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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. Vase line).
  • Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse 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 In Installation Screw Hole Of Transfer Drive Gear Bearing In Transaxle Case
    G02394861Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Tighten the mounting bolts of the transfer drive gear bearing to the specified torque.

    F4A4B: seven mounting bolts

    F4A5A: eight mounting bolts

    Tightening torque: 

    34 +/- 2 N.m (25 +/- 1 ft-lb) 

    Fig 2: Tightening Mounting Bolts Of Transfer Drive Gear Bearing
    G02394862Courtesy 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 Into Transaxle Case
    G02394863Courtesy 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 Into Groove Of One-Way Clutch Inner Race
    G02394864Courtesy 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, as shown in illustration.
    Fig 5: Locating Identification Notches in One-Way Clutch Inner Race
    G02394865Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998903 < F4A4B > or MD998338 < F4A5A > and MD998924 as shown in illustration, and then compress the one-way clutch inner race and install the snap ring.
    Fig 6: Compressing One-Way Clutch Inner Race And Install Snap Ring (1 Of 2)
    G02394866Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 7: Compressing One-Way Clutch Inner Race And Install Snap Ring (2 Of 2)
    G02394867Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 8: Installing Wave Spring Onto Low-Reverse Brake Piston
    G02394868Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Install the brake discs (six pieces), brake plates (five pieces) and snap ring as shown in the figure.
    NOTE: Do not install the pressure plate at this time.
  10. Install special tool MB991631 < F4A4B > or MB991632 < F4A5A > on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991631 < F4A4B > or MB991632 < F4A5A > 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.
    Fig 9: Measuring End Play Of Reaction Plate By Moving Special Tool MB991631 (F4A4B )
    G02394869Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    Standard value: 0 - 0.16 mm (0 - 0.0063 inch) 

    Fig 10: Measuring End Play Of Reaction Plate By Moving Special Tool MB991631 (F4A5A )
    G02394870Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Install the brake discs and brake plates as shown in the figure.

    Number of second brake discs and plates

    SECOND BRAKE DISCS & PLATES REFERENCE CHART

    A/T MODEL SECOND BRAKE DISC SECOND BRAKE PLATE
    F4A4B 3 2
    F4A5A 4 3
    NOTE: Do not install the pressure plate at this time.
    Fig 11: Installing Brake Discs And Brake Plates
    G02394871Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Place special tool MB991631 < F4A4B > or MB991632 < F4A5A > on top of the brake disc in place of the pressure plate.
  15. Install the return spring, second brake piston and snap ring.
    Fig 12: Installing Return Spring, Second Brake Piston And Snap Ring
    G02394872Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Move special tool MB991631 < F4A4B > or MB991632 < F4A5A > and measure its movement.

    Standard value of end play (Reference): 

    0.79 - 1.25 mm (0.0311 - 0.0492 inch) < F4A4B > 

    1.09 - 1.55 mm (0.0429 - 0.0610 inch) < F4A5A > 

  17. Select a pressure plate whose thickness corresponds to the measured amount of movement shown in the following tables.
    Fig 13: Moving Special Tool And Measuring Its Movement
    G02394873Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    PRESSURE PLATE FOR SECOND BRAKE < F4A4B > MOVEMENT AMOUNT AND THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    0.6 - 0.8 (0.024 - 0.031) 1.6 (0.063) L
    0.8 - 1.0 (0.031 - 0.039) 1.8 (0.071) 1
    1.0 - 1.2 (0.039 - 0.047) 2.0 (0.079) 0
    1.2 - 1.4 (0.047 - 0.055) 2.2 (0.087) 2
    1.4 - 1.6 (0.055 - 0.063) 2.4 (0.094) 4
    1.6 - 1.8 (0.063 - 0.071) 2.6 (0.102) 6
    Fig 14: Measuring Amount Of Movement (F4A4B)
    G02394874Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    PRESSURE PLATE FOR SECOND BRAKE < F4A5A > MOVEMENT AMOUNT AND THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.1 - 1.3 (0.043 - 0.051) 1.8 (0.071) E
    1.3 - 1.5 (0.051 - 0.059) 2.0 (0.079) D
    1.5 - 1.7 (0.059 - 0.067) 2.2 (0.087) C
    1.7 - 1.9 (0.067 - 0.075) 2.4 (0.094) B
    1.9 - 2.1 (0.075 - 0.083) 2.6 (0.102) A
    2.1 - 2.3 (0.083 - 0.091) 2.8 (0.110) 0
    Fig 15: Measuring Amount Of Movement (F4A5A)
    G02394875Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 < F4A4B > or MB991632 < F4A5A > and measure its movement.

