TRANSMISSION
<F4A4>
   
1.
Torque converter
2.
Roll stopper bracket
3.
Harness bracket
4.
Harness bracket
5.
Control cable support bracket
6.
Oil level gauge
7.
Eye bolt
8.
Oil cooler feed tube
9.
Air breather
10.
Input shaft speed sensor
11.
Output shaft speed sensor
12.
Manual control lever
13.
Inhibitor switch
14.
Sealing cap
15.
Valve body cover
16.
Manual control shaft detent

       
17.
Valve body
18.
Gasket
19.
Snap ring
20.
Solenoid valve harness
21.
Strainer
22.
Second brake retainer oil seal
23.
Accumulator piston
24.
Accumulator spring
25.
Accumulator spring
26.
Manual control lever shaft roller
27.
Parking pawl rod
28.
O-ring
29.
Manual control lever shaft

       
30.
Converter housing
31.
O-ring
32.
Differential
33.
Oil filter
34.
Oil pump
35.
Gasket
36.
Thrust washer No.1
37.
Underdrive clutch and input shaft
38.
Thrust bearing No.2
39.
Underdrive clutch hub
40.
Outer race
41.
Spacer

       
42.
Parking pawl shaft
43.
Spacer
44.
Parking pawl spring
45.
Parking roller support shaft
46.
Parking pawl
47.
Parking roller support
48.
Thrust race No.8
49.
Seal ring
50.
Rear cover
51.
Input shaft rear bearing
52.
O-ring
53.
Thrust bearing No.7
54.
Reverse and overdrive clutch
55.
Thrust bearing No.6
56.
Overdrive clutch hub
57.
Thrust bearing No.5
58.
Planetary reverse sun gear
59.
Snap ring
60.
Second brake
61.
Return spring
62.
Pressure plate
63.
Second brake disc
64.
Second brake plate
65.
Planetary gear
66.
Snap ring
67.
Reaction plate
68.
Snap ring
69.
Low-reverse brake disc
70.
Low-reverse brake plate
71.
Pressure plate
72.
Wave spring
73.
Snap ring
74.
One-way clutch inner race
75.
O-ring
76.
Spring retainer
77.
Return spring
78.
Low-reverse brake
79.
Transfer drive gear
80.
Cap
81.
Lock nut
82.
Output shaft
83.
Taper roller bearing
84.
Collar
85.
Outer race
86.
Spacer
87.
Snap ring
88.
Outer race
89.
Transmission case

<W4A4>
   
1.
Transfer
2.
O-ring
3.
Torque converter
4.
Roll stopper bracket, front
5.
Roll stopper bracket, rear <R. H. drive vehicles>
6.
Roll stopper bracket, rear <L. H. drive vehicles>
7.
Roll stopper bracket adapter <L. H. drive vehicles>
8.
Harness bracket
9.
Harness bracket
10.
Control cable support bracket
11.
Oil level gauge
12.
Eye bolt
13.
Oil cooler feed tube
14.
Air breather
15.
Input shaft speed sensor
16.
Output shaft speed sensor
17.
Manual control lever
18.
Inhibitor switch
19.
Sealing cap
20.
Valve body cover
21.
Manual control shaft detent

       
22.
Valve body
23.
Gasket
24.
Snap ring
25.
Solenoid valve harness
26.
Strainer
27.
Second brake retainer oil seal
28.
Accumulator piston
29.
Accumulator spring
30.
Accumulator spring
31.
Manual control lever shaft roller
32.
Parking pawl rod
33.
O-ring
34.
Manual control lever shaft

       
35.
Converter housing
36.
O-ring
37.
Differential
38.
Oil filter
39.
Oil pump
40.
Gasket
41.
Thrust washer No.1
42.
Underdrive clutch and input shaft
43.
Thrust bearing No.2
44.
Underdrive clutch hub
45.
Outer race
46.
Spacer

