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Home >> Mitsubishi >> 2003 >> Galant LS, 2.4 G >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul >> Transaxle >> Disassembly And Assembly >> Assembly

Disassembly And Assembly: Assembly

CAUTION:
  • Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
  • Do not use grease other than petroleum jelly (Vaseline).
  • Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
  • When replacing a bushing, replace the assembly which it belongs to.
  • Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.
  1. Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case. Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.
    Fig 1: Installing Transfer Drive Gear Bearing And Gear In Transaxle Case
    G03336464Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Tighten the seven mounting bolts (F4A42) and eight mounting bolts (F4A51) of the transfer drive gear bearing to the specified torque.

    Tightening torque: 34 N.m (25 ft-lb) 

    Fig 2: Tightening Mounting Bolts Of Transfer Drive Gear Bearing To Specified Torque
    G03336465Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
  4. Fit a new O-ring into the groove of one-way clutch inner race.
  5. Check the placement of the identification notches in the one way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.
    Fig 3: Installing One-Way Clutch Inner Race To Transfer Drive Gear Bearing
    G03336466Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998703 < F4A42 > or MD998338 < F4A51 > and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.
    NOTE: This illustration shows F4A51.
    Fig 4: Compressing One-Way Clutch Inner Race And Installing Snap Ring
    G03336467Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 5: Installing Wave Spring Onto Low-Reverse Brake Piston
    G03336468Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
  9. Install the six brake discs, five brake plates and snap ring as shown in the figure.
    NOTE: Do not install the pressure plate at this time.
  10. Install special tool MB991631 < F4A42 > or MB991632 < F4A51 > on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991631 < F4A42 > or MB991632 < F4A51 > to measure the end play of reaction plate. Then replace the snap ring installed in  Step 11 to adjust the end play to standard value.

    Standard value: 0 - 0.16 mm (0 - 0.0063 inch) 

    Fig 6: Measuring End Play Of Reaction Plate - F4A42
    G03336469Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 7: Measuring End Play Of Reaction Plate - F4A51
    G03336470Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Install the brake discs and brake plates as shown in the figure.

    Number of brake discs and plates 

    NUMBER OF BRAKE DISCS AND PLATES

    A/T MODEL BRAKE DISC BRAKE PLATE
    F4A42 3 2
    F4A51 4 3
    Fig 8: Installing Return Spring, Second Brake Piston And Snap Ring - F4A42
    G03336471Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Place special tool MB991631 < F4A42 > or MB991632 < F4A51 > on top of the brake disc in place of the pressure plate.
  15. Install the return spring, second brake piston and snap ring.
    Fig 9: Installing Return Spring, Second Brake Piston And Snap Ring - F4A51
    G03336472Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Move special tool MB991631 < F4A42 > or MB991632 < F4A51 > and measure its movement.

    Standard value of end play (Reference): 

    0.79 - 1.25 mm (0.0311 - 0.0492 inch) < F4A42 > 

    1.09 - 1.55 mm (0.0429 - 0.0610 inch) < F4A51 > 

  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
    Fig 10: Installing Special Tool
    G03336473Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    PRESSURE PLATE FOR F4A42 

    PRESSURE PLATE FOR F4A42 SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    0.6 - 0.8 (0.024 - 0.031) 1.6 (0.063) L MD759567
    0.8-1.0 (0.031 - 0.039) 1.8(0.071) 1 MD759414
    1.0 - 1.2 (0.039 - 0.047) 2.0 (0.079) 0 MD759415
    1.2 - 1.4 (0.047 - 0.055) 2.2 (0.087) 2 MD759416
    1.4 - 1.6 (0.055 - 0.063) 2.4 (0.094) 4 MD759417
    1.6 - 1.8 (0.063 - 0.071) 2.6(0.102) 6 MD759418
    Fig 11: Measuring End Play - F4A42
    G03336474Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 12: Measuring End Play - F4A51
    G03336475Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    PRESSURE PLATE FOR F4A51 

