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Disassembly And Assembly: Assembly

CAUTION:
  • Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
  • Do not use grease, use petroleum jelly (i.e. Vaseline).
  • Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch discs or brake discs in ATF for at least two hours before assembling them.
  • When replacing a bushing, replace the assembly which it belongs to.
  • Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.
  1. Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case. Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.
    Fig 1: Installing Special Tool MD998412
    G02426247Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Tighten the seven mounting bolts < F4A42 > and eight mounting bolts < F4A51 > of the transfer drive gear bearing to the specified torque.
    • Tightening torque: 34 +/- 2 N.m (25 +/- 1 ft-lb) 
    Fig 2: Tightening Seven Mounting Bolts F4A42
    G02426248Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
    Fig 3: Installing Low-Reverse Brake Piston, Return Spring, And Spring Retainer
    G02426249Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Fit a new O-ring into the groove of one-way clutch inner race.
    Fig 4: Fitting O-Ring
    G02426250Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  5. Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.
    Fig 5: Checking Placement Of Identification Notches
    G02426251Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998703 < F4A42 > or MD998338 < F4A51 > and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.
    NOTE: This illustration shows F4A51.
    Fig 6: Installing Special Tools
    G02426252Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 7: Installing Wave Spring
    G02426253Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Install the six brake discs, five brake plates and snap ring as shown.
    NOTE: Do not install the pressure plate at this time.
    Fig 8: Installing Brake Discs, Brake Plates & Snap Ring (F4A42)
    G02426254Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 9: Installing Brake Discs, Brake Plates & Snap Ring (F4A51)
    G02426255Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  10. Install special tool MB991631 < F4A42 > or MB991632 < F4A51 > on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991631 < F4A42 > or MB991632 < F4A51 > to measure the end play of reaction plate. Then replace the snap ring installed in step 11 to adjust the end play to standard value.
    • Standard value: 0 - 0.16 mm (0 - 0.0063 inch) 
  13. Install the brake discs and brake plates as shown in the figure.

    Number of brake discs and plates 

    NUMBER OF BRAKE DISCS AND PLATES REFERENCE

    A/T MODEL BRAKE DISC BRAKE PLATE
    F4A42 3 2
    F4A51 4 3
    Fig 10: Installing Special Tool MB991631 (F4A42)
    G02426256Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Place special tool MB991631 < F4A42 > or MB991632 < F4A51 > on top of the brake disc in place of the pressure plate.
    Fig 11: Installing Special Tool MB991631 F4A51
    G02426257Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  15. Install the return spring, second brake piston and snap ring.
  16. Move special tool MB991631 < F4A42 > or MB991632 < F4A51 > and measure its movement.
    • Standard value of end play (Reference): 
      • 0.79 - 1.25 mm (0.0311 - 0.0492 inch) < F4A42 > 
      • 1.09 - 1.55 mm (0.0429 - 0.0610 inch) < F4A51 > 
      Fig 12: Installing Special Tools
      G02426258Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 13: Measuring Movement F4A42
      G02426259Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 14: Measuring Movement F4A51
      G02426260Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

    PRESSURE PLATE FOR SECOND BRAKE < F4A42 > 

    THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    0.6 - 0.8 (0.024 - 0.031) 1.6 (0.063) L MD759567
    0.8 - 1.0 (0.031 - 0.039) 1.8 (0.071) 1 MD759414
    1.0 - 1.2 (0.039 - 0.047) 2.0 (0.079) 0 MD759415
    1.2 - 1.4 (0.047 - 0.055) 2.2 (0.087) 2 MD759416
    1.4 - 1.6 (0.055 - 0.063) 2.4 (0.094) 4 MD759417
    1.6 - 1.8 (0.063 - 0.071) 2.6 (0.102) 6 MD759418

    PRESSURE PLATE FOR SECOND BRAKE < F4A51 > 

    THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.1 - 1.3 (0.043 - 0.051) 1.8 (0.071) E MD759425
    1.3 - 1.5 (0.051 - 0.059) 2.0 (0.079) D MD759426
    1.5 - 1.7 (0.059 - 0.067) 2.2 (0.087) C MD759427
    1.7 - 1.9 (0.067 - 0.075) 2.4 (0.094) B MD759428
    1.9 - 2.1 (0.075 - 0.083) 2.6 (0.102) A MD759429
    2.1 - 2.3 (0.083 - 0.091) 2.8 (0.110) 0 MD759430
  18. Turn the transaxle over so that the installation surface of the torque converter housing is facing up.

