)
| 1. |
Transfer |
||
| 2. |
Torque converter |
||
| 3. |
Roll stopper bracket |
||
| 4. |
Harness bracket |
||
| 5. |
Harness bracket |
||
| 6. |
Control cable support bracket |
||
| 7. |
Oil level gauge |
||
| 8. |
Oil level tube |
||
| 9. |
Eye bolt |
||
| 10. |
Oil cooler feed tube |
||
| 11. |
Input shaft speed sensor |
||
| 12. |
Output shaft speed sensor |
||
| 13. |
Manual control lever |
||
| 14. |
Inhibitor switch |
||
| 15. |
Sealing cap |
||
| 16. |
Valve body cover |
||
| 17. |
Manual control shaft detent |
||
| 18. |
Valve body |
||
| 19. |
Steel ball |
||
| 20. |
Gasket |
||
| 21. |
Snap ring |
||
| 22. |
Solenoid valve harness |
||
| 23. |
Strainer |
||
| 24. |
Second brake retainer oil seal |
||
| 25. |
Accumulator piston |
||
| 26. |
Accumulator spring |
||
| 27. |
Accumulator spring |
||
| 28. |
Snap ring |
||
| 29. |
Accumulator cover |
||
| 30. |
Accumulator spring |
||
| 31. |
Accumulator piston |
||
| 32. |
Manual control lever shaft roller |
||
| 33. |
Manual control lever shaft |
||
| 34. |
Parking pawl rod |
)
| 35. |
Converter housing |
||
| 36. |
Centre differential |
||
| 37. |
Oil filter |
||
| 38. |
Oil pump |
||
| 39. |
Gasket |
||
| 40. |
Pipe |
||
| 41. |
Thrust washer No.1 |
||
| 42. |
Underdrive clutch and input shaft |
||
| 43. |
Thrust bearing No.2 |
||
| 44. |
Underdrive clutch hub |
||
| 45. |
Snap ring |
||
| 46. |
Reduction brake piston cover |
||
| 47. |
Snap ring |
||
| 48. |
Reduction brake piston |
||
| 49. |
Reduction brake spring |
||
| 50. |
Parking pawl shaft |
||
| 51. |
Parking pawl spring |
||
| 52. |
Parking roller support shaft |
||
| 53. |
Parking pawl |
||
| 54. |
Parking roller support |
||
| 55. |
Direct planetary carrier assembly |
||
| 56. |
Anchor plug |
||
| 57. |
Direct clutch |
||
| 58. |
Reduction brake band |
||
| 59. |
Thrust bearing No.11 |
||
| 60. |
Thrust race No.12 |
||
| 61. |
Rear cover |
||
| 62. |
Thrust race No.8 |
||
| 63. |
Seal ring |
||
| 64. |
Input shaft rear bearing |
||
| 65. |
Accumulator piston |
||
| 66. |
Accumulator spring |
||
| 67. |
Thrust bearing No.7 |
||
| 68. |
Reverse and overdrive clutch |
||
| 69. |
Thrust bearing No.6 |
||
| 70. |
Overdrive clutch hub |
||
| 71. |
Thrust bearing No.5 |
||
| 72. |
Planetary reverse sun gear |
||
| 73. |
Snap ring |
||
| 74. |
Second brake piston |
||
| 75. |
Return spring |
||
| 76. |
Pressure plate |
||
| 77. |
Second brake disc |
||
| 78. |
Second brake plate |
||
| 79. |
Planetary carrier assembly |
||
| 80. |
Snap ring |
||
| 81. |
Reaction plate |
||
| 82. |
Snap ring |
||
| 83. |
Low-reverse brake disc |
||
| 84. |
Low-reverse brake plate |
||
| 85. |
Pressure plate |
||
| 86. |
Wave spring |
||
| 87. |
Snap ring |
||
| 88. |
One-way clutch inner race |
||
| 89. |
O-ring |
||
| 90. |
Spring retainer |
||
| 91. |
Return spring |
||
| 92. |
Low-reverse brake piston |
||
| 93. |
Transfer drive gear |
||
| 94. |
Snap ring |
||
| 95. |
One-way clutch |
||
| 96. |
Seal ring |
||
| 97. |
Needle bearing |
||
| 98. |
Outer race |
||
| 99. |
Spacer |
||
| 100. |
Outer race |
||
| 101. |
Transmission case |
DISASSEMBLY
CAUTION- The automatic transmission includes many high-precision parts. Handle these parts extremely carefully not to scratch or damage them during disassembly and reassembly.
