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 Screw Hole Of Transfer Drive Gear Bearing Located In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the mounting bolts (seven pieces) of the transfer drive gear bearing to the specified torque.
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, Return Spring, And Spring Retainer Into Transaxle Case
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: Locating Identification Notches
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put the snap ring on the inner race.
Set special tools MD998903 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.

Fig 6: Compressing One-Way Clutch Inner Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring onto the low-reverse brake piston.

Fig 7: Installing Wave Spring Onto Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the brake discs, brake plates and snap ring as shown in the figure.

Fig 8: Installing Reaction Plate And Used Snap Ring (F4A4B-1)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Number of brake discs and plates

NUMBER OF BRAKE DISCS AND PLATES CHART

Model	Brake disc	Brake plate
F4A4B-1	4*	5
F4A4B-4	5*	6

NOTE: Do not namest="col1" nameend="col2" align="left" install the pressure plate at this time.

Install special tool MB991631 on the brake disc.
Install the reaction plate and the used snap ring.
Move special tool MB991631 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 Reaction Plate And Used Snap Ring (F4A4B-4)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the brake discs (three pieces) and brake plates (two pieces) as shown in the figure.

Fig 10: Installing Return Spring, Second Brake Piston And Snap Ring (F4A4B-1)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: Do not install the pressure plate at this time.
Place special tool MB991631 on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.

Fig 11: Installing Return Spring, Second Brake Piston And Snap Ring (F4A4B-4)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move special tool MB991631 and measure its movement.

Fig 12: Measuring Amount Of Movement
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Standard value of end play (Reference):

0.79 - 1.25 mm (0.0311 - 0.0492 inch)

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

Fig 13: Measuring Amount Of Movement (F4A4B-1)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 14: Measuring Amount Of Movement (F4A4B-4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR SECOND BRAKE

PRESSURE PLATE FOR SECOND BRAKE 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

Turn the transaxle over so that the installation surface of the torque converter housing is facing up.

Fig 15: Measuring Amount Of Movement
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install special tool MD998913 in a dial gauge, and then move special tool MB991631 and measure its movement.

Standard value of end play (Reference):

1.35 - 1.81 mm (0.0531 - 0.0713 inch) < F4A4B-1 >

1.65 - 2.11 mm (0.0649 - 0.0831 inch) < F4A4B-4 >

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

Fig 16: Measuring Amount Of Movement (F4A4B-1)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A4B-1 >

PRESSURE PLATE FOR LOW-REVERSE BRAKE (F4A4B-1) SPECIFICATION

MOVEMENT AMOUNT mm (in)	THICKNESS mm (in)	ID SYMBOL
1.0 - 1.2 (0.039 - 0.047)	1.6 (0.063)	L
1.2 - 1.4 (0.047 - 0.055)	1.8 (0.071)	1
1.4 - 1.6 (0.055 - 0.063)	2.0 (0.079)	0
1.6 - 1.8 (0.063 - 0.071)	2.2 (0.087)	2
1.8 - 2.0 (0.071 - 0.079)	2.4 (0.094)	4
2.0 - 2.2 (0.079 - 0.087)	2.6 (0.102)	6
2.2 - 2.4 (0.087 - 0.094)	2.8 (0.110)	8
2.4 - 2.6 (0.094 - 0.102)	3.0 (0.118)	D

PRESSURE PLATE FOR LOW-REVERSE BRAKE < F4A4B-4 >

Fig 17: Measuring Amount Of Movement (F4A4B-4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR LOW-REVERSE BRAKE (F4A4B-4) 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

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 18: Taping Output Shaft Bearing Outer Race In 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 +/- 2 ft-lb)

Fig 19: Tightening Mounting Bolts Of Output Shaft Bearing Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.

Fig 20: Installing Collar And Taper Roller Bearing On Output Shaft
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 21: Tightening Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move the output shaft to measure the end play and record the measurement value.
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 22: Measuring End Play Output Shaft

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 23: Staking Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
se special tools MB990931 and MB990938 to install the cap as shown in the illustration.

Fig 24: Installing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary carrier assembly.

Fig 25: Installing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary reverse sun gear.

Fig 26: Installing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring on the low-reverse brake piston.

