Disassembly And Assembly: Disassembly

CAUTION:

Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
Work or a rubber mat and keep it clean at all times.
Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
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 plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
If the transaxle body has been damaged, disassemble and clean the cooler system.

Remove the torque converter.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt gauge, gaskets and the oil cooler feed tube.
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 1: Removing Input Shaft Speed Sensor & Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.
Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.

Fig 2: Removing Manual Control Lever & Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the Sealing cap and o-ring.

Fig 3: Removing Sealing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 4: Removing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control shaft detent.

Fig 5: Removing Manual Control Shaft Detent
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Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.

Fig 6: Disconnecting Solenoid Valve Harness
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CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See step 8.
Remove the valve body mounting bolts (27 pieces).

Fig 7: Removing Valve Body Mounting Bolts
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CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket, and the two steel balls.

Fig 8: Removing Valve Body, Gasket & Steels Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.

Fig 9: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 10: Removing Strainer & Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring.

Fig 11: Identifying Accumulator Piston & Spring (1 Of 2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 12: Identifying Accumulator Piston & Spring (2 Of 2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft roller.

Fig 13: Removing Manual Control Lever Shaft Roller, Manual Control Lever Shaft & Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft and the parking pawl rod.
Remove the torque converter housing mounting bolts (18 bolts), and then remove the torque converter housing.

Fig 14: Removing Torque Converter Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential bearing outer race and spacer from the torque converter housing.
Remove the O-rings (two pieces).

Fig 15: Removing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.

Fig 16: Removing Differential
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Remove the differential bearing outer race from the transaxle case.
Remove the oil filter.

Fig 17: Removing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump mounting bolts (six bolts).

Fig 18: Removing Oil Pump Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998333 in hole "A".

Fig 19: Identifying Oil Pump Remover (MD998333)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.
Remove thrust washer number 1.

Fig 20: Removing Thrust Washer #1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 21: Removing Underdrive Clutch & Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 22: Removing Thrust Bearing #2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 23: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the rear cover and input shaft rear bearing.

Fig 24: Removing Rear Cover, Input Shaft Rear Bearing, Thrust Race #8 & Seal Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust race number 8.
Remove the seal rings (four pieces).
Remove the O-rings (three pieces).

Fig 25: Removing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 26: Removing Thrust Bearing #7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 27: Removing Overdrive Clutch Hub & Clutch Bearing #6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 28: Removing Thrust Bearing #5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 29: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 30: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 31: Removing Second Brake Piston & Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure plate, brake discs and brake plate.

Fig 32: Removing Pressure Plate, Brake Discs & Brake Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 33: Identifying Number Of Brake Discs & Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 34: Removing Planetary Carrier Assembly
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Remove the snap ring.

Fig 35: Removing Snap Ring
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Remove the reaction plate and the brake disc.

Fig 36: Removing Reaction Plate & Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 37: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (four pieces), brake discs (five pieces) and pressure plate.

Fig 38: Removing Brake Plates, Brake Discs & Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 39: Removing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 40: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the two parking roller support shafts, and then remove the parking roller support.

Fig 41: Removing Parking Roller Support Shafts & Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998903 and MD998924, compress the one-way clutch inner race.
  
  Fig 42: Identifying Spring Compressor (MD998903) & Spring Compressor Retainer (MD998924)
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
Remove the four or three transfer drive gear bearing mounting bolts.
Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

Fig 43: Removing Transfer Drive Gear Bearing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 44: Removing Transfer Drive Gear
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Remove the cap by jabbing a screw driver in to the center of the cap and prying it up.

Fig 45: Removing Cap
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Using a chisel, straighten the staked portions from the output shaft nut.

Fig 46: Unstaking Output Shaft Nut
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CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 47: Identifying Socket (41) (MB991625) & Torque Wrench Socket (MB990607)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolt.

Fig 48: Removing Bearing Retainer Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 49: Removing Output Shaft, Taper Roller Bearing & Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.

Fig 50: Removing Outer Race & Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.