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 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 air breather
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 1: Locating Input And 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: Locating Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the Sealing cap and o-ring.

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

Fig 4: Removing Valve Body Cover
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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 & 2 Steel 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
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Remove the strainer and the second brake retainer oil seal.

Fig 10: Removing Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove each accumulator piston and spring.

COMPONENTS NUMBER REFERENCE

NUMBER	NAME
1	For low-reverse brake
2	For underdrive clutch
3	For second brake
4	For overdrive clutch

Fig 11: Removing Each Accumulator Piston And Spring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the manual control lever shaft roller.

Fig 12: Removing Manual Control Lever Shaft Roller
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 13: Removing Mounting Bolts, Differential Bearing Outer Race & Spacer From Torque Converter Housing
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 14: Removing O-Rings
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Remove the differential.
Remove the differential bearing outer race from the transaxle case.

Fig 15: Removing Differential Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 16: Removing Oil Filter
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Remove the oil pump mounting bolts (six bolts).
Install special tool MD998333 in hole "A."

Fig 17: Installing Special Tool MD98333
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 18: Turning Special Tools MD998333
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 19: Removing Thrust Washer Number 1
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Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 20: Removing Underdrive Clutch And Input Shaft
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Remove thrust bearing number 2.

Fig 21: Removing Thrust Bearing Number 2
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Remove the underdrive clutch hub.

Fig 22: Removing Underdrive Clutch Hub
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Remove the rear cover and input shaft rear bearing.

Fig 23: Removing Rear Cover & Input Shaft Rear Bearing, Thrust Race No. 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 24: Removing O-Rings
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Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 25: Removing Reverse And Overdrive Clutch And Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 26: Removing Overdrive Clutch Hub And Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 27: Removing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 28: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 29: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 30: Removing Second Brake Piston And Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the pressure plate, brake discs and brake plate.

NUMBER OF BRAKE DISCS AND PLATES REFERENCE

A/T MODEL	BRAKE DISC	BRAKE PLATE	(PRESSURE PLATE
F4A42	3	2	1
F4A51	4	3	1

Fig 31: Removing Pressure Plate And Brake Discs And Brake Plate

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the planetary carrier assembly.

Fig 32: Removing Planetary Carrier Assembly
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Remove the snap ring.

Fig 33: Removing Snap Ring
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Remove the reaction plate and the brake disc.

Fig 34: Removing Reaction Plate And Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 35: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.

Fig 36: Removing Brake Plates & Pressure Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 37: Removing Wave Spring
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Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 38: 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 39: Removing Two 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 < F4A42 > or MD998338 < F4A51 > and MD998924, compress the one-way clutch inner race.
  NOTE: This illustration shows F4A51.
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.
  
  Fig 40: Removing One-Way Clutch Inner Race & Low-Reverse Brake Piston
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the four < F4A51 > or three < F4A42 > transfer drive gear bearing mounting bolts.
Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

F4A42 = seven mounting bolts

F4A51 = eight mounting bolts

Fig 41: Removing Transfer Drive Gear Bearing Mounting Bolts F4A42
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 42: Removing Transfer Drive Gear Bearing Mounting Bolts F4A51
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 43: Removing Transfer Drive Gear
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Remove the cap by jabbing a screw driver into the center of the cap and prying it up.

Fig 44: Removing Cap
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Using a chisel, straighten the staked portions from the output shaft nut.

Fig 45: Straightening Staked Portions From 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 46: Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolt.

Fig 47: Removing Bearing Retainer Mounting Bolt
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 48: Removing Output Shaft
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Tap out the outer race and the spacer.
Remove the snap ring.

Fig 49: Removing Snap Ring
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