    Install special tool MD998913 in a dial gauge, and then move special tool MB991631 < F4A42 > or MB991632 < F4A51 > and measure its movement.

    • Standard value of end play (Reference): 1.65 - 2.11 mm (0.065 - 0.083 inch) 
    Fig 15: Installing Special Tool MD998913 In Dial Gauge
    G02426261Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.
    Fig 16: Measuring Movement F4A42
    G02426262Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 17: Measuring Movement F4A51
    G02426263Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    PRESSURE PLATE FOR OW-REVERSE BRAKE < F4A42 > 

    THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.3 - 1.5 (0.051 - 0.059) 1.6 (0.063) L MD759567
    1.5 - 1.7 (0.059 - 0.067) 1.8 (0.071) 1 MD759414
    1.7 - 1.9 (0.067 - 0.075) 2.0 (0.079) 0 MD759415
    1.9 - 2.1 (0.075 - 0.083) 2.2 (0.087) 2 MD759416
    2.1 - 2.3 (0.083 - 0.091) 2.4 (0.094) 4 MD759417
    2.3 - 2.5 (0.091 - 0.098) 2.6 (0.102) 6 MD759418
    2.5 - 2.7 (0.098 - 0.106) 2.8 (0.110) 8 MD759419
    2.7 - 2.9 (0.106 - 0.114) 3.0 (0.118) D MD759420

    PRESSURE PLATE FOR OW-REVERSE BRAKE < F4A51 > 

    THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.0 - 1.2 (0.039 - 0.047) 1.6 (0.063) F MD759568
    1.2 - 1.4 (0.047 - 0.055) 1.8 (0.071) E MD759425
    1.4 - 1.6 (0.055 - 0.063) 2.0 (0.079) D MD759426
    1.6 - 1.8 (0.063 - 0.071) 2.2 (0.087) C MD759427
    1.8 - 2.0 (0.071 - 0.079) 2.4 (0.094) B MD759428
    2.0 - 2.2 (0.079 - 0.087) 2.6 (0.102) A MD759429
    2.2 - 2.4 (0.087 - 0.094) 2.8 (0.110) 0 MD759430
    2.4 - 2.6 (0.094 - 0.102) 3.0 (0.118) 1 MD759431
    CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
  20. Remove all parts and special tools that were installed to take the measurements in steps 9 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.
  21. Install the snap ring into the groove of transaxle case output shaft bore.
  22. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.
    Fig 18: Taping Output Shaft Bearing Outer Race In Transaxle Case
    G02426264Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not reuse the bolt, as it has had sealant applied.
  23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
    • Tightening torque: 
      • 23 +/- 3 N.m (17 +/- 2 ft-lb) < F4A42 > 
      • 54 +/- 5 N.m (40 +/- 4 ft-lb) < F4A51 > 
    Fig 19: Tightening Mounting Bolts
    G02426265Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
    Fig 20: Installing Collar And Taper Roller Bearing
    G02426266Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
    • Tightening torque: 167 +/- 10 N.m (123 +/- 7 ft-lb) 
    NOTE: The jam nut is reverse threaded.
    Fig 21: Tightening Jam Nut
    G02426267Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  26. Move the output shaft to measure the end play and record the measurement value.
    Fig 22: Measuring End Play
    G02426268Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Remove the parts that were installed in steps 22 to 25.
  28. Select a spacer whose thickness corresponds to the measured amount of movement from the following table.