Fig 27: 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 and brake plates, one on top of the other.

Number of brake discs and plates

NUMBER OF BRAKE DISCS AND PLATES SPECIFICATION

Model	Brake disc	Brake plate	Pressure plate
F4A4B-1	4	5	1
F4A4B-4	5	6	1

Fig 28: Installing Pressure Plate (F4A4B-1)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 29: Installing Pressure Plate (F4A4B-4)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the snap ring.

Fig 30: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 31: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.
Install brake discs (three pieces) and brake plates (two pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.

Fig 32: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 33: Installing Brake Discs
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring and second brake piston.

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

Install the snap ring.

Fig 35: Installing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

Fig 36: Identifying Thrust Bearing, Thrust Races, And Thrust Washers

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

THRUST WASHERS SPECIFICATION

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

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 37: Installing Hub Of Planetary Reverse Sun Gear
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 38: Attaching Thrust Bearing
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 7, and install it on the reverse clutch retainer.

Fig 39: Installing Reverse Clutch Retainer
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 40: Installing Seal Rings In Grooves Of Rear Cover
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.
  
  Fig 41: Measuring End Play Of Under Drive Sun Gear
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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).
Install the O-rings (three pieces).

Fig 42: Installing O-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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.

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)
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)

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 43: Applying 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 44: Tightening Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 45: Installing Parking Pawl, Spacer, And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking roller support, and then insert the parking roller support shafts (two pieces).

Fig 46: Inserting Parking Roller Support Shafts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub to the underdrive sun gear.

Fig 47: 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 48: Installing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch retainer.

Fig 49: Removing/Installing Underdrive Clutch & Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Adjustment of underdrive clutch retainer preload and select the thrust washer number 1.
(Refer to ADJUSTMENT OF TRANSAXLE - THRUST WASHER SELECTION FOR ADJUSTMENT OF UNDERDRIVE CLUTCH RETAINER END PLAY )
Install the selected thrust washer number 1 on the underdrive clutch retainer.

Fig 50: Identifying Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown.
Install the new oil pump gasket on the transaxle case.
Install the oil pump and tighten the six mounting bolts to the specified torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 2 ft-lb)

Fig 51: Identifying Special Tool Guide MD998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the input shaft end play meet's the standard value.
Standard value : 0.70 - 1.45 mm (0.028 - 0.057 inch)

Fig 52: Measuring Input Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 53: Identifying Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990935 and MB990938 to tap the differential bearing outer race in the transaxle case.

Fig 54: Taping Differential Bearing Outer Race In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential.

Fig 55: Installing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Adjustment of torque converter housing preload and select the spacer.
(Refer to ADJUSTMENT OF TRANSAXLE - SPACER SELECTION FOR ADJUSTMENT OF CONVERTER HOUSING END PLAY )
Install the selected spacer to the torque converter housing.

Fig 56: Installing Selected Spacer To Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990935 and MB990938 to press the outer race into housing.

Fig 57: Pressing Differential Bearing Outer Race Into Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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). 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 58: Applying Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (two pieces).

Fig 59: 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 (36 +/- 4 ft-lb)

Fig 60: Installing Torque Converter Housing To Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole

Fig 61: Aligning Hole A With Groove In Manual Control Lever Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert the new seal rings in the grooves of the accumulator pistons.
NOTE: The piston and seal ring are common parts.

Fig 62: Inserting Seal Rings In Grooves Of Accumulator Pistons
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.

Fig 63: Identifying Accumulator Pistons

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

BLUEING IDENTIFICATION CHART

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

Install the strainer and second brake retainer oil seal.

Fig 64: Identifying 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 65: 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 66: Installing Steel Balls
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 67: 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 68: Attaching Solenoid Valve Harness To Valve Body

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 69: Tightening Manual Control Shaft Detent And Tighten Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 ATF for approximately one hour.

Fig 70: 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 71: Tightening Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 72: Identifying Sealing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 73: Installing Park/Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 74: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
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91 Press Face "A" of the air breather to be on the same plane as the Face "B" of the transmission case as shown in the drawing.

Fig 75: Pressing Face A Of Air Breather
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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)
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)

Fig 76: Identifying Dimension A
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.