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DISASSEMBLY AND
REASSEMBLY
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| DISASSEMBLY
 CAUTION
- The automatic transmission includes many
high-precision parts. Handle these parts extremely carefully not to scratch or damage them during
disassembly and reassembly.
- Work bench should be covered with a rubber mat and keep it clean at all times.
- Do not wear any cloth gloves and do not use any rags during disassembly. Use only
nylon cloth or paper towels if necessary.
- All removed parts must be washed clean. Metal parts may be washed in an ordinary
solvent, but they should be dried completely using compressed air.
- Clutch discs, plastic thrust plates and rubber parts should be washed in automatic
transmission fluid (ATF) and keep them free of dirt after washing.
- If the transmission has been found damaged and repaired, also disassemble and clean
the ATF cooler system.
- Remove the transfer and O-ring. <W4A4>
- Remove the torque converter.
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- Use a dial gauge to measure the input shaft end play.
- Remove each bracket.
- Remove the oil level gauge.
- Remove the oil cooler feed tube.
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- Remove the input shaft speed sensor and output shaft speed sensor.
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 CAUTION
Be sure to remove the manual control lever mounting nut before removing the
valve body. If the removal sequence is reversed, the inhibitor switch could be broken.
- Remove the manual control lever, then remove the inhibitor switch.
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- Remove the valve body cover.
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- Remove the manual control shaft detent.
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- Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature
sensor and all the connectors.
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 CAUTION
Do not remove the bolts (four pieces) shown in the illustration.
- Remove the valve body mounting bolts (twenty seven pieces).
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 CAUTION
Be careful not to lose the steel balls (two pieces).
- Remove the valve body, gasket and the steel balls (two pieces).
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- Remove the snap ring from the connector, then push the connector into the transmission
case to remove the solenoid valve harness.
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- Remove the strainer and second brake retainer oil seal.
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- Remove the accumulator pistons and their springs.
No.
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Accumulator
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1
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For low-reverse brake
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2
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For underdrive clutch
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3
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For second brake
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4
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For overdrive clutch
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NOTE: Put tags to the removed accumulator pistons and springs so that you will be able to reinstall
them in the correct positions.
- Remove the manual control lever shaft roller.
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- Remove the manual control lever shaft and the parking pawl rod.
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- Remove the converter housing mounting bolts, then remove the converter housing.
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- Remove the O-rings (two pieces).
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- Remove the centre differential.
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- Remove the oil pump mounting bolts.
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- Use special tool oil pump remover (MD998333) in position shown in the illustration.
- Screw the special tools Oil pump remover (MD998333) evenly to remove the oil pump.
- Remove the oil pump gasket.
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- Remove the thrust washer No.1.
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- Holding the input shaft, remove the underdrive clutch and input shaft.
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- Remove the thrust bearing No.2.
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- Remove the underdrive clutch hub.
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- Pull out the parking pawl shaft, then remove the spacer and spring.
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- Remove the parking roller support shafts (two pieces), then remove the parking pawl and
parking roller support.
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- Remove the rear cover.
- Remove the thrust race No.8.
- Remove the seal rings (four pieces).
- Remove the input shaft rear bearing.
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- Remove the O-rings (three pieces).
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- Remove the reverse and overdrive clutch and the thrust bearing No.7.
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- Remove the overdrive clutch hub and thrust bearing No.6.
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- Remove the thrust bearing No.5.
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- Remove the planetary reverse sun gear.
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- Remove the second brake and return spring.
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- Remove the pressure plate, brake discs (three pieces) and brake plates (two pieces).
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- Remove the planetary carrier assembly.
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- Remove the reaction plate and brake disc.
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- Remove the brake plates, brake discs and pressure plate.
Number of brake discs and plates
Model
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Brake disc
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Brake plate
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Pressure plate
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F4A4
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5*
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4
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1
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W4A4
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6*
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5
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1
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NOTE: *Includes the brake discs removed in step 49.
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- Use the special tools to press down the one-way clutch inner race, then remove the snap
ring.
- Spring compressor (MD998903)
- Spring compressor retainer (MD998924)
- Remove the one-way clutch inner race, O-ring, spring retainer, return spring, and
low-reverse brake.
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- Remove the four or three of the transfer drive gear mounting bolts. Then turn the gear
1/8 of a turn (45°) and remove the remaining three or four bolts.
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- Remove the transfer drive gear.
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- Unbend the locking tab of the output shaft lock nut.
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 CAUTION
The lock nut thread is left-handed.
- Use the special tools to remove the output shaft lock nut.
- Special socket (MB991625)
- Torque wrench socket (MB990607)
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- Remove the bearing retainer mounting bolts.
