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 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.

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 Transfer Drive Gear Bearing And Gear In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.

Fig 3: Installing Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 Identification Notches In One-Way Clutch Inner Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put the snap ring on the inner race.
Set special tools MD998903 < F4A4B > or MD998338 < F4A5A > and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.

Fig 6: Putting Snap Ring On Inner Race (F4A4B)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 7: Putting Snap Ring On Inner Race (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring onto the low-reverse brake piston.

Fig 8: Installing Wave Spring Onto Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
Install special tool MB991631 < F4A4B > or MB991632 < F4A5A > on the brake disc.
Install the reaction plate and the used snap ring.
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.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)

Fig 9: Installing Brake Discs (F4A4B)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 10: Installing Brake Discs (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the brake discs and brake plates as shown in the figure.

Number of second brake discs and plates

SECOND BRAKE DISCS AND PLATES REFERENCE

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 Return Spring (F4A4B)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Place special tool MB991631 < F4A4B > or MB991632 < F4A5A > on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.

Fig 12: Installing Return Spring (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 >

Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

Fig 13: Measuring Pressure Plate Thickness

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR SECOND BRAKE < F4A4B >

SECOND BRAKE PRESSURE PLATE THICKNESS (F4A4B) 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 Pressure Plate Thickness (F4A4B)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR SECOND BRAKE < F4A5A >

SECOND BRAKE PRESSURE PLATE THICKNESS (F4A5A) 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 Pressure Plate Thickness (F4A5A)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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)

Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

Fig 16: Measuring Pressure Plate End Play

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A4B >

LOW-REVERSE BRAKE PRESSURE PLATE THICKNESS (F4A4B) 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 Pressure Plate End Play (F4A4B)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 18: Measuring Pressure Plate End Play (F4A5A)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A5A >

LOW-REVERSE BRAKE PRESSURE PLATE THICKNESS (F4A5A) 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.

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.
Install the snap ring into the groove of transaxle case output shaft bore.
Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.

Fig 19: Installing Snap Ring Into Groove Of Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the bolt, as it has had sealant applied.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 (F4A4B)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 22: Installing Collar And Taper Roller Bearing On Output Shaft (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move the output shaft to measure the end play and record the measurement value.
Standard value of output shaft end play (reference): 0.01 - 0.09 mm (0.0004 - 0.0035 inch)
Remove the parts that were installed in steps 22 to 25.

Select a spacer whose thickness corresponds to the measured amount of movement from the following table.

Fig 24: Measuring End Play

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SPACER FOR OUTPUT SHAFT

SPACER FOR OUTPUT SHAFT THICKNESS SPECIFICATION

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
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
2.29 - 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

Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 28.
Stake the jam nut with a punch (two places).

Fig 25: Staking Jam Nut With Punch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.

Fig 26: Identifying Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 27: Installing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary carrier assembly.

Fig 28: Installing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary reverse sun gear.

Fig 29: Installing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring on the low-reverse brake piston.

Fig 30: Installing Wave Spring On Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 32: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 33: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.

Fig 34: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 AND PLATES REFERENCE

A/T MODEL	SECOND BRAKE DISC	SECOND BRAKE PLATE
F4A4B	3	2
F4A5A	4	3

Fig 35: Installing Second Brake Discs And Second Brake Plates (F4A4B)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 36: Installing Second Brake Discs And Second Brake Plates (F4A5A)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the return spring and second brake piston.

Fig 37: Removing Return Spring And Second Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the snap ring.

Fig 38: Installing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

Fig 39: Identifying Thrust Bearing, Thrust Races, And Thrust Washers

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

ID AND OD SPECIFICATION

SYMBOL	OD mm (in)	ID mm (in)	THICKNESS mm (in)
No. 1	59 (2.32)	47 (1.85)	1.8 (0.071)
	59 (2.32)	47 (1.85)	2.0 (0.079)
	59 (2.32)	47 (1.85)	2.2 (0.087)
	59 (2.32)	47 (1.85)	2.4 (0.094)
	59 (2.32)	47 (1.85)	2.6 (0.102)
	59 (2.32)	47 (1.85)	2.8 (0.110)
No. 2	49 (1.93)	34 (1.34)	3.6 (0.142)
No. 3	49 (1.93)	34 (1.34)	3.6 (0.142)
No. 4	46 (1.81)	31 (1.22)	3.3 (0.130)
No. 5	49 (1.93)	34 (1.34)	3.6 (0.142)
No. 6	49 (1.93)	34 (1.34)	3.6 (0.142)
No. 7	59 (2.32)	37 (1.46)	2.8 (0.110)
No.8	48.9 (1.925)	37 (1.46)	1.6 (0.063)
	48.9 (1.925)	37 (1.46)	1.7 (0.067)
	48.9 (1.925)	37 (1.46)	1.8 (0.071)
	48.9 (1.925)	37 (1.46)	1.9 (0.075)
	48.9 (1.925)	37 (1.46)	2.0 (0.079)
	48.9 (1.925)	37 (1.46)	2.1 (0.083)
	48.9 (1.925)	37 (1.46)	2.2 (0.087)
	48.9 (1.925)	37 (1.46)	2.3 (0.091)
	48.9 (1.925)	37 (1.46)	2.4 (0.094)
	48.9 (1.925)	37 (1.46)	2.5 (0.098)
	48.9 (1.925)	37 (1.46)	2.6 (0.102)

CAUTION: Be sure to install the thrust bearing in the correct direction as shown.