    Standard value of end play (Reference): 

    1.65 - 2.11 mm (0.0649 - 0.0831 inch) 

  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
    Fig 16: Moving Special Tool And Measuring Its Movement
    G02394876Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A4B > MOVEMENT AMOUNT AND THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.3 - 1.5 (0.051 - 0.059) 1.6 (0.063) L
    1.5 - 1.7 (0.059 - 0.067) 1.8 (0.071) 1
    1.7 - 1.9 (0.067 - 0.075) 2.0 (0.079) 0
    1.9 - 2.1 (0.075 - 0.083) 2.2 (0.087) 2
    2.1 - 2.3 (0.083 - 0.091) 2.4 (0.094) 4
    2.3 - 2.5 (0.091 - 0.098) 2.6 (0.102) 6
    2.5 - 2.7 (0.098 - 0.106) 2.8 (0.110) 8
    2.7 - 2.9 (0.106 - 0.114) 3.0 (0.118) D
    Fig 17: Measuring Amount Of Movement (F4A4B)
    G02394877Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 18: Measuring Amount Of Movement (F4A5A)
    G02394878Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A5A > MOVEMENT AMOUNT AND THICKNESS SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.0 - 1.2 (0.039 - 0.047) 1.6 (0.063) F
    1.2 - 1.4 (0.047 - 0.055) 1.8 (0.071) E
    1.4 - 1.6 (0.055 - 0.063) 2.0 (0.079) D
    1.6 - 1.8 (0.063 - 0.071) 2.2 (0.087) C
    1.8 - 2.0 (0.071 - 0.079) 2.4 (0.094) B
    2.0 - 2.2 (0.079 - 0.087) 2.6 (0.102) A
    2.2 - 2.4 (0.087 - 0.094) 2.8 (0.110) 0
    2.4 - 2.6 (0.094 - 0.102) 3.0 (0.118) 1
    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 19: Tapping Output Shaft Bearing Outer Race In Transaxle Case By Using Special Tools MB990930 and MB990938
    G02394879Courtesy 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: 

    29 +/- 2 N.m (21 +/- 1 ft-lb) < F4A4B > 

    54 +/- 5 N.m (40 +/- 4 ft-lb) < F4A5A > 

    Fig 20: Tightening Mounting Bolts Of Output Shaft Bearing Retainer
    G02394880Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Use special tool MD998350 < F4A4B > or MB998323 < F4A5A > to install the collar and taper roller bearing on the output shaft.
    Fig 21: Installing Collar And Taper Roller Bearing On Output Shaft By Using Special Tool MD998350 (F4A4B)
    G02394881Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 22: Installing Collar And Taper Roller Bearing On Output Shaft By Using Special Tool MD998323 (F4A5A)
    G02394882Courtesy 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: 170 +/- 10 N.m (125+/- 7 ft-lb) 

    NOTE: The jam nut is reverse threaded.
    Fig 23: Tightening Jam Nut To Specified Torque
    G02394883Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  26. Move the output shaft to measure the end play and record the measurement value.
    Fig 24: Measuring End Play By Moving Output shaft
    G02394884Courtesy 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 tables.
    SPACER FOR OUTPUT SHAFT MOVEMENT AMOUNT AND THICKNESS SPECIFICATION (1 OF 2)

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.81 - 1.85 (0.0713 - 0.0728) 1.88 (0.0740) 88
    1.85 - 1.89 (0.0728 - 0.0744) 1.92 (0.0756) 92
    1.89 - 1.93 (0.0744 - 0.0760) 1.96 (0.0772) 96
    1.93 - 1.97 (0.0760 - 0.0776) 2.00 (0.0787) 00
    SPACER FOR OUTPUT SHAFT MOVEMENT AMOUNT AND THICKNESS SPECIFICATION (2 OF 2)