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- Remove the output shaft, taper roller bearing, and collar by striking the rear end of
the output shaft.
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- Remove the spacer and outer race.
- Remove the differential bearing outer race and spacer from the converter housing.
- Remove the differential bearing outer race from the transmission case.
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| REASSEMBLY
 CAUTION
- Never reuse any gasket, O-ring, and oil seal.
Always replace them with new ones.
- Never use any product other than blue petrolatum jelly or white Vaseline to lubricate
or hold parts during assembly.
- Apply ATF to friction elements, rotating parts, and sliding parts before installation.
Soak new clutch discs or brake discs in ATF for at least two hours before installing them.
- Never apply sealant or adhesive to gaskets.
- When a bushing requires replacement, replace the assembly of which the bushing forms
a part.
- Never use any cloth gloves or any rags during reassembly. Use only nylon cloth or
paper towels if necessary.
- Change also the ATF in the cooler circuit.
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- Use the special tool Guide (MD998412) to install the transfer drive gear.
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- Tighten the transfer drive gear mounting bolts to the specified torque of 34 ±
2
N·m.
- Install the low-reverse brake piston, return spring and spring retainer.
- Fit a new O-ring in the groove in the one-way clutch inner race.
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- Locate the identification notches on the one-way clutch inner race, then install the one-way
clutch inner race in the transfer drive gear bearing with the notches aligned with the A-A line
as shown in the illustration.
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- Use the special tools to hold down the one-way clutch inner race, then fit the snap ring
in position.
- Spring compressor retainer (MD998924)
- Spring compressor (MD998903)
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- Install the wave spring on the low-reverse brake piston.
- Install the brake discs, brake plates, and snap ring for the low-reverse brake as
shown in the illustration.
NOTE: Do not install the pressure plate yet.
Number of brake discs and plates
Model
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Brake disc
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Brake plate
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F4A4
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5
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4
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W4A4
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6
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5
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- Install the special tool on the stack of the brake discs.
- Install the reaction plate and the snap ring that was removed during disassembly.
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- Move up the special tool Clearance dummy plate (MB991631) to check whether the end play
of the reaction plate is within the standard value range. If necessary, remove the snap ring
that has been installed in step 10 and install another appropriate snap ring.
Standard value: 0 -
0.16 mm
- Install the brake discs (three pieces) and brake plates (two pieces) for the second
brake as shown in the illustration.
NOTE: Do not install the pressure plate yet.
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- Install the special tool Clearance dummy plate (MB991631).
- Install the return spring, second brake piston, and snap ring.
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- Move the special tool Clearance dummy plate (MB991631) to measure the amount of movement.
Select a pressure plate whose thickness corresponds to the measured amount of movement from
the following table.
Standard value (reference): 0.79 -
1.25 mm
Available pressure plates
Amount of movement mm
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Thickness mm
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Identification mark
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0.6 -
0.8
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1.6
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L
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0.8 -
1.0
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1.8
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1
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1.0 -
1.2
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2.0
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0
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1.2 -
1.4
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2.2
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2
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1.4 -
1.6
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2.4
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4
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1.6 -
1.8
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2.6
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6
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- Turn the transmission upside down.
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- Move the special tool Clearance dummy plate (MB991631) and measure the amount of movement
using a dial gauge fitted with the special tool Dial gauge extension (MD998913). Select a pressure
plate whose thickness corresponds to the measured amount of movement from the following table.
Standard value of low-reverse brake end play (reference): 1.65 -
2.11 mm
Available pressure plates
Amount of movement mm
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Thickness mm
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Identification mark
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1.3 -
1.5
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1.6
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L
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1.5 -
1.7
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1.8
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1
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1.7 -
1.9
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2.0
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0
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1.9 -
2.1
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2.2
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2
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2.1 -
2.3
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2.4
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4
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2.3 -
2.5
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2.6
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6
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2.5 -
2.7
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2.8
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8
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2.7 -
2.9
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3.0
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D
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- Remove all the parts has been installed in steps 7. through 17.
- Install the snap ring in the groove formed in the output shaft hole in the transmission
case.
- Install the thinnest spacer (thickness: 1.88 mm) for adjusting the output shaft preload.
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- Use the special tools to drive the output shaft bearing outer race into the transmission
case.
- Installer adapter (MB990930)
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 CAUTION
Do not reuse the output shaft bearing retainer mounting bolts as they are
pre-coated with a sealant.
- Install the output shaft bearing retainer mounting bolts and tighten them to the specified
torque of 29 ±
2 N·m.
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- Use the special tool Bearing installer (MD998350) to install the collar and taper roller
bearing on the output shaft.
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 CAUTION
The lock nut thread is left-handed.