       
47.
Parking pawl shaft
48.
Spacer
49.
Parking pawl spring
50.
Parking roller support shaft
51.
Parking pawl
52.
Parking roller support
53.
Thrust race No.8
54.
Seal ring
55.
Rear cover
56.
Input shaft rear bearing
57.
O-ring
58.
Thrust bearing No.7
59.
Reverse and overdrive clutch
60.
Thrust bearing No.6
61.
Overdrive clutch hub
62.
Thrust bearing No.5
63.
Planetary reverse sun gear
64.
Snap ring
65.
Second brake
66.
Return spring
67.
Pressure plate
68.
Second brake disc
69.
Second brake plate
70.
Planetary gear
71.
Snap ring
72.
Reaction plate
73.
Snap ring
74.
Low-reverse brake disc
75.
Low-reverse brake plate
76.
Pressure plate
77.
Wave spring
78.
Snap ring
79.
One-way clutch inner race
80.
O-ring
81.
Spring retainer
82.
Return spring
83.
Low-reverse brake
84.
Transfer drive gear
85.
Cap
86.
Lock nut
87.
Output shaft
88.
Taper roller bearing
89.
Collar
90.
Outer race
91.
Spacer
92.
Snap ring
93.
Outer race
94.
Transmission case

   
  1. Use a dial gauge to measure the input shaft end play.
  1. Remove each bracket.
  1. Remove the oil level gauge.
  1. Remove the oil cooler feed tube.
       
    1. Remove the air breather.
         
      1. Remove the input shaft speed sensor and output shaft speed sensor.
           
           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.
        1. Remove the manual control lever, then remove the inhibitor switch.
             
          1. Remove the sealing cap.
               
            1. Remove the valve body cover.
                 
              1. Remove the manual control shaft detent.
                   
                1. Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.
                     
                     CAUTION
                    Do not remove the bolts (four pieces) shown in the illustration.
                  1. Remove the valve body mounting bolts (twenty seven pieces).
                       
                       CAUTION
                      Be careful not to lose the steel balls (two pieces).
                    1. Remove the valve body, gasket and the steel balls (two pieces).
                         
                      1. Remove the snap ring from the connector, then push the connector into the transmission case to remove the solenoid valve harness.
                           
                        1. Remove the strainer and second brake retainer oil seal.
                             
                          1. Remove the accumulator pistons and their springs.
                          2. No.
                            Accumulator
                            1
                            For low-reverse brake
                            2
                            For underdrive clutch
                            3
                            For second brake
                            4
                            For overdrive clutch

                            NOTE: Put tags to the removed accumulator pistons and springs so that you will be able to reinstall them in the correct positions.
                          1. Remove the manual control lever shaft roller.
                               
                            1. Remove the manual control lever shaft and the parking pawl rod.
                                 
                              1. Remove the converter housing mounting bolts, then remove the converter housing.
                                   
                                1. Remove the O-rings (two pieces).
                                     
                                  1. Remove the centre differential.
                                       
                                    1. Remove the oil filter.
                                         
                                      1. Remove the oil pump mounting bolts.
                                           
                                        1. Use special tool oil pump remover (MD998333) in position shown in the illustration.
                                        1. Screw the special tools Oil pump remover (MD998333) evenly to remove the oil pump.
                                        1. Remove the oil pump gasket.
                                             
                                          1. Remove the thrust washer No.1.
                                               
                                            1. Holding the input shaft, remove the underdrive clutch and input shaft.
                                                 
                                              1. Remove the thrust bearing No.2.
                                                   
                                                1. Remove the underdrive clutch hub.
                                                     
                                                  1. Pull out the parking pawl shaft, then remove the spacer and spring.
                                                       
                                                    1. Remove the parking roller support shafts (two pieces), then remove the parking pawl and parking roller support.
                                                         
                                                      1. Remove the rear cover.
                                                      1. Remove the thrust race No.8.
                                                      1. Remove the seal rings (four pieces).
                                                      1. Remove the input shaft rear bearing.
                                                           