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.97 - 2.01 (0.0776 - 0.0791) 2.04 (0.0803) 04
    2.01 - 2.05 (0.0791 - 0.0807) 2.08 (0.0819) 08
    2.05 - 2.09 (0.0807 - 0.0823) 2.12 (0.0835) 12
    2.09 - 2.13 (0.0823 - 0.0839) 2.16 (0.0850) 16
    2.13 - 2.17 (0.0839 - 0.0854) 2.20 (0.0866) 20
    2.17 - 2.21 (0.0854 - 0.0870) 2.24 (0.0882) 24
    2.21 - 2.25 (0.0870 - 0.0886) 2.28 (0.0898) 28
    2.25 - 2.29 (0.0886 - 0.0902) 2.32 (0.0913) 32
    29 - 2.33 (0.0902 - 0.0917) 2.36 (0.0929) 36
    2.33 - 2.37 (0.0917 - 0.0933) 2.40 (0.0945) 40
    2.37 - 2.41 (0.0933 - 0.0949) 2.44 (0.0961) 44
    2.41 - 2.45 (0.0949 - 0.0965) 2.48 (0.0976) 48
    2.45 - 2.49 (0.0965 - 0.0980) 2.52 (0.0992) 52
    2.49 - 2.53 (0.0980 - 0.0996) 2.56 (0.1008) 56
    2.53 - 2.57 (0.0996 - 0.1012) 2.60 (0.1024) 60
    2.57 - 2.61 (0.1012 - 0.1028) 2.64 (0.1039) 64
    2.61 - 2.65 (0.1028 - 0.1043) 2.68 (0.1055) 68
    2.65 - 2.69 (0.1043 - 0.1059) 2.72 (0.1071) 72
    2.69 - 2.73 (0.1059 - 0.1075) 2.76 (0.1087) 76
  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 25: Staking Jam Nut With Punch
    G02394885Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 26: Installing Cap By Using Special Tools MB990931 And MB990938 (1 Of 2)
    G02394886Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 27: Installing Cap By Using Special Tools MB990931 And MB990938 (2 Of 2)
    G02394887Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Install the planetary carrier assembly.
    Fig 28: Installing Planetary Carrier Assembly
    G02394888Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the planetary reverse sun gear.
    Fig 29: Installing Planetary Reverse Sun Gear
    G02394889Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the wave spring on the low-reverse brake piston.
    Fig 30: Installing Wave Spring On Low-Reverse Brake Piston
    G02394890Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. Install the pressure plate that was selected in step 19. Next, install brake discs (six pieces) and brake plates (five pieces), one on top of the other.
    Fig 31: Installing Brake Discs And Brake Plates
    G02394891Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the snap ring.
    Fig 32: Installing Snap Ring
    G02394892Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the reaction plate.
    Fig 33: Installing Reaction Plate
    G02394893Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the snap ring that was selected in step 12.
    Fig 34: Installing Snap Ring
    G02394894Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install second brake discs and second brake plates, one on top of the other. Next, install the pressure plate that was selected in step 17.

    Number of second brake discs and plates:

    SECOND BRAKE DISCS & PLATES REFERENCE CHART

    A/T MODEL SECOND BRAKE DISC SECOND BRAKE PLATE
    F4A4B 3 2
    F4A5A 4 3
    Fig 35: Installing Brake Discs And Brake Plates (1 Of 2)
    G02394895Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 36: Installing Brake Discs And Brake Plates (2 Of 2)
    G02394896Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the return spring and second brake piston.
    Fig 37: Installing Return Spring And Brake Piston
    G02394897Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install the snap ring.
    Fig 38: Installing Snap Ring
    G02394898Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 39: Identifying Thrust Bearing, Thrust Races And Thrust Washers
    G02394899Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown in illustration.
  42. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
    Fig 40: Installing Thrust Bearing No. 5 On Hub Of Planetary Reverse Sun Gear
    G02394900Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use care to install the thrust bearing in the proper direction.
  43. Attach thrust bearing number 6 to the inside of the overdrive dutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.
    Fig 41: Installing Thrust Bearing No. 6 & Overdrive Clutch Hub
    G02394901Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Install the reverse and overdrive clutch.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown in illustration.
  45. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
    Fig 42: Checking Installation Direction Of Thrust Bearing No. 7
    G02394902Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  46. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
  47. Install the seal rings (four pieces) in the grooves of the rear cover.
    Fig 43: Tapping Input Shaft Rear Bearing In Rear Cover
    G02394903Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  48. Measure the end play of the under drive sun gear by the following procedures:
    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.
      Fig 44: Measuring End Play Of Underdrive Sun Gear
      G02394904Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    4. Install the under drive clutch hub on the underdrive 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).
  49. Install the O-rings (three pieces).
    Fig 45: Installing O-Rings
    G02394905Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  50. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 47 from the following table. Install it on thrust bearing number 7.
    THRUST RACE NO. 8 THICKNESS REFERENCE