- Apply ATF to a new lock nut, and use the special tools to tighten the lock nut to the
specified torque of 170 ±
10 N·m. Then loosen the nut one turn, then tighten
it again to the specified torque of 170 ±
10 N·m.
- Torque wrench socket (MB990607)
- Special socket (MB991625)
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- Move the output shaft and to measure the amount of movement;
record the measurement.
- Remove all the parts having installed in steps 20. through 24.
- Select and install a spacer whose thickness is equivalent to the sum of the measurement
recorded in step 25., 1.88 mm (the thickness of the spacer installed in step 20.), and an amount
between 0.01 and 0.09 mm (output shaft preload).
- Repeat steps 21. through 24. to reinstall the parts.
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- Stake the lock nut (at two places).
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- Use the special tools to install the cap as shown in the illustration.
- Installer adapter (MB990931)
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- Install the planetary carrier assembly.
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- Install the planetary reverse sun gear.
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- Install the wave spring on the low-reverse brake piston.
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- Install the pressure plate that has been selected in step 17. Then install the brake discs
and brake plates.
Number of brake discs and plates
Model
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Brake disc
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Brake plate
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Pressure plate
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F4A4
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5
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4
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1
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W4A4
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6
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5
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1
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- Install the reaction plate.
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- Install the snap ring that has been selected in step 11.
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- Install the brake discs (three pieces), brake plates (two pieces), and the pressure plate
that has been selected in step 15.
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- Install the return spring and second brake.
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 CAUTION
Be sure to install the thrust bearing with the indicated side facing down.
- Install the thrust bearing No.5.
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IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST
WASHERS
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O.D. mm
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I.D. mm
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Thickness mm
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Marking
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O.D. mm
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I.D. mm
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Thickness mm
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Marking
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59
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47
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1.8
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No.1
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48.9
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37
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1.6
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No.8
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2.0
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1.7
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2.2
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1.8
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2.4
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1.9
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2.6
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2.0
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2.8
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2.1
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49
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34
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3.6
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No.2
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2.2
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49
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34
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3.6
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No.3
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2.3
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45.3
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31
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3.3
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No.4
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2.4
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49
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34
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3.6
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No.5
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2.5
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49
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34
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3.6
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No.6
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2.6
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59
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37
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2.8
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No.7
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 CAUTION
Be sure to install the thrust bearing with the indicated side facing down.
- Install the overdrive clutch hub and thrust bearing No.6 in the reverse and overdrive
clutch.
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 CAUTION
Be sure to install the thrust bearing with the indicated side facing down.
- Install the reverse and overdrive clutch and thrust bearing No.7.
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- Use the special tool Handle (MB990938) to press-fit the input shaft rear bearing into
the rear cover.
- Install the four seal rings.
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- Measure the end play of the underdrive sun gear using the following procedure to select
a thrust race No.8 of proper thickness.
- Install the thinnest thrust race No.8 (thickness: 1.6 mm) on the thrust bearing No.7.
- Install the rear cover on the transmission and tighten the bolts to the specified
torque of 23 ±
3 N·m.
- Turn the transmission upside down, thus making the torque converter housing mounting
end face up.
- Install the underdrive clutch hub on the underdrive sun gear.
- Measure the end play of the underdrive sun gear and record the measurement.
Standard value (reference): 0.25 -
0.45 mm
- Remove all the parts installed in substeps (1) through (4).
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- Install the O-rings (three places).
- Select a thrust race No.8 whose thickness corresponds to the measurement recorded
in substep (5) of step 46. from the table below and install the thrust race on the thrust bearing No.7.
Measurement mm
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Thickness mm
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0.3 -
0.4
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1.6
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0.4 -
0.5
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1.7
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0.5 -
0.6
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1.8
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0.6 -
0.7
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1.9
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0.7 -
0.8
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2.0
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0.8 -
0.9
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2.1
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0.9 -
1.0
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2.2
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1.0 -
1.1
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2.3
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1.1 -
1.2
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2.4
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1.2 -
1.3
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2.5
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1.3 -
1.4
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2.6
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- Apply an approx. 1.6 mm diameter bead of form-in-place gasket (FIPG) to the rear cover
along its circumference as shown in the illustration.
Specified sealant:
- Mitsubishi genuine sealant Part No. MD974421 or equivalent
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- Install the rear cover and tighten its mounting bolts to the specified torque of 23 ±
3
N·m.
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- Install the parting pawl, spacer and spring in position, then install the parking pawl
shaft.
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- Install the parking roller support, then install the two parking roller support shafts.
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- Install the underdrive clutch hub.
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 CAUTION
Install the thrust bearing with the indicated side facing down.
- Install the thrust bearing No.2.
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- Install the underdrive clutch holding the input shaft.
