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Transmission Reassembly

NOTE: For bearing race and thrust bearing locations and installation direction, See Fig 7 .
CAUTION: Lubricate all components with ATF. Clutch disc should be soaked in ATF for 2 hours prior to installation. Coat thrust bearings and races with petroleum jelly. Ensure ends of snap rings are not aligned with cutout area of case.
  1. Position transmission case with front facing upward. Assemble No. 3 brake secondary piston, reaction sleeve and primary piston. Press assembled pistons into case with hand pressure. Using appropriate spring compressor, install return spring assembly on primary piston. Install snap ring. Ensure No. 3 brake piston moves smoothly when compressed air is applied. See Figure .
  2. Install bearing race No. 19. Install output shaft thrust bearing No. 18 into case. Install brake apply tube into transmission case, aligning locking tab with cutout in valve body side of transmission case. Ensure lips of tube end are completely inserted onto outer piston. See Fig 1 . Install rear planetary gear and output shaft into case.
    Fig 1: Installing Brake Apply Tube
    G95H20336Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install pressure plate, with flat surface facing forward. Install discs and plates, starting with a disc and alternating each component. Measure No. 3 brake clutch pack clearance. See Figure . Clearance should be .024-.104" (.61-2.64 mm).
  4. Remove one-way clutch inner race from planetary gear assembly. Install front planetary gear. Mesh splines of planetary gear with flukes of discs by rotating and pushing planetary gear. Position one-way clutch inner race with notched tooth "A" toward valve body side of case. See Fig 2 . Push plate into place. Install snap ring. Ensure snap ring is fully seated.
  5. Align oil hole and bolt hole of center support toward valve body side. Align center support bolt holes with case holes and install. Install bolts with wave washers. Tighten bolt on accumulator piston side first to 18 ft. lbs. (25 N.m). Install direct clutch assembly while rotating to align with center support.
    Fig 2: Positioning One-Way Clutch Inner Race
    G95I20337Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. If fully installed, splined center of clutch will be even with end of sun gear shaft. Install bearing race No. 12, thrust bearing No. 13 and bearing race No. 14 over splined end of forward clutch. Install thrust bearing No. 4 on forward clutch. See Fig 7 . Install forward clutch. Rotate and push forward clutch to mesh splines of front clutch with flukes of discs.
  7. Using calipers and Clutch Drum Thrust Plate Gauge (MD998217), measure distance between top of case and forward clutch drum. Measured value minus thickness of plate gauge equals forward clutch installation height. See Fig 3 . Distance should be .059" (1.5 mm). If distance is not as specified, check installation of previously installed components. Install thrust bearing No. 8 and bearing race No. 7 to forward clutch. Install Guide Rods (MD998412) finger tight in front case bolt holes.
    Fig 3: Measuring Forward Clutch Installed Height
    G95J20338Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install OD case over guide pins with notch area toward valve body side of case. See Fig 4 . Install thrust washer on OD case and OD planetary gear. Ensure washer lugs align with holes in OD case and planetary gear assembly.
  9. Install OD planetary gear assembly with OD clutch and one-way clutch. Rotate and push OD planetary gear to mesh splines with flukes of discs. Ensure thrust washer does not fall during installation. Using calipers and Clutch Drum Thrust Plate Gauge (MD998217), measure distance between top of case and OD clutch drum. Measured value minus thickness of plate gauge equals OD clutch installation height. See Fig 5 . Distance should be .08" (2.0 mm). If distance is not as specified, check installation of previously installed components.
    Fig 4: Installing OD Case
    G95A20339Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 5: Measuring OD Clutch Installed Height
    G95D20340Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  10. Install "O" ring on OD case. Install converter housing to transmission case. Tighten 10-mm bolts to 25 ft. lbs. (34 N.m) and 12 mm bolts to 42 ft. lbs. (57 N.m). Install bearing race No. 2 on input shaft. Install thrust bearing No. 1 on rear of oil pump. Ensure oil seal rings and "O" ring are installed on oil pump.
  11. Install oil pump over guide studs and into transmission case. Ensure thrust bearing does not fall off oil pump. Coat oil pump retaining bolts below bolt heads with Loctite (242). Remove guide studs. Install bolts and tighten to 16 ft. lbs. (21 N.m). Ensure input shaft turns freely. Using a dial indicator, check input shaft end play. Position dial indicator against end of input shaft. End play should be .012-.035" (.30-.90 mm).
  12. Apply air pressure to specific oil passage to check appropriate operating components. See Fig 6 . Component application should be heard while applying air. Install NEW oil seals in transmission case. Lubricate oil seal lips prior to installation. Install NEW spacer on manual valve lever. Install manual valve lever shaft into case and through manual valve lever. Install NEW spring pin with slot at right angle to shaft.
    Fig 6: Checking Component Piston Operation
    G95E20341Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Align spacer hole to hollow area of lever. Stake spacer to lever. Ensure manual valve lever shaft turns smoothly. Install parking lock pawl, pivot pin and spring in case. Install lock rod on manual valve lever and install parking lock pawl. Install parking pawl bracket on case. Ensure collar on control rod is toward front of transmission. Tighten bracket bolts to 65 INCH lbs. (7.4 N.m).
  14. Check operation of parking lock pawl. Ensure output shaft is locked when manual valve lever is in "P" position. Determine proper accumulator piston locations. See Figure . Ensure accumulator pistons are correct diameter. See ACCUMULATOR PISTON DIAMETER  table. Determine proper spring free length and outer diameter for accumulator piston application. See ACCUMULATOR SPRING SPECIFICATIONS  table.
    ACCUMULATOR PISTON DIAMETER (1)

