Automatic Transaxle Overhaul - SPORTBACK: Transaxle: Assembly

CAUTION:

Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
Do not use grease. Use petroleum jelly (i.e Vaseline).
Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse parts, and sliding parts before installation. Immerse new clutch discs or brake in ATF for at least two hours before assembling them.
When replacing a bushing, replace the assembly which in belongs to.
Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.

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 Special Tool Md998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the mounting bolts (seven pieces) of the transfer drive gear bearing to the specified torque.
Tightening torque:

34 +/- 2 N.m (25 +/- 1 ft-lb)

Fig 2: Tightening Mounting Bolts
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Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.

Fig 3: Installing Low-Reverse Brake Piston
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Fit a new O-ring into the groove of one-way clutch inner race.

Fig 4: Installing O-Ring
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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 A-A line.

Fig 5: Checking Placement Of Identification Notches
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Put the snap ring on the inner race.
Set special tools MD998903 and MD998924 as shown, and then compress the one-way clutch inner race install the snap ring.

Fig 6: Installing Special Tool
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Install the was spring onto the low-reverse brake piston.

Fig 7: Installing Wave Spring
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Install the brake discs (six pieces), brake plates (five pieces), and snap ring as shown in the figure.
NOTE: Do not install the pressure plate at this time.
Install special tool MB991631 on the brake disc.
Install the reaction plate and the used snap disc.
Move special tool MB991631 to measure the end play of reaction plate. Then replace the snap ring installed in step 11 to adjust the endplay to standard value.
Standard value: 0-0.16 mm (0-0.0063 inch)

Fig 8: Installing Special Tool Mb991631
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the brake discs (three pieces) and brake plates (two pieces) as shown in the figure.
NOTE: Do not install the pressure plate at this time.
Place special tool MB991631 on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.

Fig 9: Installing Special Tool Mb991631
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move special tool MB991631 and measure its movement.
Standard value of end play (Reference):

0.79-1.25 mm 0.0311-0.0492 inch)

Fig 10: Installing Special Tool
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Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

Fig 11: Pressure Plate For Second Brake Thickness And Movement Specification
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 12: Measuring Movement
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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 and measure its movement.

Standard value of end play (Reference):

1.65-2.11 mm (0.0649-0.831 inch)

Fig 13: Install Special Tool Md998913
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Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

Fig 14: Pressure Plate Thickness And Movement Specification
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Fig 15: Measuring Amount Of Movement
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Fig 16: Pressure Plate Thickness And Movement Specification
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CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
Remove all the parts and special tools that were installed to take the measurements in steps 9 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.
Install the snap ring into the groove of transaxle case output shaft bore.
Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.

Fig 17: Installing Special Tool
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CAUTION: Do not reuse the bolt, as it has sealant applied.
Tighten the mounting blots of the output shaft bearing retainer to the specified torque.
Tightening torque:

29 +/- 2 N.m (21 +/- 1 ft-lb)

Fig 18: Tightening Mounting Blots
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Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.

Fig 19: Installing Collar And Taper Roller Bearing
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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: 170 +/- 10 N.m (125 +/- 7 ft-lb)

NOTE: The jam nut is reverse threaded.

Fig 20: Installing Special Tool
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Move the output shaft to measure the end play and record the measurement value.
Remove the parts that were installed in steps 22 to 25.
Select a spacer whose thickness corresponds to the measured amount of movement from the following table.

Fig 21: Spacer Output Shaft Specification
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 22: Measuring End Play
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Fig 23: Spacer Output Shaft Specification
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Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 28.
Stake the jam nut with a punch (two places).

Fig 24: Staking Jam Nut With Punch
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Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.

Fig 25: Installing Cap Using Special Tools
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Install the planetary carrier assembly.

Fig 26: Installing Planetary Carrier Assembly
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Install the planetary reverse sun gear.

Fig 27: Installing Planetary Reverse Sun Gear
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Install the wave spring on the low-reverse brake piston.

Fig 28: Installing Wave Spring
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Install the pressure plate that was selected in step 19. Next, install brake discs (six pieces) and brake plates (five pieces), one on top of the other.

Fig 29: Installing Pressure Plate
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Install the snap ring.

Fig 30: Installing Snap Ring
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Install the reaction plate.

Fig 31: Installing Reaction Plate
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Install the snap ring that was selected in step 12.

Fig 32: Installing Snap Ring
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Install brake discs (three pieces) and brake plates (two pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.

Fig 33: Installing Brake Discs
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Install the return spring and second brake piston.

Fig 34: Installing Return Spring
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Install the snap ring.

Fig 35: Installing Snap Ring
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Fig 36: Locating Identification Of Thrust Bearing, Thrust Races, And Thrust Washers
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CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.

Fig 37: Checking Installation Direction Of Thrust Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Use care to install the thrust bearing in the direction.
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 38: Attaching Thrust Bearing
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CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.

Fig 39: Checking Installation Direction Of Thrust Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
Install the seal rings (four pieces) in the grooves of the rear cover.

Fig 40: Installing Input Shaft Rear Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 tighten the bolts to the specified torque.
  Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
3. Turn over the transaxle case so that installation surface of the torque converter housing is facing up.
4. Install the under drive clutch hub on the underdrive 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 measurement in steps (5), take out the installed parts in steps (1) through (4).
  
  Fig 41: Measuring End Play Of Underdrive Sun Gear
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (three pieces).

Fig 42: Installing O-Rings
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Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 47 from the table below. Install it on thrust bearing number 7.

Fig 43: Thrust Washer Thickness Specification
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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). Leaks will occur if the rear cover is installed after the sealant dries.