                                                        1. Remove the O-rings (three pieces).
                                                             
                                                          1. Remove the reverse and overdrive clutch and the thrust bearing No.7.
                                                               
                                                            1. Remove the overdrive clutch hub and thrust bearing No.6.
                                                                 
                                                              1. Remove the thrust bearing No.5.
                                                                   
                                                                1. Remove the planetary reverse sun gear.
                                                                     
                                                                  1. Remove the snap ring.
                                                                       
                                                                    1. Remove the second brake and return spring.
                                                                         
                                                                      1. Remove the pressure plate, brake discs (three pieces) and brake plates (two pieces).
                                                                           
                                                                        1. Remove the planetary carrier assembly.
                                                                             
                                                                          1. Remove the snap ring.
                                                                               
                                                                            1. Remove the reaction plate and brake disc.
                                                                                 
                                                                              1. Remove the snap ring.
                                                                                   
                                                                                1. Remove the brake plates, brake discs and pressure plate.
                                                                                2. Number of brake discs and plates
                                                                                  Model
                                                                                  Brake disc
                                                                                  Brake plate
                                                                                  Pressure plate
                                                                                  F4A4
                                                                                  5*
                                                                                  4
                                                                                  1
                                                                                  W4A4
                                                                                  6*
                                                                                  5
                                                                                  1

                                                                                  NOTE: *Includes the brake discs removed in step 49.
                                                                                     
                                                                                  1. Remove the wave spring.
                                                                                       
                                                                                    1. 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)
                                                                                    1. Remove the one-way clutch inner race, O-ring, spring retainer, return spring, and low-reverse brake.
                                                                                         
                                                                                      1. 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.
                                                                                           
                                                                                        1. Remove the transfer drive gear.
                                                                                             
                                                                                          1. Remove the cap.
                                                                                               
                                                                                            1. Unbend the locking tab of the output shaft lock nut.
                                                                                                 
                                                                                                 CAUTION
                                                                                                The lock nut thread is left-handed.
                                                                                              1. Use the special tools to remove the output shaft lock nut.
                                                                                                • Special socket (MB991625)
                                                                                                • Torque wrench socket (MB990607)
                                                                                                   
                                                                                                1. Remove the bearing retainer mounting bolts.
                                                                                                     
                                                                                                  1. Remove the output shaft, taper roller bearing, and collar by striking the rear end of the output shaft.
                                                                                                       
                                                                                                    1. Remove the spacer and outer race.
                                                                                                    1. Remove the differential bearing outer race and spacer from the converter housing.
                                                                                                    1. Remove the differential bearing outer race from the transmission case.
                                                                                                       
                                                                                                    1. Use the special tool Guide (MD998412) to install the transfer drive gear.
                                                                                                         
                                                                                                      1. Tighten the transfer drive gear mounting bolts to the specified torque of 34 ± 2 N·m.
                                                                                                      1. Install the low-reverse brake piston, return spring and spring retainer.
                                                                                                      1. Fit a new O-ring in the groove in the one-way clutch inner race.
                                                                                                           
                                                                                                        1. 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.
                                                                                                             
                                                                                                          1. 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)
                                                                                                               
                                                                                                            1. Install the wave spring on the low-reverse brake piston.
                                                                                                            1. Install the brake discs, brake plates, and snap ring for the low-reverse brake as shown in the illustration.
                                                                                                            2. NOTE: Do not install the pressure plate yet.
                                                                                                              Number of brake discs and plates
                                                                                                              Model
                                                                                                              Brake disc
                                                                                                              Brake plate
                                                                                                              F4A4
                                                                                                              5
                                                                                                              4
                                                                                                              W4A4
                                                                                                              6
                                                                                                              5

                                                                                                            1. Install the special tool on the stack of the brake discs.
                                                                                                            1. Install the reaction plate and the snap ring that was removed during disassembly.
                                                                                                                     