    SPACER FOR OUTPUT SHAFT 

    THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.81 - 1.85 (0.0713 - 0.0728) 1.88 (0.0740) 88 MD756579
    1.85 - 1.89 (0.0728 - 0.0744) 1.92 (0.0756) 92 MD756580
    1.89 - 1.93 (0.0744 - 0.0760) 1.96 (0.0772) 96 MD756581
    1.93 - 1.97 (0.0760 - 0.0776) 2.00 (0.0787) 00 MD756582
    1.97 - 2.01 (0.0776 - 0.0791) 2.04 (0.0803) 04 MD756583
    2.01 - 2.05 (0.0791 - 0.0807) 2.08 (0.0819) 08 MD756584
    2.05 - 2.09 (0.0807 - 0.0823) 2.12 (0.0835) 12 MD756585
    2.09 - 2.13 (0.0823 - 0.0839) 2.16 (0.0850) 16 MD756586
    2.13 - 2.17 (0.0839 - 0.0854) 2.20 (0.0866) 20 MD756587
    2.17 - 2.21 (0.0854 - 0.0870) 2.24 (0.0882) 24 MD756588
    2.21 - 2.25 (0.0870 - 0.0886) 2.28 (0.0898) 28 MD756589
    2.25 - 2.29 (0.0886 - 0.0902) 2.32 (0.0913) 32 MD756590
    2.29 - 2.33 (0.0902 - 0.0917) 2.36 (0.0929) 36 MD756591
    2.33 - 2.37 (0.0917 - 0.0933) 2.40 (0.0945) 40 MD756592
    2.37 - 2.41 (0.0933 - 0.0949) 2.44 (0.0961) 44 MD756593
    2.41 - 2.45 (0.0949 - 0.0965) 2.48 (0.0976) 48 MD756594
    2.45 - 2.49 (0.0965 - 0.0980) 2.52 (0.0992) 52 MD756595
    2.49 - 2.53 (0.0980 - 0.0996) 2.56 (0.1008) 56 MD756596
    2.53 - 2.57 (0.0996 - 0.1012) 2.60 (0.1024) 60 MD756597
    2.57 - 2.61 (0.1012 - 0.1028) 2.64 (0.1039) 64 MD756598
    2.61 - 2.65 (0.1028 - 0.1043) 2.68 (0.1055) 68 MD756599
    2.65 - 2.69 (0.1043 - 0.1059) 2.72 (0.1071) 72 MD760685
    2.69 - 2.73 (0.1059 - 0.1075) 2.76 (0.1087) 76 MD760686
  29. Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 28.
  30. Stake the jam nut with a punch (two places).
    Fig 23: Staking Jam Nut With Punch
    G02426269Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 24: Installing Cap
    G02426270Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 25: Installing Parking Pawl, Spacer, And Spring
    G02426271Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the parking roller support, and then insert the two parking roller support shafts.
    Fig 26: Installing Parking Roller Support
    G02426272Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS 

    Fig 27: Identifying Location Of Thrust Bearing, Thrust Races, And Thrust Washers
    G02426273Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 28: Part Number And Thickness Specification Chart (1 Of 2)
    G02426274Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 29: Part Number And Thickness Specification Chart (2 Of 2)
    G02426275Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the planetary carrier assembly.
    Fig 30: Installing Planetary Carrier Assembly
    G02426276Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. Install the planetary reverse sun gear.
    Fig 31: Installing Planetary Reverse Sun Gear
    G02426277Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the wave spring on the low-reverse brake piston.
    Fig 32: Installing Wave Spring
    G02426278Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the pressure plate that was selected in step 19. Next, install six brake discs and five brake plates, one on top of the other.
    Fig 33: Installing Pressure Plate
    G02426279Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the snap ring.
    Fig 34: Installing Snap Ring
    G02426280Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install the reaction plate.
    Fig 35: Installing Reaction Plate
    G02426281Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the snap ring that was selected in step 12.
    Fig 36: Installing Snap Ring
    G02426282Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install three brake discs < F4A42 > or four brake discs < F4A51 > and two brake plates < F4A42 > or three brake plates < F4A51 >, one on top of the other. Next, install the pressure plate that was selected in step 17.
    Fig 37: Installing Pressure Plate
    G02426283Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  42. Install the return spring and second brake piston.
    Fig 38: Installing Return Spring And Second Brake Piston
    G02426284Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Install the snap ring.
    Fig 39: Installing Snap Ring
    G02426285Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  44. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
    Fig 40: Checking Installation Direction Of Thrust Bearing
    G02426286Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use care to install the thrust bearing in the proper direction.
  45. Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.
    Fig 41: Attaching Thrust Bearing Number 6 To Inside Of Overdrive Clutch Hub
    G02426287Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  46. Install the reverse and overdrive clutch.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
    Fig 42: Checking Installation Direction Of Thrust Bearing Number 7
    G02426288Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
  48. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
    Fig 43: Taping Input Shaft Rear Bearing
    G02426289Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  49. Install the four seal rings in the grooves of the rear cover.
  50. Measure the end play of the under drive sun gear by the following procedures:
    Fig 44: Measuring End Play
    G02426290Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    1. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7.
    2. Install the rear cover on the transaxle case and tighten the bolts to the specified torque.

      Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

    3. Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.
    4. Install the under drive clutch hub on the under drive sun gear.
    5. Measure end play of the underdrive sun gear and record the measurement value.