- Work bench should be covered with a rubber mat and keep it clean at all times.
- Do not wear any cloth gloves and do not use any rags during disassembly. Use only nylon cloth or paper towels if necessary.
- All removed parts must be washed clean. Metal parts may be washed in an ordinary solvent, but they should be dried completely using compressed air.
- Clutch discs, brake discs, plastic thrust plates and rubber parts should be washed in automatic transmission fluid (ATF) and keep them free of dirt after washing.
- If the transmission has been found damaged and repaired, also disassemble and clean the ATF cooler system.
- Remove the transfer and O-ring.
- Remove the torque converter.
)
- Use a dial gauge to measure the input shaft end play.
- Remove each bracket.
- Remove the oil level gauge.
- Remove the oil cooler feed tube.
)
- Remove the input shaft speed sensor and output shaft speed sensor.
)
- Remove the manual control lever, then remove the inhibitor switch.
CAUTION)
- Remove the sealing cap.
)
- Remove the valve body cover.
)
- Remove the manual control shaft detent.
)
- Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.
)
- Remove the valve body mounting bolts (twenty seven pieces).
CAUTION)
- Remove the valve body, gasket and the steel balls (two pieces).
CAUTION)
- Remove the snap ring from the connector, then push the connector into the transmission case to remove the solenoid valve harness.
)
- Remove the strainer and second brake retainer oil seal.
)
- Remove the accumulator pistons and their springs.
| 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.
)
- Remove the reduction brake accumulator cover after removing the snap ring, then remove the spring and piston.
)
- Remove the manual control lever shaft roller.
- Remove the manual control lever shaft and the parking pawl rod.
)
- Remove the converter housing mounting bolts (twenty pieces), then remove the converter housing.
)
- Remove the O-rings (two pieces).
)
- Remove the centre differential.
)
- Remove the oil filter.
)
- Remove the pipe clamp bolts (two places).
)
- Remove the oil pump mounting bolts (six pieces).
- Install the special tools in the holes A.
)
- Screw the special tools Oil pump remover (MD998333) evenly to remove the oil pump and pipe.
- Remove the oil pump gasket.
- Remove the pipe from the oil pump.
)
- Remove the thrust washer No.1.
)
- Holding the input shaft, remove the underdrive clutch.
)
- Remove the thrust bearing No.2.
)
- Remove the underdrive clutch hub.
)
- Remove the reduction brake piston cover after removing the snap ring.
- Remove the reduction brake piston and spring after removing the snap ring.
)
- Pull out the parking pawl shaft, then remove the spring.
)
- Remove the parking roller support shafts (two pieces), then remove the parking pawl and parking roller support.
)
- Remove the direct planetary carrier assembly.
)
- Remove the anchor plug and O-ring.
)
- Remove the direct clutch.
)
- Remove the reduction brake band.
)
- Remove the thrust bearing No.11 and thrust race No.12.
)
- Remove the rear cover.
- Remove the thrust race No.8.
- Remove the seal rings (four pieces).
- Remove the input shaft rear bearing.
)
- Remove the O-rings (six pieces).
)
- Remove the direct clutch accumulator piston and spring after removing the O-ring.
)
- Remove the reverse and overdrive clutch and the thrust bearing No.7.
)
- Remove the overdrive clutch hub and thrust bearing No.6.
)
- Remove the thrust bearing No.5.
)
- Remove the planetary reverse sun gear.
)
- Remove the snap ring.
)
- Remove the second brake piston and return spring.
)
- Remove the pressure plate, brake discs (four pieces) and brake plates (three pieces).
)
- Remove the planetary carrier assembly.
)
- Remove the snap ring.
)
- Remove the reaction plate and brake discs.
)
- Remove the snap ring.
)
- Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.
NOTE: *Includes the brake discs removed in step 60.
)
- Remove the wave spring.
)
- Use the special tools to remove the snap ring.
- Spring compressor (MD999577)
- Spring compressor retainer (MD998924)
- Remove the one-way clutch inner race, O-ring, spring retainer, return spring, and low-reverse brake piston.
)
- Remove the four of the transfer drive gear mounting bolts. Then turn the gear 1/8 of a turn (45°) and remove the remaining four bolts.
)
- Remove the transfer drive gear.