Fig 44: Applying Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the rear, cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)

NOTE: After installation, keep the sealed area away from ATF for approximately one hour.

Fig 45: Installing Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 46: Installing Parking Pawl
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Install the parking roller support, and then insert the parking roller support shafts (two pieces).

Fig 47: Installing Parking Roller Support
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Install the underdrive clutch hub to the underdrive sun gear.

Fig 48: Installing Underdrive Clutch Hub
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CAUTION: Be Sure to install the bearing in the correct direction as shown.
Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.

Fig 49: Checking Installation Direction Of Thrust Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch.

Fig 50: Installing Underdrive Clutch
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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 51: Placing Two Beads Of Solder
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown.
Install the oil pump to the transaxle case.
NOTE: Do not install the oil pump gasket at this time.
Tighten the six oil pump mounting bolts to the specified torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)

Fig 52: Installing Special Tool Md998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump mounting bolts.
Using special tools MD998333, remove the oil pump and the crushed solders.

Fig 53: Removing Oil Pump
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Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.

Fig 54: Measurement Specification Chart
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Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.

Fig 55: Measuring Thickness Of Crushed Solder Beads
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Install thrust washer number 1 that was selected in step 64 on the underdrive clutch retainer.

Fig 56: Installing Thrust Washer
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Install special tool MD998412 as shown.
Install the new oil pump gasket on the transaxle case.
Install the oil pump and tighten the six mounting bolts to the specified torque.
Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb)

Fig 57: Installing Special Tool Md998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the input shaft end play meet's the standard
Standard value: 0.70-1.45 mm (0.028-0.057 inch)

Fig 58: Checking Input Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 59: Installing Oil Filter
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Use special tools MB990935 and MB990938 to tap the differential bearing outer race in the transaxle case.

Fig 60: Taping Differential Bearing Outer Race
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Install the differential.

Fig 61: Installing Differential
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Place two beads of solder [each 10 mm (0.9 inch) in length, 3mm (012 inch) in diameter] on the torque converter housing as shown in the illustration.

Fig 62: Locating Two Beads Of Solder
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990935 and MB990938 to press the differential bearing outer race into the torque converter housing.

Fig 63: Pressing Differential Bearing Outer Race
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Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.
Tightening torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.

Fig 64: Installing Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use a micrometer to measure the thickness of the crushed solder beads and record the measure 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 65: Measuring Thickness Of Crushed Solder Beads
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the spacer selected in step 77 to the torque converter housing.
Use special tools MB990935 and MB990938 to press the outer race into housing.

Fig 66: Pressing Outer Race
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Apply a 2mm (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). Leaks will occur if the rear cover is installed after the sealant dries.

NOTE: After installation, keep the sealed area away from ATF for approximately one hour.

Fig 67: Applying Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the O-rings (two pieces).

Fig 68: Installing O-Rings
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Install the torque converter housing and then tighten its mounting bolts (eighteen pieces) to the specified torque.
Tighten torque: 48 +/- 4 N.m (35 +/- 4 ft-lb)

Fig 69: Installing Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
Install the manual control lever shaft and parking pawl rod.
Align hole "A" With the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".

Fig 70: Aligning Hole - A
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Insert the new seal rings in the grooves of the accumulator pistons.
NOTE: The piston and seal ring are common parts.

Fig 71: Inserting New Seal Rings In Grooves
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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.

Fig 72: Accumulator Springs Specification
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 73: Identifying Accumulator Spring
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Install the strainer and second brake retainer oil seal.

Fig 74: Installing Strainer
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Insert a new O-ring to the groove of the solenoid valve harness connector.
Insert the solenoid valve harness connector into the hole from in 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 75: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
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 control lever.

Fig 76: Installing Steel Balls
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Install the valve body mounting bolts (twenty seven pieces), and tighten to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)

Fig 77: Installing Valve Body Mounting Bolts
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Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.

Fig 78: Solenoid Valve Harness Specification
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 79: Attaching Solenoid Valve Harness
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Fig 80: Solenoid Valve Harness Specification
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Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6.0 +/- 1.0 N.m (52 +/- 9 in-lb)

Fig 81: Installing Manual Control Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 (wit 15 minutes) or leaks will occur if the rear cover is ATF for approximately one hour.

Fig 82: Applying Sealant
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)

Fig 83: Installing Valve Body Cover
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Install the Sealing cap and tighten the bolt to the specified torque.
Tightening torque:5.0 +/- 1.0 N.m (43 +/- 9 in-lb)

Fig 84: Installing Sealing Cap
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the park/neutral position switch and tighten the bolt to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
Install the manual control lever and tighten the nut to the specified torque.
Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb)

Fig 85: Installing Park/Neutral Position Switch
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Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
Tightening torque:11 +/- 1 N.m (95 +/- 9 in-lb)

Fig 86: Installing Input Shaft Speed Sensor
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Press Face "A" of the air breather to be on the same plane as the Face "B" of the transmission case as shown in the drawing.
Apply ATF on the both sides of the new gasket and threads of the eyebolts, and then tighten to the specified torque.
Tightening torque:24 +/- 3 N.m (18 +/- 2 ft-lb)
Tighten the oil cooler feed pipe clamp bolt to the specified torque.
Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb)
Install the oil dipstick.
Install the cable support brackets to the specified torque.
Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
Install the roll stopper brackets.
Tightening torque: 70 +/- 10 N.m (52 +/- 7 ft-lb)

Fig 87: Pressing Face Of Air Breather
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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.
Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value.
Reference value:

Approximately 12.2 mm (0.48 inch)

Fig 88: Installing Torque Converter And Align With Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.