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.<
The working area should be covered with a rubber mat to 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 input shaft speed sensor and output shaft speed sensor.

Fig 1: Identifying Input 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: Removing Sealing Cap And O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the valve body cover.

Fig 4: Removing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control shaft detent.

Fig 5: Removing Manual Control Shaft Detent
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.

Fig 6: Disconnecting Solenoid Valve Harness From Valve Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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: Removing Valve Body Mounting Bolts (27 Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 Two Steel Balls
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring from the connector and then push the connector into the transaxle case and remove the solenoid valve harness.

Fig 9: Removing Snap Ring From Connector And Solenoid Valve Harness
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 10: Removing Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove each accumulator piston and spring.

ACCUMULATOR PISTON AND SPRING IDENTIFICATION

NUMBER	NAME
1	For low-reverse brake
2	For underdrive clutch
3	For second brake
4	For overdrive clutch

Fig 11: 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 12: Removing Manual Control Lever Shaft And Parking Pawl Rod
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (18 pieces), and then remove the torque converter housing.
Remove the differential bearing outer race and spacer from the torque converter housing.

Fig 13: Identifying Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (two pieces).

Fig 14: Removing O-Rings (Two Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential.
Remove the differential bearing outer race from the transaxle case.

Fig 15: Removing Differential Bearing Outer Race From Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 16: Removing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump mounting bolts (six pieces).
Install special tool MD998333 in hole "A."

Fig 17: Removing Oil Pump Mounting Bolts (Six Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 18: Removing Oil Pump Gasket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 19: Removing Washer Number 1
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Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 20: Removing Underdrive Clutch And Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 2.

Fig 21: Removing Bearing Number 2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the underdrive clutch hub.

Fig 22: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the rear cover.
Remove thrust race number 8.
Remove the seal rings (four pieces).

Fig 23: Removing Seal Rings And Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-rings (three pieces).

Fig 24: Removing O-Rings (Three Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 25: Removing Reverse And Overdrive Clutch And Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and thrust bearing number 6.

Fig 26: Removing Clutch Hub And Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 27: Removing Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the planetary reverse sun gear.

Fig 28: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 29: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the second brake piston and the return spring.

Fig 30: Removing Second Brake Piston And Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the pressure plate, brake discs and brake plate.

Number of brake discs and plates:

NUMBER OF BRAKE DISCS AND PLATES

A/T MODEL	BRAKE DISC	BRAKE PLATE	PRESSURE PLATE
F4A42	3	2	1
F4A51	4	3	1

Fig 31: Removing Pressure Plate, Brake Discs And Brake Plate

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the planetary carrier assembly.

Fig 32: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 33: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reaction plate and the brake disc.

Fig 34: Removing Reaction Plate And Brake Disc
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the snap ring.

Fig 35: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.

Fig 36: Removing Brake Plates (Five Pieces), Brake Discs (Six Pieces) And Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 37: Removing Wave Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 38: Removing Parking Pawl Shaft, And Spacer And Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the two parking roller support shafts, and then remove the parking roller support.

Fig 39: Removing Two Parking Roller Support Shafts, And Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 40: Removing One-Way Clutch Inner Race And Low-Reverse Brake Piston
  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 41: Removing F4A51 or F4A42 Transfer Drive Gear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 42: Removing Transfer Drive Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cap.

Fig 43: Removing Cap
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Using a chisel, remove the staked nut from the output shaft.

Fig 44: Removing Staked Nut From Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 45: Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolt.

Fig 46: Removing Bearing Retainer Mounting Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 47: Removing Output Shaft, Taper Roller Bearing And Collar
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the outer race and the spacer.
Remove the snap ring.

Fig 48: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.