)
- Remove the snap ring.
)
- Remove the one-way clutch.
- Remove the seal rings (two pieces).
- Remove the needle bearing.
- Remove the differential bearing outer race and spacer from the converter housing.
- Remove the differential bearing outer race from the transmission case.
REASSEMBLY
CAUTION- Never reuse any gasket, O-ring, and oil seal. Always replace them with new ones.
- Never use any product other than blue petrolatum jelly or white Vaseline to lubricate or hold parts during assembly.
- Apply ATF to friction elements, rotating parts, and sliding parts before installation.
Soak new clutch discs or brake discs in ATF for at least two hours before installing them.
- Never apply sealant or adhesive to gaskets.
- When a bushing requires replacement, replace the assembly of which the bushing forms a part.
- Never use any cloth gloves or any rags during reassembly. Use only nylon cloth or paper towels if necessary.
- Change also the ATF in the cooler circuit.
)
- Use the special tool Guide (MD998412) to install the transfer drive gear.
- Tighten the transfer drive gear mounting bolts (eight pieces) to the specified torque of 34 ± 2 N·m.
)
- Install the low-reverse brake piston, return spring and spring retainer.
- Fit a new O-ring in the groove in the one-way clutch inner race.
- 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.
)
- Use the special tools to fit the snap ring in position.
- Spring compressor (MD999577)
- Spring compressor retainer (MD998924)
- Install the wave spring on the low-reverse brake piston.
- Install the brake discs (six pieces), brake plates (five pieces), and snap ring for the low-reverse brake as shown in the illustration.
NOTE: Do not install the pressure plate yet.
- Install the special tool on the stack of the brake discs.
- Install the reaction plate and the snap ring that was removed during disassembly.
)
- Move up the special tool Clearance dummy plate (MB991632) to check whether the end play of the reaction plate is within the standard value range. If necessary, remove the snap ring that has been installed in step 10. and install another appropriate snap ring.
Standard value: 0 -
0.16 mm
- Install the brake discs (four pieces) and brake plates (three pieces) for the second brake.
NOTE: Do not install the pressure plate yet.
- Install the special tool Clearance dummy plate (MB991632).
)
- Install the return spring, second brake piston, and snap ring.
)
)
- Move the special tool Clearance dummy plate (MB991632) to measure the amount of movement. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
Standard value of second brake end play (reference): 1.09 -
1.55 mm
| Amount of movement mm |
Thickness mm |
Identification mark |
|---|---|---|
| 1.7 -
1.9 |
2.4 |
P |
| 1.9 -
2.1 |
2.6 |
R |
| 2.1 -
2.3 |
2.8 |
S |
| 2.3 -
2.5 |
3.0 |
T |
| 2.5 -
2.7 |
3.2 |
U |
| 2.7 -
2.9 |
3.4 |
V |
- Turn the transmission upside down.
)
- Move the special tool Clearance dummy plate (MB991632) and measure the amount of movement using a dial gauge fitted with the special tool Dial gauge extension (MD998913). Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
Standard value of low-reverse brake end play (reference): 1.65 -
2.11 mm
| Amount of movement mm |
Thickness mm |
Identification mark |
|---|---|---|
| 1.0 -
1.2 |
1.6 |
F |
| 1.2 -
1.4 |
1.8 |
E |
| 1.4 -
1.6 |
2.0 |
D |
| 1.6 -
1.8 |
2.2 |
C |
| 1.8 -
2.0 |
2.4 |
B |
| 2.0 -
2.2 |
2.6 |
A |
| 2.2 -
2.4 |
2.8 |
0 |
| 2.4 -
2.6 |
3.0 |
1 |
- Remove all the parts that have been installed in steps 7. through 17.
)
- Install the needle bearing as shown in the illustration.
- Install the two seal rings.
)
- Install the one-way clutch with the identification mark facing up.
- Install the snap ring.