                                                                                                              1. 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.
                                                                                                              2. Standard value: 0 - 0.16 mm
                                                                                                              1. Install the brake discs (three pieces) and brake plates (two pieces) for the second brake as shown in the illustration.
                                                                                                              2. NOTE: Do not install the pressure plate yet.
                                                                                                                   
                                                                                                                1. Install the special tool Clearance dummy plate (MB991631).
                                                                                                                1. Install the return spring, second brake piston, and snap ring.
                                                                                                                         
                                                                                                                  1. 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.
                                                                                                                  2. Standard value (reference): 0.79 - 1.25 mm
                                                                                                                    Available pressure plates
                                                                                                                    Amount of movement mm
                                                                                                                    Thickness mm
                                                                                                                    Identification mark
                                                                                                                    0.6 - 0.8
                                                                                                                    1.6
                                                                                                                    L
                                                                                                                    0.8 - 1.0
                                                                                                                    1.8
                                                                                                                    1
                                                                                                                    1.0 - 1.2
                                                                                                                    2.0
                                                                                                                    0
                                                                                                                    1.2 - 1.4
                                                                                                                    2.2
                                                                                                                    2
                                                                                                                    1.4 - 1.6
                                                                                                                    2.4
                                                                                                                    4
                                                                                                                    1.6 - 1.8
                                                                                                                    2.6
                                                                                                                    6

                                                                                                                  1. Turn the transmission upside down.
                                                                                                                       
                                                                                                                    1. 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.
                                                                                                                    2. Standard value of low-reverse brake end play (reference): 1.65 - 2.11 mm
                                                                                                                      Available pressure plates
                                                                                                                      Amount of movement mm
                                                                                                                      Thickness mm
                                                                                                                      Identification mark
                                                                                                                      1.3 - 1.5
                                                                                                                      1.6
                                                                                                                      L
                                                                                                                      1.5 - 1.7
                                                                                                                      1.8
                                                                                                                      1
                                                                                                                      1.7 - 1.9
                                                                                                                      2.0
                                                                                                                      0
                                                                                                                      1.9 - 2.1
                                                                                                                      2.2
                                                                                                                      2
                                                                                                                      2.1 - 2.3
                                                                                                                      2.4
                                                                                                                      4
                                                                                                                      2.3 - 2.5
                                                                                                                      2.6
                                                                                                                      6
                                                                                                                      2.5 - 2.7
                                                                                                                      2.8
                                                                                                                      8
                                                                                                                      2.7 - 2.9
                                                                                                                      3.0
                                                                                                                      D

                                                                                                                    1. Remove all the parts has been installed in steps 7. through 17.
                                                                                                                    1. Install the snap ring in the groove formed in the output shaft hole in the transmission case.
                                                                                                                    1. Install the thinnest spacer (thickness: 1.88 mm) for adjusting the output shaft preload.
                                                                                                                         
                                                                                                                      1. Use the special tools to drive the output shaft bearing outer race into the transmission case.
                                                                                                                        • Installer adapter (MB990930)
                                                                                                                        • Handle (MB990938)
                                                                                                                           
                                                                                                                           CAUTION
                                                                                                                          Do not reuse the output shaft bearing retainer mounting bolts as they are pre-coated with a sealant.
                                                                                                                        1. Install the output shaft bearing retainer mounting bolts and tighten them to the specified torque of 29 ± 2 N·m.
                                                                                                                             
                                                                                                                          1. Use the special tool Bearing installer (MD998350) to install the collar and taper roller bearing on the output shaft.
                                                                                                                               
                                                                                                                               CAUTION
                                                                                                                              The lock nut thread is left-handed.
                                                                                                                            1. 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)
                                                                                                                                 
                                                                                                                              1. Move the output shaft and to measure the amount of movement; record the measurement.
                                                                                                                              1. Remove all the parts having installed in steps 20. through 24.
                                                                                                                              1. 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).
                                                                                                                              1. Repeat steps 21. through 24. to reinstall the parts.
                                                                                                                                   
