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: Transfer Drive Gear Bearing Using Special Tool
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.
Install a new O-ring into the groove of one-way clutch inner race.

Fig 4: Installing O-Ring
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: Identifying Transmission Case And 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 in the illustration, and then compress the one-way clutch inner race and install the snap ring.

Fig 6: Compressing One-Way Clutch Inner Race Using Special Tools
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 (six pieces), brake plates (five pieces) and snap ring as shown in the illustration.
NOTE: Do not 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 of end play:

0 - 0.16 mm (0 - 0.006 inch)

Fig 8: Measuring End Play Of Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the brake discs (three pieces) and brake plates (two pieces) as shown in the illustration.
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 9: Installing Return Spring, Second Brake Piston And Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move special tool MB991631 and measure its movement.
Standard value of end play (Reference):

0.79 - 1.25 mm (0.031 - 0.049 inch)

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

Fig 10: Measuring Transaxle Case Movement Using Special Tool (MB991631)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR SECOND BRAKE

THICKNESS CHART

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 11: Measuring Pressure Plate Thickness

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 and measure its movement.

Standard value of end play (Reference):

1.65 - 2.11 mm (0.065 - 0.083 inch)

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

Fig 12: Measuring Transaxle Case Movement Using Special Tool (MB991631)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE FOR LOW-REVERSE BRAKE

THICKNESS CHART

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 13: Identifying Pressure Plate Thickness

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 14: Tapping Output Shaft Bearing Outer Race
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)

Fig 15: Identifying Output Shaft Bearing Retainer And Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.

Fig 16: Installing Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply ATF to a new lock nut, and use special tools MB990607 and MB991625 to tighten the lock 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 lock nut is reverse threaded.

Fig 17: Installing Output Shaft 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 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 18: Measuring End Play

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SPACER FOR OUTPUT SHAFT

THICKNESS CHART

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 lock nut with a punch (two places).

Fig 19: Staking Lock 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 20: Installing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary carrier assembly.

Fig 21: Installing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary reverse sun gear.

Fig 22: Installing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring on the low-reverse brake piston.

Fig 23: 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 24: Installing Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 25: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 26: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.

Fig 27: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 28: Installing Brake Discs
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring and second brake piston.

Fig 29: Installing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the snap ring.

Fig 30: Installing Snap Ring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

Fig 31: Identifying Identification Of Thrust Bearing, Thrust Races, And Thrust Washers

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SYMBOL REFERENCE

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)		48.9 (1.925)	37 (1.46)	2.6 (0.102)

Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.

Fig 32: Installing 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 33: Installing Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.

Fig 34: 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 35: Taping Input Shaft Rear Bearing In 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.
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 underdrive clutch hub on the underdrive sun gear.
5. Measure end play of the underdrive sun gear and record the measurement value.
  Standard value of end play (Reference):
  
  0.25 - 0.45 mm (0.010 - 0.017 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 36: Measuring End Play Of Under Drive Sun Gear

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

THICKNESS CHART

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)

Fig 37: Installing O-Rings

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION:

Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
Make sure the starting point and the ending point are about the middle between the bolts.

Apply a 1.6 mm (0.06 inch) diameter bead of sealant to the illustrated position of the rear cover.
Specified sealant:

Mitsubishi Part No. MD974421 or equivalent

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 38: Applying Sealant Illustrated Position Of Rear Cover
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 39: Installing Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 40: 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 41: Installing Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub to the underdrive sun gear.

Fig 42: Installing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 43: Installing Thrust Bearing In Correct Direction
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch.
Adjustment of input shaft end play and select the thrust washer number 1. (Refer to ADJUSTMENT OF TRANSAXLE .

Fig 44: Installing Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown in the illustration.
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.
Tightening torque: 29 ± 2 N.m (21 ± 1 ft-lb)

Fig 45: Installing Oil Pump To Transaxle Case Using Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the input shaft end play meets the standard value.
Standard value of end play:

0.70 - 1.45 mm (0.028 - 0.057 inch)

Fig 46: Checking Input Shaft End Play Values
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 47: Installing 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 48: Taping Differential Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential.
Adjustment of differential case preload and select the spacer. (Refer to ADJUSTMENT OF TRANSAXLE .

Fig 49: Identifying Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the selected spacer to the torque converter housing.

Fig 50: Locating Selected Spacer To Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990935 and MB990938 to press the differential bearing outer race into the torque converter housing.

Fig 51: Pressing Differential Bearing Outer Race Into Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.
Apply a 1.6 mm (0.06 inch) diameter bead of sealant to the torque converter housing in the area shown in the illustration.
Specified sealant:

Mitsubishi Part No. MD974421 or equivalent

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 52: Applying Sealant Area Of Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (two pieces).

Fig 53: Removing Differential Bearing
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 54: Tightening Mounting Bolts
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".

Fig 55: Inserting Manual Control Lever Shaft Roller
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 56: 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.

THICKNESS 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

Fig 57: Identifying Second Brake Retainer Oil Seal And Strainer

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the strainer and second brake retainer oil seal.

Fig 58: Installing Strainer
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 59: Installing 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 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 60: 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 (97 ± 9 in-lb)

Fig 61: Locating Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Attach the solenoid valve harness to valve body by connecting the all the connectors.

Fig 62: Identifying Fluid Temperature Sensor

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SOLENOID VALVE HARNESS CHART

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	Damper clutch control solenoid valve	Blue, Yellow, Yellow	Black

Install the fluid temperature sensor to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6.0 ± 1.0 N.m (53 ± 9 in-lb)

Fig 63: Installing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.
Apply a 2.5 mm (0.1 inch) diameter bead of sealant to the valve body cover in the area shown in the illustration.
Specified sealant:

Mitsubishi Part No. MD974421 or equivalent

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 64: Identifying Valve Body Cover Sealant Area
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 (97 ± 9 in-lb)

Fig 65: Identifying Valve Body Cover
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 (97 ± 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 66: Identifying Park/Neutral Position Switch And Manual Control Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install a new O-ring on the input shaft speed sensor and output shaft speed sensor.
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 (97 ± 9 in-lb)

Fig 67: Installing Input Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Press Face "A" of the air breather to be on the same plane as the Face "B" of the transaxle case as shown in the illustration.
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 tube clamp bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the oil dipstick.
Install the control cable support brackets to the specified torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the harness bracket to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the roll stopper brackets.
Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)

Fig 68: Locating Transaxle Case Face
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 in the illustration dimension "A" meets the reference value.
Reference value: Approximately 12.2 mm (0.48 inch)

Fig 69: Identifying Oil Pump Dimension
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.