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 Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Use care to install the thrust bearing in the proper direction.
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: Installing Thrust Bearing In Proper Direction
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reverse and overdrive clutch.
CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
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 Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
Install the seal rings (four pieces) in the grooves of the rear cover.

Fig 43: Installing Seal Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)
  
  Fig 44: Measuring End Play Of Under Drive Sun Gear
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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).
Install the O-rings (three pieces).

Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 47 from the table below. Install it on thrust bearing number 7.

Fig 45: Installing Thrust Bearing Number 7

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

THICKNESS SPECIFICATION

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)
.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)

Apply a 1.6 mm (0.06 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 Diameter Bead Of Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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: Installing Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 48: Installing Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking roller support, and then insert the parking roller support shafts (two pieces).

Fig 49: Installing Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub to the underdrive sun gear.

Fig 50: Identifying Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.

Fig 51: Removing/Installing Underdrive Clutch & Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch.

Fig 52: Removing/Installing Underdrive Clutch & Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Adjustment of input shaft end play and select the thrust washer number 1. (Refer to THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY .)
Install thrust washer number 1 that was selected in step 58 on the underdrive clutch retainer.

Fig 53: Identifying Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown.
Install the oil pump to the transaxle case.
NOTE: Do not install the oil pump gasket at this time.
Tighten the six oil pump mounting bolts to the specified torque.

Fig 54: Identifying Special Tool Guide MD998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)
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 55: Measuring Input Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 56: Identifying Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990935 < F4A4B > or MB990936 < F4A5A > and MB990938 to tap the differential bearing outer race in the transaxle case.

Fig 57: Taping Differential Bearing Outer Race In Transaxle Case (F4A4B)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 58: Taping Differential Bearing Outer Race In Transaxle Case (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential.

Fig 59: Installing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Adjustment of differential case preload and select the spacer. (Refer to ADJUSTMENT OF TRANSAXLE - SPACER SELECTION FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD .)
Install the selected spacer to the torque converter housing.

Fig 60: Installing Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990935 < F4A4B > or MB990936 < F4A5A > and MB990938 to press the differential bearing outer race into the torque converter housing.

Fig 61: Pressing Differential Bearing Outer Race Into Torque Converter Housing (F4A4B)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 62: Pressing Differential Bearing Outer Race Into Torque Converter Housing (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply a 1.6 mm (0.06 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). 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 63: Installing Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (two pieces).

Fig 64: Installing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)
Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
Install the manual control lever shaft and parking pawl rod.

Fig 65: Installing Manual Control Lever Shaft And Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".
Insert the new seal rings in the grooves of the accumulator pistons.
NOTE: The piston and seal ring are common parts.

Fig 66: Aligning Hole A With Groove In Manual Control Lever Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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.

BLUEING IDENTIFICATION

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 67: Identifying Accumulator Piston Into Each Hole Of Transaxle Case

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 68: Identifying Accumulator Pistons

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the strainer and second brake retainer oil seal.

Fig 69: Installing Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert a new O-ring to the groove of the solenoid valve harness connector.
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 70: Identifying Connector Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
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 71: Installing Steel Balls Into Each Of Two Holes In Top Face Of Valve Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 72: Installing Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.

Fig 73: Attaching Solenoid Valve Harness To Valve Body

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SOLENOID VALVE HARNESS SPECIFICATION

NO.	PARTS TO BE CONNECTED	SOLENOID VALVE HARNESS
NO.	PARTS TO BE CONNECTED	CABLE COLOR	CONNECTOR HOUSING COLOR
1	Underdrive solenoid valve	White, red, red	Black
2	Overdrive solenoid valve	Orange, red	Black
3	Low-reverse solenoid valve	Brown, yellow	Milky white
4	Second solenoid valve	Blue, red, red	Milky white
5	Torque converter clutch control solenoid valve	Blue, yellow, yellow	Black

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 74: Installing Manual Control Shaft Detent
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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.
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 75: Applying Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 76: Tightening Mounting Bolts
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Install the sealing cap and tighten the bolt to the specified torque. < Type with sealing cap >
Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 9 in-lb)

Fig 77: Identifying Sealing Cap
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Install the park/neutral position switch and tighten the bolt to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
Install the manual control lever and tighten the nut to the specified torque.
Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb)

Fig 78: Installing Manual Control Lever
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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 79: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
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Press Face "A" of the air breather to be even with Face "B" of the transmission case as shown in the drawing.
Apply ATF on the both sides of the new gasket and threads of the eyebolts, and then tighten to the specified torque.
Tightening torque: 24 +/- 3 N.m (18 +/- 2 ft-lb)

Fig 80: Identifying Press Face A Of Air Breather And Face B Of Transmission Case
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Tighten the oil cooler feed pipe clamp bolt to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
Install the oil dipstick.
Install the cable support brackets to the specified torque.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
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.
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) < F4A4B >

Approximately 9.4 mm (0.37 inch) < F4A5A >

Fig 81: Installing Torque Converter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.