    PRESSURE PLATE FOR F4A51 SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.1 - 1.3 (0.043 - 0.051) 1.8(0.071) E MD759425
    1.3 - 1.5 (0.051 - 0.059) 2.0 (0.079) D MD759426
    1.5 - 1.7 (0.059 - 0.067) 2.2 (0.087) C MD759427
    1.7 - 1.9 (0.067 - 0.075) 2.4 (0.094) B MD759428
    1.9 - 2.1 (0.075 - 0.083) 2.6(0.102) A MD759429
    2.1 - 2.3 (0.083 - 0.091) 2.8(0.110) 0 MD759430
  18. Turn the transaxle over so that the installation surface of the torque converter housing is facing up. Install special tool MD998913 in a dial gauge, and then move special tool MB991631 < F4A42 > or MB991632 < F4A51 > and measure its movement.

    Standard value of end play (Reference): 

    1.65 - 2.11 mm (0.050 - 0.0831 inch) 

    Fig 13: Installing Special Tool MD998913 In Dial Gauge
    G03336476Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.
    NOTE: This illustration shows F4A51.

    PRESSURE PLATE FOR F4A42 

    PRESSURE PLATE FOR F4A42 SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.3 - 1.5 (0.051 - 0.059) 1.6 (0.063) L MD759567
    1.5 - 1.7 (0.059 - 0.067) 1.8(0.071) 1 MD759414
    1.7 - 1.9 (0.067 - 0.075) 2.0 (0.079) 0 MD759415
    1.9 - 2.1 (0.075 - 0.083) 2.2 (0.087) 2 MD759416
    2.1 - 2.3 (0.083 - 0.091) 2.4 (0.094) 4 MD759417
    2.3 - 2.5 (0.091 - 0.098) 2.6(0.102) 6 MD759418
    2.5 - 2.7 (0.098 - 0.106) 2.8(0.110) 8 MD759419
    2.7 - 2.9 (0.106 - 0.114) 3.0(0.118) D MD759420
    Fig 14: Measuring End Play Of Pressure Plate - F4A42
    G03336477Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    PRESSURE PLATE FOR F4A51 

    PRESSURE PLATE FOR F4A51 SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.0 - 1.2 (0.039 - 0.047) 1.6 (0.063) F MD759568
    1.2 - 1.4 (0.047 - 0.055) 1.8(0.071) E MD759425
    1.4 - 1.6 (0.055 - 0.063) 2.0 (0.079) D MD759426
    1.6 - 1.8 (0.063 - 0.071) 2.2 (0.087) C MD759427
    Fig 15: Measuring End Play Of Pressure Plate - F4A51
    G03336478Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    PRESSURE PLATE FOR F4A51 SPECIFICATION

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL PRESSURE PLATE PART NO.
    1.8 - 2.0 (0.071 - 0.079) 2.4 (0.094) B MD759428
    2.0 - 2.2 (0.079 - 0.087) 2.6(0.102) A MD759429
    2.2 - 2.4 (0.087 - 0.094) 2.8(0.110) 0 MD759430
    2.4 - 2.6 (0.094 - 0.102) 3.0(0.118) 1 MD759431
  20. Remove all parts and special tools that were installed to take the measurements in steps 8 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12,16 and 18.
  21. Install the snap ring into the groove of transaxle case output shaft bore.
  22. Install the thinnest output shaft preload adjustment spacer [thickness 1.88 mm (0.0740 in); part number MD756579].
  23. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.
    Fig 16: Installing Output Shaft Bearing Outer Race
    G03336479Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not reuse the bolt, as it has had sealant applied.
  24. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.

    Tightening torque: 

    29 N.m(21 ft-lb) < F4A42 > 

    54 N.m(40ft-lb) < F4A51 > 

    Fig 17: Tightening Mounting Bolts Of Output Shaft Bearing Retainer To Specified Torque
    G03336480Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
    Fig 18: Installing Collar And Taper Roller Bearing On Output Shaft
    G03336481Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  26. Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.