      Standard value (Reference): 0.25 - 0.45 mm (0.0098 - 0.0177 inch) 

    6. After taking the measurement in steps (5), take out the installed parts in steps (1) through (4).
  51. Install the three O-rings.
    Fig 45: Installing O-Rings
    G02426291Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  52. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 50 from the table below. Install it on thrust bearing number 7.
    Fig 46: Locating Thrust Race
    G02426292Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    THICKNESS SPECIFICATION

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) PART NO.
    0.3 - 0.4 (0.012 - 0.016) 1.6 (0.063) MD707267
    0.4 - 0.5 (0.016 - 0.020) 1.7 (0.067) MD759681
    0.5 - 0.6 (0.020 - 0.024) 1.8 (0.071) MD723064
    0.6 - 0.7 (0.024 - 0.028) 1.9 (0.075) MD754794
    0.7 - 0.8 (0.028 - 0.031) 2.0 (0.079) MD707268
    0.8 - 0.9 (0.031 - 0.035) 2.1 (0.083) MD754795
    0.9 - 1.0 (0.035 - 0.039) 2.2 (0.087) MD723065
    1.0 - 1.1 (0.039 - 0.043) 2.3 (0.091) MD754796
    1.1 - 1.2 (0.043 - 0.047) 2.4 (0.094) MD724358
    1.2 - 1.3 (0.047 - 0.051) 2.5 (0.098) MD754797
    1.3 - 1.4 (0.051 - 0.055) 2.6 (0.102) MD754798
  53. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the illustrated position of the rear cover.
    NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.
    Fig 47: Applying Sealant
    G02426293Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Install the rear cover, and tighten its mounting bolts to the specified torque.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
    NOTE: After installation, kepp the sealed area away from the atf for approximately one hour.
    Fig 48: Installing Rear Cover
    G02426294Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  55. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 49: Installing Underdrive Clutch Hub
    G02426295Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  56. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
    Fig 50: Checking Installation Direction Of Thrust Bearing
    G02426296Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. Hold the input shaft, and install the underdrive clutch.
    Fig 51: Installing Underdrive Clutch
    G02426297Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14 inch) in diameter] on the underdrive clutch retainer as shown in the illustration.
    Fig 52: Placing Solder On Underdrive Clutch Retainer
    G02426298Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Install special tool MD998412 as shown.
    Fig 53: Installing Special Tool MD998412
    G02426299Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  60. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
  61. Tighten the oil pump mounting bolts (six pieces) to the specified torque.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
  62. Remove the oil pump mounting bolts.
  63. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 54: Removing Oil Pump
    G02426300Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  64. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
  65. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.
    Fig 55: Measuring Thickness Of Crushed Solder Beads
    G02426301Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    THICKNESS SPECIFICATION

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) ID SYMBOL PART NO.
    2.25 - 2.45 (0.089 - 0.096) 1.8 (0.071) 18 MD754509
    2.45 - 2.65 (0.096 - 0.104) 2.0 (0.079) 20 MD754508
    2.65 - 2.85 (0.104 - 0.112) 2.2 (0.087) 22 MD754507
    2.85 - 3.05 (0.112 - 0.120) 2.4 (0.094) 24 MD753793
    3.05 - 3.25 (0.120 - 0.128) 2.6 (0.102) 26 MD753794
    3.25 - 3.45 (0.128 - 0.136) 2.8 (0.110) 28 MD753795
  66. Install thrust washer number 1 that was selected in step 66 on the underdrive clutch retainer.
    Fig 56: Installing Thrust Washer Number 1
    G02426302Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Install special tool MD998412 as shown.
    Fig 57: Installing Special Tool MD998412
    G02426303Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Install the new oil pump gasket on the transaxle case.
  69. Install the oil pump and tighten the mounting bolts (six pieces) to the specified torque.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
  70. Make sure that the input shaft end play meets the standard value.
    • Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch) 
    Fig 58: Measuring End Play
    G02426304Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Install the oil filter.
    Fig 59: Installing Oil Filter
    G02426305Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 60: Taping Differential Bearing Outer Race In Transaxle Case
    G02426306Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Install the differential.
    Fig 61: Installing Differential
    G02426307Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  74. Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter] on the torque converter housing as shown in the illustration.
    Fig 62: Placing Beads Of Solder On Torque Converter Housing
    G02426308Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  75. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to press in the differential bearing outer race into the torque converter housing.
    Fig 63: Pressing In Differential Bearing Outer Race
    G02426309Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  76. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.
    • Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb) 
  77. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
    Fig 64: Tightening Mounting Bolts
    G02426310Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  78. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to the measured value and select a spacer with the corresponding thickness. Adjustment spacer sizes are all listed on VALVE BODY SPRING IDENTIFICATION TABLE . Select the most suitable one from among those listed.
    NOTE: * is the thickness for the differential case preload.
    Fig 65: Measuring Thickness Of Crushed Solder Beads
    G02426311Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  79. Install the spacer selected in step 79 to the torque converter housing.
  80. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to press the outer race into housing.
    Fig 66: Pressing Outer Race Into Housing
    G02426312Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  81. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the torque converter housing in the area shown.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.
    NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
    Fig 67: Applying Bead Of Sealant
    G02426313Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Install the two O-rings.
    Fig 68: Installing O-Rings
    G02426314Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  83. Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque.
    • Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb) 
    Fig 69: Tightening Mounting Bolts
    G02426315Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  84. Insert the two O-rings into the grooves of the manual control lever shaft.
  85. Install the manual control lever shaft and parking pawl rod.
    Fig 70: Installing Manual Control Lever Shaft And Parking Pawl Rod
    G02426316Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  86. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A."
  87. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
  88. Identify the accumulator spring and insert it and the accumulator piston into each hole of the transaxle case.
    NOTE: Accumulator springs are identified as shown in the illustration.
    IDENTIFICATION NUMBER REFERENCE