    MEASUREMENT VALUE mm (in) THICKNESS mm (in)
    0.3 - 0.4 (0.012 - 0.016) 1.6 (0.063)
    0.4 - 0.5 (0.016 - 0.020) 1.7 (0.067)
    0.5 - 0.6 (0.020 - 0.024) 1.8 (0.071)
    0.6 - 0.7 (0.024 - 0.028) 1.9 (0.075)
    0.7 - 0.8 (0.028 - 0.031) 2.0 (0.079)
    0.8 - 0.9 (0.031 - 0.035) 2.1 (0.083)
    0.9 - 1.0 (0.035 - 0.039) 2.2 (0.087)
    1.0 - 1.1 (0.039 - 0.043) 2.3 (0.091)
    1.1 - 1.2 (0.043 - 0.047) 2.4 (0.094)
    1.2 - 1.3 (0.047 - 0.051) 2.5 (0.098)
    1.3 - 1.4 (0.051 - 0.055) 2.6 (0.102)
  51. 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). Leaks will occur if the rear cover is installed after the sealant dries.
    Fig 46: Applying Bead Of Sealant To Rear Cover
    G02394906Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  52. 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, keep the sealed area away from ATF for approximately one hour.
    Fig 47: Tightening Rear Cover Mounting Bolts
    G02394907Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 48: Inserting Parking Pawl Shaft
    G02394908Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Install the parking roller support, and then insert the parking roller support shafts (two pieces).
    Fig 49: Inserting Parking Roller Support Shafts
    G02394909Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  55. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 50: Installing Underdrive Clutch Hub To Underdrive Sun Gear
    G02394910Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown in illustration.
  56. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
    Fig 51: Install Thrust Bearing No. 2 On Underdrive Clutch Hub
    G02394911Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. Hold the input shaft, and install the underdrive clutch.
    Fig 52: Installing Underdrive Clutch
    G02394912Courtesy 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 53: Placing Beads Of Solder On Underdrive Clutch Retainer
    G02394913Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Install special tool MD998412 as shown in illustration.
  60. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
    Fig 54: Installing Special Tool MD998412
    G02394914Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Tighten the six oil pump mounting bolts to the specified torque.

    Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb) 

  62. Remove the oil pump mounting bolts.
  63. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 55: Removing Oil Pump And Crushed Solders
    G02394915Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  64. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
    Fig 56: Measuring Thickness Of Crushed Solder Beads Using Micrometer
    G02394916Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Select a thrust washer number 1 whose thickness corresponds to the measured value from the following table.
    THRUST WASHER NO. 1 THICKNESS REFERENCE

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) ID SYMBOL
    2.25 - 2.45 (0.089 - 0.096) 1.8 (0.071) 18
    2.45 - 2.65 (0.096 - 0.104) 2.0 (0.079) 20
    2.65 - 2.85 (0.104 - 0.112) 2.2 (0.087) 22
    2.85 - 3.05 (0.112- 0.120) 2.4 (0.094) 24
    3.05 - 3.25 (0.120 - 0.128) 2.6 (0.102) 26
    3.25 - 3.45 (0.128 - 0.136) 2.8 (0.110) 28
  66. Install thrust washer number 1 that was selected in step 64 on the underdrive clutch retainer.
    Fig 57: Installing Thrust Washer No. 1
    G02394917Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Install special tool MD998412 as shown in illustration.
  68. Install the new oil pump gasket on the transaxle case.
  69. Install the oil pump and tighten the six mounting bolts to the specified torque.

    Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb) 

    Fig 58: Installing Special Tool MD998412
    G02394918Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 59: Checking Input Shaft End Play
    G02394919Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Install the oil filter.
    Fig 60: Installing Oil Filter
    G02394920Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Use special tools MB990935 < F4A4B > or MB990936 < F4A5A > and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 61: Tapping Differential Bearing Outer Race In Transaxle Case By Using Special Tools MB990935 (F4A4B)
    G02394921Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 62: Tapping Differential Bearing Outer Race In Transaxle Case By Using Special Tools MB990936 (F4A5A)
    G02394922Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Install the differential.
    Fig 63: Installing Differential
    G02394923Courtesy 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 64: Placing Beads Of Solder On Torque Converter Housing
    G02394924Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  75. Use special tools MB990935 < F4A4B > or MB990936 < F4A5A > and MB990938 to press the differential bearing outer race into the torque converter housing.
    Fig 65: Pressing Differential Bearing Outer Race Into Torque Converter Housing By Using Special Tools MB990935 (F4A4B)
    G02394925Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 66: Pressing Differential Bearing Outer Race Into Torque Converter Housing By Using Special Tools MB990936 (F4A5A)
    G02394926Courtesy 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 67: Removing Torque Converter Housing
    G02394927Courtesy 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 ADJUSTING PLATE, SNAP RING AND SPACERS . Select the most suitable one from among those listed.
    NOTE: * is the thickness for the differential case preload.
  79. Install the spacer selected in step 77 to the torque converter housing.
    Fig 68: Measuring Thickness Of Crushed Solder Beads Using Micrometer
    G02394928Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. Use special tools MB990935 < F4A4B > or MB990936 < F4A5A > and MB990938 to press the outer race into housing.
    Fig 69: Pressing Outer Race Into Housing By Using Special Tools MB990935 (F4A4B)
    G02394929Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 70: Pressing Outer Race Into Housing By Using Special Tools MB990936 (F4A5A)
    G02394930Courtesy 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 in illustration.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes). Leaks will occur if the rear cover is installed after the sealant dries.
    NOTE: After installation, keep the sealed area away from ATF for approximately one hour.
    Fig 71: Applying Bead Of Sealant To Torque Converter Housing
    G02394931Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Install the O-rings (two pieces).
    Fig 72: Installing O-Rings (2)
    G02394932Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  83. Install the torque converter housing and then tighten its mounting bolts (eighteen pieces) to the specified torque.

    Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb) 

  84. Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
  85. Install the manual control lever shaft and parking pawl rod.
    Fig 73: Tightening Torque Converter Housing Mounting Bolts
    G02394933Courtesy 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", as shown in illustration.
  87. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
    Fig 74: Aligning Hole "A" With Groove In Manual Control Lever Shaft
    G02394934Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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.
    ACCUMULATOR SPRING NAME AND IDENTIFICATION 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 75: Identifying Accumulator Springs
    G02394935Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 76: Inserting Accumulator Spring And Accumulator Piston Into Hole Of Transaxle Case
    G02394936Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Install the strainer and second brake retainer oil seal.
    Fig 77: Installing Strainer And Second Brake Retainer Oil Seal
    G02394937Courtesy 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 78: Installing Snap Ring To Connector Groove
    G02394938Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  92. Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
  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.
    Fig 79: Installing Steel Balls Into Holes In Top Face Of Valve Body
    G02394939Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  94. Install the valve body mounting bolts (twenty seven pieces), and tighten to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 80: Installing Valve Body Mounting Bolts
    G02394940Courtesy 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 81: Attaching Solenoid Valve Harness To Valve Body (1 Of 2)
    G02394941Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 82: Attaching Solenoid Valve Harness To Valve Body (2 Of 2)
    G02394942Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  96. Install the manual control shaft detent and tighten the bolt to the specified torque.

    Tightening torque: 6.0 +/- 1.0 N.m (52 +/- 9 in-lb) 

    Fig 83: Installing Manual Control Shaft Detent And Tightening Bolt
    G02394943Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  97. Apply a 2.4 - 2.6 mm (0.09 - 0.10 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown in illustration.
    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 ATF for approximately one hour.
    Fig 84: Applying Bead Of Sealant To Valve Body Cover
    G02394944Courtesy 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 85: Tightening Valve Body Cover Mounting Bolts
    G02394945Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  99. Install the sealing cap and tighten the bolt to the specified torque.

    Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 9 in-lb) 

    Fig 86: Installing Sealing Cap And Tightening Bolt
    G02394946Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  100. Install the park/neutral position switch and tighten the bolt to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

  101. Install the manual control lever and tighten the nut to the specified torque.

    Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb) 

    Fig 87: Installing Manual Control Lever And Tightening Nut
    G02394947Courtesy 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 88: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor And Tightening Bolt
    G02394948Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  103. Press Face "A" of the air breather to be even with Face "B" of the transmission case as shown in the illustration.
  104. Apply ATF on the both sides of the new gasket and threads of the eye bolts, and then tighten to the specified torque.

    Tightening torque: 24 +/- 3 N.m (18 +/- 2 ft-lb) 

  105. Tighten the oil cooler feed pipe clamp bolt to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 89: Pressing Face "A" Of Air Breather To Be Even With Face "B" Of Transmission Case
    G02394949Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  106. Install the oil dipstick.
  107. Install the cable support brackets to the specified torque.

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

  108. Install the roll stopper brackets.

    Tightening torque: 70 +/- 10 N.m (52+/- 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 dimension "A" shown in illustration meets the reference value.

    Reference value: 

    Approximately 12.2 mm (0.48 inch) < F4A4B > 

    Approximately 9.4 mm (0.37 inch) < F4A5A > 

    Fig 90: Installing Torque Converter To Dimension "A"
    G02394950Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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