    Tightening torque: 167 N.m (123 ft-lb) 

    NOTE: The jam nut is reverse threaded.
    Fig 19: Tightening Jam Nut To Specified Torque
    G03336482Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Move the output shaft to measure the end play and record the measurement value.
  28. Remove the parts that were installed in steps 21 to 25.
  29. Add 1.88 mm (0.074 inch)* and 0.01 to 0.09 mm (0.0004 to 0.0035 inch)** to the measured value in  Step 26 and select a spacer of the same thickness. Adjustment spacer sizes are all listed on ADJUSTING PLATE, SNAP RING AND SPACERS . Select the most suitable one from among those listed.
    NOTE: * is the thickness of the spacer installed in  Step 21. ** is the preload of the output shaft.
  30. Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 27.
  31. Stake the jam nut with a punch (two places).
    Fig 20: Measuring End Play
    G03336483Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 21: Staking Jam Nut With Punch (Two Places)
    G03336484Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 22: Installing Cap
    G03336485Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 23: Installing Parking Pawl, Spacer, And Spring
    G03336486Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the parking roller support, and then insert the two parking roller support shafts.
    Fig 24: Installing Parking Roller Support, And Inserting Parking Roller Support Shafts
    G03336487Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 25: Identifying Thrust Bearing, Thrust Races And Thrust Washers
    G03336488Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS mm (in) 

    IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

    SYMBOL OD ID THICKNESS PART NO. APPLICATION
    No.1 59 (2.32) 47 (1.85) 1.8(0.071) MD754509 -
    59 (2.32) 47 (1.85) 2.0 (0.079) MD754508 -
    59 (2.32) 47 (1.85) 2.2 (0.087) MD754507 -
    59 (2.32) 47 (1.85) 2.4 (0.094) MD753793 -
    59 (2.32) 47 (1.85) 2.6(0.102) MD753794 -
    59 (2.32) 47 (1.85) 2.8(0.110) MD753795 -
    No.2 49 (1.93) 34 (1.34) 3.6 (0.142) MD756846 -
    No.3 49 (1.93) 34 (1.34) 3.6(0.142) MD756846 F4A42
    57 (2.24) 38.5(1.516) 4.12(0.1622) MD758556 F4A51
    No.4 45.3 (1.783) 31 (1.22) 3.3(0.130) MD757647 F4A42
    55.4(2.181) 38.5(1.516) 3.3(0.130) MD761683 F4A51
    No.5 49 (1.93) 34 (1.34) 3.6(0.142) MD756846 F4A42
    57 (2.244) 38.5(1.516) 4.1 (0.161) MD758556 F4A51
    No.6 49 (1.93) 34 (1.34) 3.6(0.142) MD756846 F4A42
    57 (2.244) 38.5(1.516) 4.1 (0.161) MD758556 F4A51
    No.7 59 (2.32) 37 (1.46) 2.8(0.110) MD754595 -
    No.8 48.9 (1.925) 37 (1.46) 1.6 (0.063) MD707267 -
    48.9 (1.925) 37 (1.46) 1.7 (0.067) MD759681 -
    48.9 (1.925) 37 (1.46) 1.8(0.071) MD723064 -
    48.9 (1.925) 37 (1.46) 1.9 (0.075) MD754794 -
    48.9 (1.925) 37 (1.46) 2.0 (0.079) MD707268 -
    48.9 (1.925) 37 (1.46) 2.1 (0.083) MD754795 -
    48.9 (1.925) 37 (1.46) 2.2 (0.087) MD723065 -
    48.9 (1.925) 37 (1.46) 2.3(0.091) MD754796 -
    48.9 (1.925) 37 (1.46) 2.4 (0.094) MD724358 -
    48.9 (1.925) 37 (1.46) 2.5 (0.098) MD754797 -
    48.9 (1.925) 37 (1.46) 2.6(0.102) MD754798 -
  35. Install the planetary carrier assembly.
    Fig 26: Installing Planetary Carrier Assembly
    G03336489Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the planetary reverse sun gear.
    Fig 27: Installing Planetary Reverse Sun Gear
    G03336490Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the wave spring on the low-reverse brake piston.
    Fig 28: Installing Wave Spring On Low-Reverse Brake Piston
    G03336491Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the pressure plate that was selected in step  18. Next, install six brake discs and five brake plates, one on top of the other.
    Fig 29: Installing Brake Discs & Brake Plates
    G03336492Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install the snap ring.
    Fig 30: Installing Snap Ring
    G03336493Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the reaction plate.
    Fig 31: Installing Reaction Plate
    G03336494Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install the snap ring that was selected in step  12.
    Fig 32: Installing Snap Ring
    G03336495Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  42. Install three brake discs < F4A42 > or four brake discs < F4A51 > and two brake plates < F4A42 > or three brake plates < F4A51 >, one on top of the other. Next, install the pressure plate that was selected in step  16.
    Fig 33: Installing Brake Discs And Brake Plates
    G03336496Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Install the return spring and second brake piston.
    Fig 34: Installing Return Spring And Second Brake Piston
    G03336497Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Install the snap ring.
    Fig 35: Installing Snap Ring
    G03336498Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  45. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
    Fig 36: Identifying Installation Direction Of Thrust Bearing
    G03336499Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use care to install the thrust bearing in the proper direction.
  46. Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.
    Fig 37: Attaching Thrust Bearing To Inside Of Overdrive Clutch Hub Using Petroleum Jelly
    G03336500Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Install the reverse and overdrive clutch.
    Fig 38: Installing Reverse And Overdrive Clutch
    G03336501Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  48. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
  49. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
  50. Install the four seal rings in the grooves of the rear cover.
    Fig 39: Installing Seal Rings In Grooves Of Rear Cover
    G03336502Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  51. Measure the end play of the under drive sun gear by the following procedures:
    1. Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7.
    2. Install the rear cover on the transaxle case and tighten the bolts to the specified torque.