    NO. NAME IDENTIFICATION "BLUEING"
    1 For low-reverse brake None
    2 For underdrive clutch Half
    3 For second brake Whole surface
    4 For overdrive clutch None
    Fig 71: Identifying Accumulator Spring
    G02426317Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 72: Installing Accumulator Spring
    G02426318Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Install the strainer and second brake retainer oil seal.
    Fig 73: Installing Strainer And Second Brake Retainer Oil Seal
    G02426319Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  90. Insert a new O-ring to the groove of the solenoid valve harness connector.
  91. Insert the solenoid valve harness connector into the hole from the inside of the transaxle case so it is oriented as shown in the illustration. Then secure the snap ring to the connector groove.
    Fig 74: Installing Snap Ring
    G02426320Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  92. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
    Fig 75: Installing Steel Ball
    G02426321Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  93. Install the valve body and gasket to the transaxle case. Make sure that the manual valve's pin is in the groove in the detent plate of the manual control lever.
  94. Install the 27 valve body mounting bolts, and tighten to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
    Fig 76: Tightening Bolts
    G02426322Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  95. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
    Fig 77: Attaching Solenoid Valve Harness To Valve Body
    G02426323Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 78: Parts And Harness Reference Chart
    G02426324Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  96. Install the manual control shaft detent and tighten the bolt to the specified torque.
    • Tightening torque: 6 +/- 1 N.m (52 +/- 9 in-lb) 
    Fig 79: Installing Manual Control Shaft Detent
    G02426325Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  97. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes) or leaks will occur if the rear cover is installed after the sealant dries.
    NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.
    Fig 80: Applying Bead Of Sealant
    G02426326Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  98. Install the valve body cover, and then tighten its mounting bolts to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
    Fig 81: Installing Valve Body Cover
    G02426327Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  99. Install the Sealing cap and tighten the bolt to the specified torque.
    • Tightening torque: 5 +/- 1 N.m (43 +/- 9 in-lb) 
    Fig 82: Installing Sealing Cap
    G02426328Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  100. Install the park/neutral position switch and tighten the bolt to specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
  101. Install the manual control lever and tighten the nut to specified torque.
    • Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb) 
    Fig 83: Installing Manual Control Lever
    G02426329Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  102. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
      • Fig 84: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
      G02426330Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  103. Apply ATF on the both sides of the new gasket and threads of the eyebolts.
  104. Install the oil cooler feed tube together with new gaskets and tighten the eye bolts to the specified torque.
    • Tightening torque: 30 +/- 3 N.m (22 +/- 2 ft-lb) 
  105. Tighten the oil cooler feed pipe clamp bolt.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
  106. Install the oil dipstick.
  107. Install the cable support bracket.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
  108. Install the roll stopper brackets.
    • Tightening torque: 69 +/- 10 N.m (51 +/- 7 ft-lb) 
    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.
  109. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value.
    • Reference value: 
      • Approximately 12.2 mm (0.48 inch) < F4A42 > 
      • Approximately 9.4 mm (0.37 inch) < F4A51 > 
    Fig 85: Installing Torque Converter
    G02426331Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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