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- Install the thinnest thrust washer No.1 for adjusting the input shaft end play
(thickness: 1.8 mm) on the underdrive clutch retainer.
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 CAUTION
Never use a gasket that has been tightened.
- Use the special tool Guide (MD998412) to install a new oil pump gasket and the oil pump.
- Tighten the oil pump mounting bolts to the specified torque of 29 ±
2 N·m.
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- Measure the end play of the input shaft. Select a thrust washer No.1 of the thickness
corresponding to the measurement and replace with it the thrust washer that has been installed
in step 56.
Standard value (reference): 0.70 -
1.45 mm
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- Use the special tools to drive the differential bearing outer race into the transmission
case.
- Installer adapter (MB990935)
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- Install the differential <F4A4>
or centre differential <W4A4>.
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- Place two pieces of about 10 mm long, 3 mm diameter solder on the converter housing at
the locations indicated in the illustration.
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- Use the special tools to drive the outer race into position.
- Installer adapter (MB990935)
- Bush remover &
installer base (MB991445)
- Install the converter housing on the transmission case without applying FIPG. Tighten
the mounting bolts to the specified torque of 48 ±
6 N·m.
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- Remove the bolts and converter housing, and take out the solder pieces.
- Use a micrometer to measure the thickness of the crashed solder.
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- Select a spacer of the thickness equivalent to the micrometer reading plus the standard
preload value.
Standard preload value: 0.045 -
0.105 mm
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- Install the spacer selected in step 68. into the converter housing and drive the outer
race into position using the special tools.
- Installer adapter (MB990935)
- Bush remover &
installer base (MB991445)
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- Apply an approx. 1.6 mm diameter bead of from-in-place gasket (FIPG) to the converter
housing along its circumference as shown in the illustration.
Specified sealant:
- Mitsubishi genuine sealant Part No. MD974421 or equivalent
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- Install the two O-rings (two pieces).
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- Install the converter housing and tighten the mounting bolts to the specified torque of
48 ±
6 N·m.
- Install the manual control lever shaft and parking pawl rod.
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- Install the manual control lever shaft roller.
- Fit a new seal ring to each accumulator piston.
NOTE: All the four accumulator pistons and seal rings are identical.
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- Identify the accumulator spring for each accumulator and install it in the correct hole
in the transmission case together with the piston.
NOTE: The accumulator springs are identified as shown in the table below.
No.
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Accumulator spring
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Blue ink marking
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1
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For low-reverse brake
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No marking
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2
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For underdrive clutch
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Half of surface
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3
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For second brake
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Entire surface
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4
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For overdrive clutch
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No marking
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- Install the strainer and second brake retainer oil seal as shown in the illustration.
- Fit a new O-ring into the groove in the solenoid valve harness connector.
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- Insert the solenoid valve harness connector into the hole in the transmission case from
inside the case. After making sure that the connector is positioned as shown in the illustration,
fit the snap ring snugly into the connector groove.
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- Install the steel balls one each in the two holes on the top of the valve body (outside
valve body).
- Install the valve body and gasket. Make sure that the pin of the manual valve is in
place in the detent plate groove in the manual control lever shaft.
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- Install the valve body mounting bolts and tighten them to the specified torque of 11 ±
1
N·m.
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- Install the oil temperature sensor and them connect the connector to the valve body.
No.
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Solenoid valve
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Wire colour
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Connector housing colour
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1
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Underdrive solenoid valve
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White/red/red
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Black
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2
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Overdrive solenoid valve
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Orange/red
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Black
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3
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Low-reverse solenoid valve
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Brown/yellow
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Milky white
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4
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Second solenoid valve
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Blue/red/red
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Milky white
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5
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Damper clutch control solenoid valve
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Blue/yellow/yellow
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Black
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- Install the manual control shaft detent spring and detent.
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- Apply an approx. 2.5 mm diameter bead of from-in-place gasket (FIPG) to the valve body
cover along its circumference as shown in the illustration.
Specified sealant:
- Mitsubishi genuine sealant Part No. MD974421 or equivalent
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- Install the valve body cover and tighten its mounting bolts to the specified torque of
11 ±
1 N·m.
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- Install the sealing cap.
- Install the inhibitor switch.
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- Install the manual control lever.
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- Install the input shaft speed sensor and output shaft speed sensor.
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- 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 illustration.
- Apply ATF on the both sides of the new gasket and threads of the eyebolt, and then
tighten to the specified torque of 24 ±
3 N·m.
- Install the oil level gauge.
- Install the brackets.
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 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 secure it so that the dimension (A) indicated in the
illustration meets the reference value.
Reference value: 12.2 mm
- Install the transfer after fitting a new O-ring on it. <W4A4>
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