      Tightening torque: 23 N.m (17 ft-lb) 

    3. Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.
    4. Install the under drive clutch hub on the under drive sun gear.
    5. Measure end play of the underdrive sun gear and record the measurement value.

      Standard value (Reference): 

      0.25 - 0.45 mm (0.0098 - 0.0177 inch) 

    6. After taking the measurements in steps (1) to (4), take out the installed parts.
      Fig 40: Measuring End Play Of Under Drive Sun Gear
      G03336503Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  52. Install the three O-rings.
  53. Select a thrust race number 8 whose thickness corresponds to the measured values taken in  Step 50 from the table below. Install it on thrust bearing number 7.
    THRUST BEARING SPECIFICATION

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) PART NO.
    0.3 - 0.4(0.012 - 0.016) 1.6 (0.063) MD707267
    0.4 - 0.5(0.016 - 0.020) 1.7 (0.067) MD759681
    0.5 - 0.6 (0.020 - 0.024) 1.8 (0.071) MD723064
    0.6 - 0.7 (0.024 - 0.028) 1.9 (0.075) MD754794
    0.7 - 0.8(0.028 - 0.031) 2.0 (0.079) MD707268
    0.8 - 0.9 (0.031 - 0.035) 2.1 (0.083) MD754795
    0.9 - 1.0 (0.035 - 0.039) 2.2 (0.087) MD723065
    1.0 - 1.1 (0.039 - 0.043) 2.3 (0.091) MD754796
    1.1 - 1.2(0.043 - 0.047) 2.4 (0.094) MD724358
    1.2 - 1.3(0.047 - 0.051) 2.5 (0.098) MD754797
    1.3 - 1.4(0.051 - 0.055) 2.6 (0.102) MD754798
    Fig 41: Installing O-Rings
    G03336504Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the illustrated position of the rear cover.
    NOTE: Be sure to install the case quickly while the sealant is wet (within 15 minutes).
    Fig 42: Applying Bead Of Sealant To Rear Cover
    G03336505Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  55. Install the rear cover, and tighten its mounting bolts to the specified torque.

    Tightening torque: 23 N.m (17 ft-lb) 

    NOTE: After installation, keep the sealed area away from the oil for approximately one hour.
    Fig 43: Installing Rear Cover, And Tightening Mounting Bolts
    G03336506Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 44: Installing Underdrive Clutch Hub To Underdrive Sun Gear
    G03336507Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  57. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
    Fig 45: Installing Thrust Bearing On Underdrive Clutch Hub
    G03336508Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Hold the input shaft, and install the underdrive clutch.
    Fig 46: Installing Underdrive Clutch
    G03336509Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14 inch) in diameter] on the underdrive clutch retainer as shown in the illustration.
    Fig 47: Placing Beads Of Solder On Underdrive Clutch Retainer
    G03336510Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  60. Install special tool MD998412 in the illustrated place.
  61. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
  62. Tighten the oil pump mounting bolts (six pieces) to the specified torque.