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 |
1.7 |
No.8 |
|
| 2.0 |
1.8 |
|||||||
| 2.2 |
1.9 |
|||||||
| 2.4 |
2.0 |
|||||||
| 2.6 |
2.1 |
|||||||
| 2.8 |
2.2 |
|||||||
| 49 |
34 |
3.6 |
No.2 |
2.3 |
||||
| 49 |
34 |
3.6 |
No.3 |
2.4 |
||||
| 57 |
38.5 |
4.12 |
2.5 |
|||||
| 45.3 |
31 |
3.3 |
No.4 |
2.6 |
||||
| 55.4 |
38.5 |
3.3 |
72 |
48 |
4 |
No.9 |
||
| 49 |
34 |
3.6 |
No.5 |
78.5 |
60 |
2.5 |
||
| 57 |
38.5 |
4.12 |
54.6 |
43 |
3 |
No.10 |
||
| 49 |
34 |
3.6 |
No.6 |
49 |
31 |
3.3 |
No.11 |
|
| 57 |
38.5 |
4.12 |
58 |
40.7 |
4.2 |
|||
| 59 |
37 |
2.8 |
No.7 |
46.5 |
33 |
3 |
No.12 |
|
| 48.9 |
37 |
1.6 |
No.8 |
80 |
60 |
2.5 |
- Install the planetary carrier assembly.
- Install the planetary reverse sun gear.
- Install the wave spring on the low-reverse brake piston.
)
- Install the pressure plate that has been selected in step 17. Then install the brake discs (six pieces) and brake plates (five pieces).
)
- Install the snap ring.
)
- Install the reaction plate.
)
- Install the snap ring that has been selected in step 11.
)
- Install the brake discs (four pieces), brake plates (three pieces), and the pressure plate that has been selected in step 15.
)
- Install the return spring and second brake piston.
)
- Install the snap ring.
)
- Install the thrust bearing No.5.
CAUTION)
- Install the overdrive clutch hub and thrust bearing No.6 in the reverse and overdrive clutch.
CAUTION)
- Install the reverse and overdrive clutch and thrust bearing No.7.
CAUTION)
- Use the special tool Handle (MB990938) to press-fit the input shaft bearing into the rear cover.
- Install the seal rings (four pieces).
)
)
- Measure the end play of the underdrive sun gear using the following procedure to select a thrust race No.8 of proper thickness.
- Install the thinnest thrust race No.8 (thickness: 1.6 mm) on the thrust bearing No.7.
- Install the rear cover on the transmission and tighten the bolts to the specified torque 23 ± 3 N·m.
- Turn the transmission upside down, thus making the torque converter housing mounting end face up.
- Install the underdrive clutch hub on the underdrive sun gear.
- Measure the end play of the underdrive sun gear and record the measurement.
- Remove all the parts installed in substeps (1) through (4).
Standard value (reference): 0.25 -
0.45 mm
)
- Install the direct clutch accumulator spring and piston, then install the O-ring.
- Install the O-rings (six pieces).
- Select a thrust race No.8 whose thickness corresponds to the measurement recorded in substep (5) of step 38. from the table below and install the thrust race on the thrust bearing No.7.
| 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 |
)
- 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.
- Mitsubishi genuine sealant Part No. MD974421 or equivalent
Specified sealant:
- Install the rear cover and tighten its mounting bolts to the specified torque of 23 ± 3 N·m.
)
- Install the thrust race No.12 and thrust bearing No.11.
CAUTION)
- Finger-tighten the anchor plug and a new O-ring, then install the reduction brake band and direct clutch simultaneously.
)
- Make sure that the direct clutch can be rotated only in the direction indicated in the illustration.
NOTE: If the clutch can be rotated in the other direction, remove and reinstall it correctly.
)
- Tighten the anchor plug to the specified torque of 98 ± 15 N·m.
- Install the direct planetary carrier assembly.
)
- Install the reduction brake spring and piston in position in the transmission case, then install the snap ring.
)
- Adjust the reduction brake piston using the following procedure:
- Remove the nut from the reduction brake piston.
- Install the stopper of the special tool Reduction brake wrench set (MB991633) to hold the reduction brake piston against rotation.
)
- Using a torque wrench fitted with the socket of the special tool Reduction brake wrench set (MB991633), tighten the adjusting rod to 10 N·m, then loosen it. Repeat this operation twice. Tighten the adjusting rod to 5 N·m, then turn it back 5-1/2 to 5-3/4 turns.
)
- Install the nut on the adjusting rod and tighten the nut to 19 ± 3 N·m using the wrench of the special tool Reduction brake wrench set (MB991633).
- Install the reduction brake piston cover and snap ring.
)
- Install the parting pawl and spring in position, then install the parking pawl shaft.
)
- Install the parking roller support, then install the two parking roller support shafts.
- Install the underdrive clutch hub.
)
- Install the thrust bearing No.2.
