Disassembly And Assembly: Disassembly

CAUTION:

Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
Work or rubber mat and keep it clean at all times.
Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
If the transaxle body has been damaged, disassemble and clean the cooler system.

Remove the torque converter.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt gauge, gaskets and the oil cooler feed tube.
Remove the air breather
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 1: Identifying Input Shaft Speed Sensor And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.
Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.

Fig 2: Identifying Manual Control Lever And Park Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the sealing cap and o-ring.

Fig 3: Identifying Sealing Cap
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Remove the valve body cover.

Fig 4: Identifying Valve Body Cover
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Remove the manual control shaft detent.

Fig 5: Identifying Manual Control Shaft Detent
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Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.

Fig 6: Identifying Harness Connectors Of Valve Body
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CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See Step 8.
Remove the valve body mounting bolts (27 pieces).

Fig 7: Locating Mounting Bolts For Removal
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CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket, and the two steel balls.

Fig 8: Removing Valve Body, Gasket And Steel Balls (2 Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.

Fig 9: Locating Snap Ring
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Remove the strainer and the second brake retainer oil seal.

Fig 10: Identifying Strainer And Second Brake Retainer Oil Seal For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring.

Fig 11: Accumulator Piston And Spring Description Table
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 12: Identifying Accumulator Piston And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 13: Identifying Manual Control Lever Shaft And Parking Pawl Rod For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (18 bolts), and then remove the torque converter housing.
Remove the differential bearing outer race and spacer from the torque converter housing.

Fig 14: Identifying Torque Converter Housing Mounting Bolts
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Remove the o-rings (two pieces).

Fig 15: Identifying O-Rings (2 Pieces) For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.
Remove the differential bearing outer race from the transaxle case.

Fig 16: Identifying Differential For Removal
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Remove the oil filter.

Fig 17: Removing Oil Filter
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Remove the oil pump mounting bolts (six bolts).
Install special tool MD998333 in hole "A."

Fig 18: Locating Hole For Installing Special Tool
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Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 19: Screwing Special Tool To Remove Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 20: Removing Thrust Washer #1
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Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 21: Removing Underdrive Clutch Hub
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Remove thrust bearing number 2.

Fig 22: Removing Thrust Bearing Number 2
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Remove the underdrive clutch hub.

Fig 23: Removing Underdrive Clutch Hub
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Remove the rear cover and input shaft rear bearing.
Remove thrust race number 8.
Remove the seal rings (four pieces).

Fig 24: Identifying Rear Cover, Input Shaft Rear Bearing, Thrust Race Number 8 And Seal Rings For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 25: Identifying O-Rings (3 Pieces) For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 26: Removing Reverse And Overdrive Clutch And Thrust Bearing #7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 27: Removing Overdrive Clutch Hub And Thrust Bearing #6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 28: Removing Thrust Bearing #5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 29: Removing Planetary Reverse Sun Gear
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Remove the snap ring.

Fig 30: Removing Snap Ring
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Remove the second brake piston and the return spring.

Fig 31: Removing Second Brake Piston And Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure plate, brake discs and brake plate.

Fig 32: Brake Discs And Plates Number Chart
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 33: Removing Pressure Plate, Brake Discs And Brake Plates
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary carrier assembly.

Fig 34: Removing Planetary Carrier Assembly
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Remove the snap ring.

Fig 35: Removing Snap Ring
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Remove the reaction plate and the brake disc.

Fig 36: Removing Reaction Plate And Brake Disc
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Remove the snap ring.

Fig 37: Removing Snap Ring
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Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.

Fig 38: Removing Brake Plates, Brake Discs And Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 39: Removing Wave Spring
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Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 40: Removing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the two parking roller support shafts, and then remove the parking roller support.

Fig 41: Removing Parking Roller Support Shafts
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Remove the one-way clutch inner race and low reverse brake piston as follows:
1. Using special tools MD998903 < F4A42 > or MD998338 < F4A51 > and MD998924, compress the one-way clutch inner race.
  NOTE: This illustration shows F4A51.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low reverse brake piston.
  
  Fig 42: Using Special Tool For Removing Snap Ring
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the four < F4A51 > or three < F4A42 > transfer drive gear bearing mounting bolts.
Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

F4A42 = seven mounting bolts

F4A51 = eight mounting bolts

Fig 43: Identifying Transfer Drive Gear Bearing Mounting Bolts F4A42
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 44: Identifying Transfer Drive Gear Bearing Mounting Bolts F4A51
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 45: Removing Transfer Drive Gear
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Remove the cap by jabbing a screw driver into the center of the cap and prying it up.

Fig 46: Removing Cap
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Using a chisel, straighten the staked portions from the output shaft unit.

Fig 47: Straightening Locking Tab Of Output Shaft Lock Nut
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CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 48: Using Special Tool For Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolt.

Fig 49: Identifying Bearing Retainer Mounting Bolt For Removal
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Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 50: Applying On Rear Of Output Shaft For Removing Output Shaft, Taper Roller Bearing And Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap out the outer race and the spacer.
Remove the snap ring.

Fig 51: Removing Snap Ring
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