    Tightening torque: 29 N.m (21 ft-lb) 

    Fig 48: Installing Special Tool
    G03336511Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  63. Remove the oil pump mounting bolts.
  64. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 49: Removing Oil Pump And Crushed Solders Using Special Tools
    G03336512Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
  66. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.
    THRUST WASHER THICKNESS SPECIFICATIONS

    MEASUREMENT VALUE mm (in) THICKNESS mm (in) ID SYMBOL PART NO.
    2.25 - 2.45 (0.089 - 0.096) 1.8 (0.071) 18 MD754509
    2.45 - 2.65 (0.096 - 0.104) 2.0 (0.079) 20 MD754508
    2.65 - 2.85 (0.104 - 0.112) 2.2 (0.087) 22 MD754507
    2.85 - 3.05 (0.112 - 0.120) 2.4 (0.094) 24 MD753793
    3.05 - 3.25 (0.120 - 0.128) 2.6 (0.102) 26 MD753794
    3.25 - 3.45 (0.128 - 0.136) 2.8 (0.110) 28 MD753795
    Fig 50: Measuring Thrust Washer Thickness
    G03336513Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Install thrust washer number 1 that was selected in Step  65 on the underdrive clutch retainer.
    Fig 51: Installing Thrust Washer
    G03336514Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Install special tool MD998412 in the illustrated place.
  69. Install the new oil pump gasket on the transaxle case.
  70. Install the oil pump and tighten the mounting bolts (six pieces) to the specified torque.

    Tightening torque: 29 N.m (21 ft-lb) 

    Fig 52: Installing Special Tool
    G03336515Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Make sure that the input shaft end play meets the standard value.

    Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch) 

    Fig 53: Measuring Input Shaft End Play
    G03336516Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Install the oil filter.
    Fig 54: Installing Oil Filter
    G03336517Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 55: Taping Differential Bearing Outer Race In Transaxle Case Using Special Tools
    G03336518Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  74. Install the differential.
    Fig 56: Installing Differential
    G03336519Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  75. Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter] on the torque converter housing as shown in the illustration.
    Fig 57: Placing Beads Of Solder On Torque Converter Housing
    G03336520Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  76. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to press in the differential bearing outer race into the torque converter housing.
    Fig 58: Pressing Differential Bearing Outer Race Into Torque Converter Housing Using Special Tools
    G03336521Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  77. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.

    Tightening torque: 48 N.m (35 ft-lb) 

  78. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
    Fig 59: Loosening Bolts
    G03336522Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  79. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to the measured value and select a spacer with the corresponding thickness. Adjustment spacer sizes are all listed on ADJUSTING PLATE, SNAP RING AND SPACERS . Select the most suitable one from among those listed.
    NOTE: * is the thickness for the differential case preload.
    Fig 60: Measuring Thickness Of Crushed Solder Beads Using Micrometer
    G03336523Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. Install the spacer selected in  Step 79 to the torque converter housing.
  81. Use special tools MB990935 < F4A42 > or MB990936 < F4A51 > and MB990938 to press the outer race into housing.
    Fig 61: Pressing Outer Race Into Housing Using Special Tools
    G03336524Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the torque converter housing in the area shown.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes).
    NOTE: After installation, keep the sealed area away from the oil for approximately one hour.
    Fig 62: Applying Bead Of Sealant To Torque Converter Housing
    G03336525Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  83. Install the two O-rings.
    Fig 63: Installing O-Rings
    G03336526Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  84. Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque.