CAUTION
- Install the underdrive clutch holding the input shaft.
)
- Install the thinnest thrust washer No.1 for adjusting the input shaft end play (thickness: 1.8 mm, part No.: MD754509) on the underdrive clutch retainer.
)
- Install the pipe on the oil pump.
)
- Use the special tool Guide (MD998412) to install a new oil pump gasket and the oil pump. Install the pipe at the same time.
CAUTION- Tighten the oil pump mounting bolts to the specified torques of 23 ± 3 N·m. Tighten the pipe clamp bolts to the specified torques of 11 ± 1 N·m.
)
- Measure the end play of the input shaft. Select a thrust washer No.1 of the thickness corresponding to the measurement from the table below and replace with it the thrust washer that has been installed in step 57.
Standard value (reference): 0.70 -
1.45 mm
- Install the oil filter.
)
- Use the special tools to drive the differential bearing outer race into the transmission case.
- Handle (MB990938)
- Installer adapter (MB990936)
- Install the centre differential.
)
- Place two pieces of about 10 mm long, 3 mm diameter solder on the converter housing at the locations indicated in the illustration.
)
- Use the special tool Bushing remover and installer base (MB991445) to drive the outer race into position.
- Install the converter housing on the transmission case without applying FIPG. Tighten the mounting bolts to the specified torque of 48 ± 6 N·m.
- Remove the bolts and converter housing, and take out the solder pieces.
)
- Use a micrometer to measure the thickness of the crashed solder.
- Select a spacer of the thickness equivalent to the micrometer reading plus the standard preload value.
Standard preload value: 0.045 -
0.105 mm
- Install the spacer selected in step 70. into the converter housing and drive the outer race into position using the special tool Bushing remover and installer base (MB991445).
)
- Apply an approx. 1.6 mm diameter bead of form-in-place gasket (FIPG) to the converter housing along its circumference as shown in the illustration.
- Mitsubishi genuine sealant Part No. MD974421 or equivalent
Specified sealant:
- Install the O-rings (two pieces).
- Install the converter housing and tighten the mounting bolts (twenty pieces) to the specified torque 48 ± 6 N·m.
- Install the manual control lever shaft and parking pawl rod.
- Install the manual control lever shaft roller.
- Install the piston and spring of the reduction brake accumulator, then install the accumulator cover.
)
- Fit a new seal ring to each accumulator piston.
NOTE: All the four accumulator pistons and seal rings are identical.
- Identify the accumulator spring for each accumulator and install it in the correct hole in the transmission case together with the piston.
NOTE: The accumulator springs are identified as shown in the table below.
| No. |
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 |
- Install the strainer and second brake retainer oil seal as shown in the illustration.
- Fit a new O-ring into the groove in the solenoid valve harness connector.
- 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.
- Install the steel balls one each in the two holes on the top of the valve body (outside valve body).
- Install the valve body and gasket. Make sure that the pin of the manual valve is in place in the detent plate groove in the manual control lever shaft.
)
- Install the valve body mounting bolts (twenty eight pieces) and tighten them to the specified torque 11 ± 1 N·m.
)
- Install the fluid temperature sensor.
- Connect the harness connectors to the solenoid valves in the valve body.
| 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 |
Green/red/red |
Milky white |
| 5 |
Damper clutch control solenoid valve |
Blue/blue/yellow |
Black |
| 6 |
Reduction solenoid valve |
Orange/yellow/yellow |
Black |
| 7 |
Fluid temperature sensor |
- |
- |
- Install the manual control shaft detent.
)
- Apply an approx. 2.5 mm (FIPG) to the valve body cover along its circumference as shown in the illustration.
- Mitsubishi genuine sealant Part No. MD974421 or equivalent
Specified sealant:
- Install the valve body cover and tighten its mounting bolts to the specified torque of 11 ± 1 N·m.
- Install the sealing cap.
- Install the inhibitor switch.
- Install the manual control lever.
- Install the input shaft speed sensor and output shaft speed sensor.
- Install the eye bolt, a new gasket, and the oil cooler feed tube.
- Install the oil level gauge.
- Install the brackets.
)
- Install the torque converter, and secure it so that the dimension (A) indicated in the illustration meets the reference value.
CAUTIONReference value: 9.4 mm
- Install a new O-ring in the transfer.
- Install the transfer and tighten its mounting bolts to the specified torque of 69 ± 10 N·m.