    Application In. (mm)
    Forward & Direct Clutch 1.252 (31.80)
    No. 2 Brake 1.370 (34.80)
    (1) For accumulator piston locations, See Figure .
    ACCUMULATOR SPRING SPECIFICATIONS (1)

    Application Diameter In. (mm) Free Length In. (mm)
    Direct Clutch
    Large Spring .610 (15.50) 1.181 (30.00)
    Small Spring .563 (14.30) 1.715 (43.56)
    Forward Clutch
    Large Spring .689 (17.50) 2.252 (57.20)
    Small Spring .500 (12.70) 1.157 (29.40)
    No. 2 Brake
    Large Spring .881 (22.39) 2.172 (55.18)
    Small Spring .636 (16.16) 1.383 (35.13)
    (1) For accumulator spring locations, See Figure .
  15. Install accumulator pistons and springs. Ensure accumulator pistons are pressed fully into bore. Install NEW "O" rings on throttle cable fitting. Install throttle cable. Align manual valve with pin on manual valve lever. Connect throttle cable to cam. Install control valve assembly and tighten bolts to 89 INCH lbs. (10 N.m). See Figure .
  16. Install gasket and oil strainer. Tighten bolts to 48 INCH lbs. (5.4 N.m). Using a plastic hammer, install oil tubes. Do not bend or damage oil tubes. Install magnets in oil pan. Ensure magnets do not interfere with oil tubes. Install NEW gasket to transmission case. Align cut part of gasket and transmission case. Install oil pan and bolts and tighten to 39 INCH lbs. (4.4 N.m).
  17. Lift governor retaining clip with screwdriver. Slide governor onto output shaft. Install retaining clip into hole on output shaft. Install lock plate and bolt. Tighten bolt to 35 INCH lbs. (3.9 N.m). Stake lock plate in place.
  18. Install snap ring, lock ball, speedometer drive gear and retaining snap rings. Install overdrive solenoid. Tighten bolts to 115 INCH lbs. (13 N.m). Insert neutral safety switch on manual valve lever shaft and temporarily tighten adjusting bolt. Install grommet and NEW lock washer. Install and tighten nut to 35 INCH lbs. (3.9 N.m). Align neutral safety switch basic line and switch groove. Tighten adjusting bolt to 48 INCH lbs. (5.4 N.m). Bend over at least 2 washer tabs.
  19. Install control shaft lever with spring washer and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Install wire harness and throttle cable clamp. Install torque converter. Ensure torque converter is installed correctly.
Fig 7: Identifying Bearing Race & Thrust Bearing Locations
G95F20342Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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