    Tightening torque: 48 N.m (35 ft-lb) 

    Fig 64: Installing Torque Converter Housing Bolts
    G03336527Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  85. Insert the two O-rings into the grooves of the manual control lever shaft.
  86. Install the manual control lever shaft and parking pawl rod. 87.Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".
    Fig 65: Inserting Manual Control Lever Shaft Roller Into Hole
    G03336528Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  87. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
  88. Identify the accumulator spring and insert it and the accumulator piston into each hole of the transaxle case.
    NOTE: Accumulator springs are identified as shown in the illustration.
    ACCUMULATOR SPRINGS SPECIFICATIONS

    NO. NAME IDENTIFICATION "BLUE-ING"
    1 For low-reverse brake None
    2 For underdrive clutch Half
    3 For second brake Whole surface
    4 For overdrive clutch None
    Fig 66: Identifying Accumulator Spring
    G03336529Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 67: Inserting Accumulator Spring And Accumulator Piston Into Hole Of Transaxle Case
    G03336530Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Install the strainer and second brake retainer oil seal.
    Fig 68: Installing Strainer And Second Brake Retainer Oil Seal
    G03336531Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  90. Insert a new O-ring to the groove of the solenoid valve harness connector.
  91. Insert the solenoid valve harness connector into the hole from the inside of the transaxle case so it is oriented as shown in the illustration. Then secure the snap ring to the connector groove.
    Fig 69: Installing Snap Ring
    G03336532Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  92. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body). 94.Install the valve body and gasket to the transaxle case.

    Make sure that the manual valve's pin is in the groove in the detent plate of the manual control lever.

    Fig 70: Installing Valve Body And Gasket To Transaxle Case
    G03336533Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  93. Install the 27 valve body mounting bolts, and tighten to the specified torque.

    Tightening torque: 11 N.m (95 in-lb) 

    Fig 71: Installing Valve Body Mounting Bolts
    G03336534Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  94. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
    SOLENOID VALVE HARNESS CONNECTIONS

    NO. PARTS TO BE CONNECTED SOLENOID VALVE HARNESS
    CABLE COLOR CONNECTOR HOUSING COLOR
    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 Torque converter clutch control solenoid valve Blue, yellow, yellow Black
    Fig 72: Attaching Solenoid Valve Harness
    G03336535Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  95. Install the manual control shaft detent and tighten the bolt to the specified torque.

    Tightening torque: 6 N.m (52 in-lb) 

    Fig 73: Installing Manual Control Shaft Detent
    G03336536Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  96. Apply a 2 mm (0.08 inch) diameter bead of sealant (MITSUBISHI Genuine Part number MD974421 or equivalent) to the valve body cover in the area shown.
    NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes).
    NOTE: After installation, keep the sealed area away from the oil for approximately one hour.
    Fig 74: Applying Bead Of Sealant To Valve Body Cover
    G03336537Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  97. Install the valve body cover, and then tighten its mounting bolts to the specified torque.

    Tightening torque: 11 N.m (95 in-lb) 

    Fig 75: Installing Valve Body Cover
    G03336538Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  98. Install the Sealing cap and tighten the bolt to the specified torque.

    Tightening torque: 5 N.m (43 in-lb) 

    Fig 76: Installing Sealing Cap
    G03336539Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  99. Install the park/neutral position switch and tighten the bolt to specified torque.

    Tightening torque: 11 N.m (95 in-lb) 

  100. Install the manual control lever and tighten the nut to specified torque.

    Tightening torque: 22 N.m (16 ft-lb) 

    Fig 77: Installing Manual Control Lever
    G03336540Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  101. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
    Fig 78: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
    G03336541Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    Tightening torque: 11 N.m (95 in-lb) 

  102. Install the oil cooler feed tube together with new gaskets and tighten the eye bolts to the specified torque.

    Tightening torque: 30 N.m (22 ft-lb) 

  103. Tighten the oil cooler feed pipe clamp bolt.

    Tightening torque: 11 N.m (95 in-lb) 

  104. Install the oil dipstick.
  105. Install the cable support bracket.

    Tightening torque: 23 N.m (17 ft-lb) 

  106. Install the roll stopper brackets.

    Tightening torque: 69 N.m (51 ft-lb) 

    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.
  107. Install the torque converter, and secure it so that the shown dimension "A" meets the reference value.

    Reference value: 

    Approximately 12.2 mm (0.48 inch) < F4A42 > 

    Approximately 9.4 mm (0.37 inch) < F4A51 > 

    Fig 79: Identifying Dimension A
    G03336542Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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