                                                                                                                                1. Stake the lock nut (at two places).
                                                                                                                                     
                                                                                                                                  1. Use the special tools to install the cap as shown in the illustration.
                                                                                                                                    • Installer adapter (MB990931)
                                                                                                                                    • Handle (MB990938)
                                                                                                                                       
                                                                                                                                    1. Install the planetary carrier assembly.
                                                                                                                                         
                                                                                                                                      1. Install the planetary reverse sun gear.
                                                                                                                                           
                                                                                                                                        1. Install the wave spring on the low-reverse brake piston.
                                                                                                                                             
                                                                                                                                          1. Install the pressure plate that has been selected in step 17. Then install the brake discs and brake plates.
                                                                                                                                          2. Number of brake discs and plates
                                                                                                                                            Model
                                                                                                                                            Brake disc
                                                                                                                                            Brake plate
                                                                                                                                            Pressure plate
                                                                                                                                            F4A4
                                                                                                                                            5
                                                                                                                                            4
                                                                                                                                            1
                                                                                                                                            W4A4
                                                                                                                                            6
                                                                                                                                            5
                                                                                                                                            1

                                                                                                                                               
                                                                                                                                            1. Install the snap ring.
                                                                                                                                                 
                                                                                                                                              1. Install the reaction plate.
                                                                                                                                                   
                                                                                                                                                1. Install the snap ring that has been selected in step 11.
                                                                                                                                                     
                                                                                                                                                  1. Install the brake discs (three pieces), brake plates (two pieces), and the pressure plate that has been selected in step 15.
                                                                                                                                                       
                                                                                                                                                    1. Install the return spring and second brake.
                                                                                                                                                         
                                                                                                                                                      1. Install the snap ring.
                                                                                                                                                           
                                                                                                                                                           CAUTION
                                                                                                                                                          Be sure to install the thrust bearing with the indicated side facing down.
                                                                                                                                                        1. Install the thrust bearing No.5.
                                                                                                                                                        IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS
                                                                                                                                                           
                                                                                                                                                        O.D. mm
                                                                                                                                                        I.D. mm
                                                                                                                                                        Thickness mm
                                                                                                                                                        Marking
                                                                                                                                                          O.D. mm
                                                                                                                                                        I.D. mm
                                                                                                                                                        Thickness mm
                                                                                                                                                        Marking
                                                                                                                                                        59
                                                                                                                                                        47
                                                                                                                                                        1.8
                                                                                                                                                        No.1
                                                                                                                                                          48.9
                                                                                                                                                        37
                                                                                                                                                        1.6
                                                                                                                                                        No.8
                                                                                                                                                            2.0
                                                                                                                                                              1.7
                                                                                                                                                         
                                                                                                                                                            2.2
                                                                                                                                                              1.8
                                                                                                                                                         
                                                                                                                                                            2.4
                                                                                                                                                              1.9
                                                                                                                                                         
                                                                                                                                                            2.6
                                                                                                                                                              2.0
                                                                                                                                                         
                                                                                                                                                            2.8
                                                                                                                                                              2.1
                                                                                                                                                         
                                                                                                                                                        49
                                                                                                                                                        34
                                                                                                                                                        3.6
                                                                                                                                                        No.2
                                                                                                                                                            2.2
                                                                                                                                                         
                                                                                                                                                        49
                                                                                                                                                        34
                                                                                                                                                        3.6
                                                                                                                                                        No.3
                                                                                                                                                            2.3
                                                                                                                                                         
                                                                                                                                                        45.3
                                                                                                                                                        31
                                                                                                                                                        3.3
                                                                                                                                                        No.4
                                                                                                                                                            2.4
                                                                                                                                                         
                                                                                                                                                        49
                                                                                                                                                        34
                                                                                                                                                        3.6
                                                                                                                                                        No.5
                                                                                                                                                            2.5
                                                                                                                                                         
