slot of manual valve. Install and tighten valve body bolts.
  18. Install solenoid valve connector in case With cut-out facing oil pan side (if equipped). Insert throttle cable into case and connect to throttle cable cam (if equipped). Install oil filter, oil pan gasket, and oil pan.
  19. Turn transaxle over so that oil pump mounting surface is facing upward. Remove sun gear holder. Install anchor rod for kickdown band, install kickdown servo spring, piston, and sleeve (if equipped) into case. Install snap ring.
    NOTE: It may be necessary to use Spring Compressor to install kickdown servo piston snap ring.
  20. Install kickdown band and attach band ends to anchor rod and servo piston rod. Install kickdown drum, meshing splines with reverse sun gear. Place kickdown band on kickdown drum and tighten kickdown servo adjusting screw (if equipped) to hold band in place.
  21. Install thrust bearing No. 8 and thrust race No. 7 on kickdown drum. See Fig 5 and Fig 6 . Install clutch hub to forward sun gear splines. Install thrust race No. 5 and thrust bearing No. 6 on clutch hub.
  22. Install rear clutch assembly. Install fiber thrust washer No. 2 on rear clutch retainer. Install thrust bearing No. 4 and metal thrust race on rear clutch retainer. Install front clutch assembly.
  23. Attach thrust race No. 3 to rear of oil pump assembly. If end play (measured during disassembly) is not .028-.056" (.7-1.4 mm), replace thrust race No. 3 to correct end play. See Fig 5 and Fig 6 .
    NOTE: If thrust race No. 3 is replaced with one of a different thickness, also replace thrust washer No. 1 between oil pump and front clutch. Replacement thrust washer should be .040" (1.0 mm) thicker than thrust race.
  24. Install original or selected thrust washer No. 1 on front clutch. Install differential assembly. Install Guide Pin in transaxle case. Install oil pump gasket and adapter.
  25. Install oil pump gasket, oil pump assembly, and remove guide pin. Install "O" ring in groove of oil pump housing and lubricate "O" ring with Dexron II. Install oil pump and tighten bolts. Ensure thrust washer does not drop out of place.
  26. Ensure transfer shaft end play (measured during disassembly) is .004-.006" (.1-.15 mm) on KM170 transaxle. End play should be 001" (.025 mm) on all others.
  27. If end play is incorrect, remove bearing outer race and replace old spacer with a NEW spacer. Spacers are available from .072" (1.84 mm) to .106" (2.68 mm) in .001" (.025 mm) increments. Reinstall bearing outer race.
  28. Apply silicone sealant to top parting surface of transaxle case. Place spacer on differential bearing outer race. Install gasket on transaxle case. Install converter housing and tighten bolts.
  29. Check differential case end play. End play should be 0-.006" (0-.15 mm). Also recheck input shaft and transfer shaft end play. If end play measurements are incorrect, readjust.
  30. Install transfer shaft cover and holder. Install drive shaft oil seals. Install inhibitor switch and manual lever. Adjust inhibitor switch. Install pulse generators (if equipped).
  31. On KM175 transaxles, insert end clutch shaft with longest spline inward. Install thrust washer with grooved side outward. Install end clutch hub. Fit thrust washer on return spring end of end clutch. Install end clutch and cover.
  32. On all transaxles, lubricate torque converter surface (where converter slides into oil pump) with Dexron II fluid and carefully install converter. Make sure converter meshes with oil pump drive gear.
    Fig 5: Cross-Sectional View Showing Locations of Thrust Bearings, Thrust Races & Thrust Washers (KM175)
    G96G15160Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 6: Cross-Sectional View Showing Locations of Thrust Bearings, Thrust Races & Thrust Washers (All Except KM175)
    G96H15161Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. After installing torque converter, measure distance from mating surface of converter housing to torque converter machined surface. Torque converter is properly installed when measurement is about .47" (12 mm). If not, remove converter and check alignment of converter with oil pump drive.
    Fig 7: Installing Parking Sprag Rod & Support
    G96I15162Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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