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.
The working area should be covered with a rubber mat to 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.
Use a dial gauge to measure the input shaft end play.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt, gaskets and the oil cooler feed tube.

Fig 1: Measuring Input Shaft End Play By Using Dial Gauge
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the air breather by inserting a screwdriver into the air breather and prying it up.

Fig 2: Removing Air Breather By Inserting Screwdriver Into Air Breather
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 3: Removing Input Shaft Speed Sensor 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 4: Removing Manual Control Lever And Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sealing cap and O-ring.

Fig 5: Removing Sealing Cap And O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 6: Removing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control shaft detent.

Fig 7: Removing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disconnect the solenoid valve harness from the valve body by disconnecting the fluid temperature sensor and all the connectors.

Fig 8: Disconnecting Solenoid Valve Connectors & Fluid Temperature Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Make sure that the manual control lever and the park/neutral position switch are removed. See step 8.
- Do not remove the bolts (four pieces) shown in the illustration.
Remove the valve body mounting bolts (twenty seven pieces).

Fig 9: Removing Valve Body Mounting Bolts (27)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket and the steel balls (two pieces).

Fig 10: Removing Valve Body, Gasket And 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 11: Removing Snap Ring From Connector
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 12: Removing Strainer And Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove each accumulator piston and spring.

ACCUMULATOR NAME REFERENCE CHART

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

Fig 13: Removing Accumulator Piston And Spring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 14: Removing Manual Control Lever Shaft And Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (eighteen pieces), and then remove the torque converter housing.
Remove the differential bearing outer race and spacer from the torque converter housing.

Fig 15: Removing Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (two pieces).

Fig 16: Removing O-Rings (2)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.

Fig 17: Removing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 18: Removing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump mounting bolts (six pieces).

Fig 19: Removing Oil Pump Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MD998333 in position shown in the illustration.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 20: Removing Oil Pump By Using Special Tools MD998333
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 21: Removing Thrust Washer No. 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 22: Removing Underdrive Clutch And Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 23: Removing Thrust Bearing No. 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 24: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 25: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking roller support shafts (two pieces), and then remove the parking pawl and parking roller support.

Fig 26: Removing Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the rear cover.
Remove thrust race number 8.
Remove the seal rings (four pieces).
Remove the input shaft rear bearing.

Fig 27: Removing Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 28: Removing O-Rings (3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 29: Removing Reverse And Overdrive Clutch And Thrust Bearing No. 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 30: Removing Overdrive Clutch Hub And Thrust Bearing No. 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 31: Removing Thrust Bearing No. 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 32: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 33: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 34: Removing Brake Piston And Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the pressure plate, second brake discs and second brake plates.

Number of second brake discs and plates:

SECOND BRAKE DISC & PLATE REFERENCE CHART

A/T MODEL	SECOND BRAKE DISC	SECOND BRAKE PLATE
F4A4 B	3	2
F4A5A	4	3

Fig 35: Removing Pressure Plate, Brake Discs And Brake Plates (1 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 36: Removing Pressure Plate, Brake Discs And Brake Plates (2 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the planetary carrier assembly.

Fig 37: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 38: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reaction plate and the brake disc.

Fig 39: Removing Reaction Plate And Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 40: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.
NOTE: *Includes the brake discs removed in step 48.

Fig 41: Removing Brake Plates, Brake Discs And Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 42: Removing Wave Spring
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 < F4A4B > or MD998338
  < F4A5A > and MD998924, compress the one-way clutch inner race.
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 43: Removing One-Way Clutch Inner Race And Low-Reverse Brake Piston (1 Of 2)
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Fig 44: Removing One-Way Clutch Inner Race And Low-Reverse Brake Piston (2 Of 2)
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear bearing mounting bolt (three or four pieces).
Then, turn the gear 1/8 turn (45 degrees) and remove the remaining bolts (three or four).

F4A4B: seven mounting bolts

F4A5A: eight mounting bolts

Fig 45: Removing Transfer Drive Gear Bearing Mounting Bolt (1 Of 3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 46: Removing Transfer Drive Gear Bearing Mounting Bolt (2 Of 3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 47: Removing Transfer Drive Gear Bearing Mounting Bolt (3 Of 3)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 48: Removing Transfer Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cap by inserting a screwdriver into the center of the cap and prying it up.

Fig 49: Removing Cap By Inserting Screwdriver Into Center Of Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a chisel, straighten the staked portions from the output shaft jam nut.

Fig 50: Straightening Staked Portions From Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 51: Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolts.

Fig 52: 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 53: Tapping On Rear End Of Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.
Remove the snap ring.
Remove the differential bearing outer race from the transaxle case.

Fig 54: Tapping Out Outer Race And Spacer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.