                                                                                                                                                        49
                                                                                                                                                        34
                                                                                                                                                        3.6
                                                                                                                                                        No.6
                                                                                                                                                            2.6
                                                                                                                                                         
                                                                                                                                                        59
                                                                                                                                                        37
                                                                                                                                                        2.8
                                                                                                                                                        No.7
                                                                                                                                                               
                                                                                                                                                             
                                                                                                                                                             CAUTION
                                                                                                                                                            Be sure to install the thrust bearing with the indicated side facing down.
                                                                                                                                                          1. Install the overdrive clutch hub and thrust bearing No.6 in the reverse and overdrive clutch.
                                                                                                                                                               
                                                                                                                                                               CAUTION
                                                                                                                                                              Be sure to install the thrust bearing with the indicated side facing down.
                                                                                                                                                            1. Install the reverse and overdrive clutch and thrust bearing No.7.
                                                                                                                                                                 
                                                                                                                                                              1. Use the special tool Handle (MB990938) to press-fit the input shaft rear bearing into the rear cover.
                                                                                                                                                              1. Install the four seal rings.
                                                                                                                                                                   
                                                                                                                                                                1. Measure the end play of the underdrive sun gear using the following procedure to select a thrust race No.8 of proper thickness.
                                                                                                                                                                  1. Install the thinnest thrust race No.8 (thickness: 1.6 mm) on the thrust bearing No.7.
                                                                                                                                                                  1. Install the rear cover on the transmission and tighten the bolts to the specified torque of 23 ± 3 N·m.
                                                                                                                                                                  1. Turn the transmission upside down, thus making the torque converter housing mounting end face up.
                                                                                                                                                                  1. Install the underdrive clutch hub on the underdrive sun gear.
                                                                                                                                                                  1. Measure the end play of the underdrive sun gear and record the measurement.
                                                                                                                                                                  2. Standard value (reference): 0.25 - 0.45 mm
                                                                                                                                                                  1. Remove all the parts installed in substeps (1) through (4).
                                                                                                                                                                     
                                                                                                                                                                  1. Install the O-rings (three places).
                                                                                                                                                                  1. 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.
                                                                                                                                                                  2. Measurement mm
                                                                                                                                                                    Thickness mm
                                                                                                                                                                    0.3 - 0.4
                                                                                                                                                                    1.6
                                                                                                                                                                    0.4 - 0.5
                                                                                                                                                                    1.7
                                                                                                                                                                    0.5 - 0.6
                                                                                                                                                                    1.8
                                                                                                                                                                    0.6 - 0.7
                                                                                                                                                                    1.9
                                                                                                                                                                    0.7 - 0.8
                                                                                                                                                                    2.0
                                                                                                                                                                    0.8 - 0.9
                                                                                                                                                                    2.1
                                                                                                                                                                    0.9 - 1.0
                                                                                                                                                                    2.2
                                                                                                                                                                    1.0 - 1.1
                                                                                                                                                                    2.3
                                                                                                                                                                    1.1 - 1.2
                                                                                                                                                                    2.4
                                                                                                                                                                    1.2 - 1.3
                                                                                                                                                                    2.5
                                                                                                                                                                    1.3 - 1.4
                                                                                                                                                                    2.6

                                                                                                                                                                       
                                                                                                                                                                    1. 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.
                                                                                                                                                                    2. Specified sealant:
                                                                                                                                                                      • Mitsubishi genuine sealant Part No. MD974421 or equivalent
                                                                                                                                                                         
                                                                                                                                                                      1. Install the rear cover and tighten its mounting bolts to the specified torque of 23 ± 3 N·m.
                                                                                                                                                                           
                                                                                                                                                                        1. Install the parting pawl, spacer and spring in position, then install the parking pawl shaft.
                                                                                                                                                                             
                                                                                                                                                                          1. Install the parking roller support, then install the two parking roller support shafts.
                                                                                                                                                                               
                                                                                                                                                                            1. Install the underdrive clutch hub.
                                                                                                                                                                                 
                                                                                                                                                                                 CAUTION
                                                                                                                                                                                Install the thrust bearing with the indicated side facing down.
                                                                                                                                                                              1. Install the thrust bearing No.2.
                                                                                                                                                                                   
                                                                                                                                                                                1. Install the underdrive clutch holding the input shaft.
                                                                                                                                                                                     
                                                                                                                                                                                  1. Install the thinnest thrust washer No.1 for adjusting the input shaft end play (thickness: 1.8 mm) on the underdrive clutch retainer.
                                                                                                                                                                                       
                                                                                                                                                                                       CAUTION
                                                                                                                                                                                      Never use a gasket that has been tightened.
                                                                                                                                                                                    1. Use the special tool Guide (MD998412) to install a new oil pump gasket and the oil pump.
                                                                                                                                                                                    1. Tighten the oil pump mounting bolts to the specified torque of 29 ± 2 N·m.
                                                                                                                                                                                         
                                                                                                                                                                                      1. 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.
                                                                                                                                                                                      2. Standard value (reference): 0.70 - 1.45 mm
                                                                                                                                                                                           
                                                                                                                                                                                        1. Install the oil filter.
                                                                                                                                                                                             
                                                                                                                                                                                          1. Use the special tools to drive the differential bearing outer race into the transmission case.
                                                                                                                                                                                            • Installer adapter (MB990935)
                                                                                                                                                                                            • Handle (MB990938)
                                                                                                                                                                                               
                                                                                                                                                                                            1. Install the differential <F4A4> or centre differential <W4A4>.
                                                                                                                                                                                                 
                                                                                                                                                                                              1. Place two pieces of about 10 mm long, 3 mm diameter solder on the converter housing at the locations indicated in the illustration.
                                                                                                                                                                                                   
                                                                                                                                                                                                1. Use the special tools to drive the outer race into position.
                                                                                                                                                                                                  • Installer adapter (MB990935)
                                                                                                                                                                                                  • Handle (MB990938)
                                                                                                                                                                                                  • Bush remover & installer base (MB991445)
                                                                                                                                                                                                1. Install the converter housing on the transmission case without applying FIPG. Tighten the mounting bolts to the specified torque of 48 ± 6 N·m.
                                                                                                                                                                                                     
                                                                                                                                                                                                  1. Remove the bolts and converter housing, and take out the solder pieces.
                                                                                                                                                                                                  1. Use a micrometer to measure the thickness of the crashed solder.
                                                                                                                                                                                                       
                                                                                                                                                                                                    1. Select a spacer of the thickness equivalent to the micrometer reading plus the standard preload value.
                                                                                                                                                                                                    2. Standard preload value: 0.045 - 0.105 mm
                                                                                                                                                                                                         
                                                                                                                                                                                                      1. 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)
                                                                                                                                                                                                        • Handle (MB990938)
                                                                                                                                                                                                        • Bush remover & installer base (MB991445)
                                                                                                                                                                                                           
                                                                                                                                                                                                        1. 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.
                                                                                                                                                                                                        2. Specified sealant:
                                                                                                                                                                                                          • Mitsubishi genuine sealant Part No. MD974421 or equivalent
                                                                                                                                                                                                             
                                                                                                                                                                                                          1. Install the two O-rings (two pieces).
                                                                                                                                                                                                               
                                                                                                                                                                                                            1. Install the converter housing and tighten the mounting bolts to the specified torque of 48 ± 6 N·m.
                                                                                                                                                                                                            1. Install the manual control lever shaft and parking pawl rod.
                                                                                                                                                                                                                 
                                                                                                                                                                                                              1. Install the manual control lever shaft roller.
                                                                                                                                                                                                              1. Fit a new seal ring to each accumulator piston.
                                                                                                                                                                                                              2. NOTE: All the four accumulator pistons and seal rings are identical.
                                                                                                                                                                                                                       
                                                                                                                                                                                                                1. Identify the accumulator spring for each accumulator and install it in the correct hole in the transmission case together with the piston.
                                                                                                                                                                                                                2. NOTE: The accumulator springs are identified as shown in the table below.
                                                                                                                                                                                                                  No.
                                                                                                                                                                                                                  Accumulator spring
                                                                                                                                                                                                                  Blue ink marking
                                                                                                                                                                                                                  1
                                                                                                                                                                                                                  For low-reverse brake
                                                                                                                                                                                                                  No marking
                                                                                                                                                                                                                  2
                                                                                                                                                                                                                  For underdrive clutch
                                                                                                                                                                                                                  Half of surface
                                                                                                                                                                                                                  3
                                                                                                                                                                                                                  For second brake
                                                                                                                                                                                                                  Entire surface
                                                                                                                                                                                                                  4
                                                                                                                                                                                                                  For overdrive clutch
                                                                                                                                                                                                                  No marking

                                                                                                                                                                                                                     
                                                                                                                                                                                                                  1. Install the strainer and second brake retainer oil seal as shown in the illustration.
                                                                                                                                                                                                                  1. Fit a new O-ring into the groove in the solenoid valve harness connector.
                                                                                                                                                                                                                       
                                                                                                                                                                                                                    1. 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.
                                                                                                                                                                                                                         
                                                                                                                                                                                                                      1. Install the steel balls one each in the two holes on the top of the valve body (outside valve body).
                                                                                                                                                                                                                      1. 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.
                                                                                                                                                                                                                           
                                                                                                                                                                                                                        1. Install the valve body mounting bolts and tighten them to the specified torque of 11 ± 1 N·m.
                                                                                                                                                                                                                             
                                                                                                                                                                                                                          1. Install the oil temperature sensor and them connect the connector to the valve body.
                                                                                                                                                                                                                          2. No.
                                                                                                                                                                                                                            Solenoid valve
                                                                                                                                                                                                                            Wire colour
                                                                                                                                                                                                                            Connector housing colour
                                                                                                                                                                                                                            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

                                                                                                                                                                                                                               
                                                                                                                                                                                                                            1. Install the manual control shaft detent spring and detent.
                                                                                                                                                                                                                                 
                                                                                                                                                                                                                              1. 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.
                                                                                                                                                                                                                              2. Specified sealant:
                                                                                                                                                                                                                                • Mitsubishi genuine sealant Part No. MD974421 or equivalent
                                                                                                                                                                                                                                   
                                                                                                                                                                                                                                1. Install the valve body cover and tighten its mounting bolts to the specified torque of 11 ± 1 N·m.
                                                                                                                                                                                                                                     
                                                                                                                                                                                                                                  1. Install the sealing cap.
                                                                                                                                                                                                                                  1. Install the inhibitor switch.
                                                                                                                                                                                                                                       
                                                                                                                                                                                                                                    1. Install the manual control lever.
                                                                                                                                                                                                                                         
                                                                                                                                                                                                                                      1. Install the input shaft speed sensor and output shaft speed sensor.
                                                                                                                                                                                                                                           
                                                                                                                                                                                                                                        1. 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.
                                                                                                                                                                                                                                        1. 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.
                                                                                                                                                                                                                                        1. Install the oil level gauge.
                                                                                                                                                                                                                                        1. Install the brackets.
                                                                                                                                                                                                                                             
                                                                                                                                                                                                                                             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.
                                                                                                                                                                                                                                          1. Install the torque converter, and secure it so that the dimension (A) indicated in the illustration meets the reference value.
                                                                                                                                                                                                                                          2. Reference value: 12.2 mm
                                                                                                                                                                                                                                          1. Install the transfer after fitting a new O-ring on it. <W4A4>
                                                                                                                                                                                                                                          ©2004 Mitsubishi Motors Corporation