LEMON Manuals: Even more car manuals for everyone
Home >> Mitsubishi >> 2005 >> Endeavor XLS, FWD >> 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 Special Tool MD998412
    G02390720Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Tighten the eight mounting bolts 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 Of Transfer Drive Gear Bearing
    G02390721Courtesy 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 as shown in illustration (see Fig 3).
    Fig 3: Installing One-Way Clutch Inner Race To Transfer Drive Gear Bearing
    G02390722Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998338 and MD998924 as shown in the illustration, and then compress the one-way clutch inner race and install the snap ring.
    Fig 4: Compressing One-Way Clutch Inner Race And Installing Snap Ring
    G02390723Courtesy 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
    G02390724Courtesy 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.
    Fig 6: Installing Six Brake Discs, Five Brake Plates & Snap Ring
    G02390725Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  10. Install special tool MB991632 on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991632 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) 
  13. Install the brake discs and brake plates as shown in the figure (see Fig 7).
  14. Place special tool MB991632 on top of the brake disc in place of the pressure plate.
  15. Install the return spring, second brake piston and snap ring.
    Fig 7: Installing Brake Discs & Brake Plates
    G02390726Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Move special tool MB991632 and measure its movement.
    • Standard value of end play (Reference): 
      • 1.09 - 1.55 mm (0.0429 - 0.0610 inch) 
    Fig 8: Measuring Movement Of Special Tool MB991632
    G02390727Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
    PRESSURE PLATE SPECIFICATIONS

    MOVEMENT AMOUNT mm (in)  THICKNESS mm (in)  ID SYMBOL 
    1.1 - 1.3 (0.043-0.051) 1.8 (0.071) E
    1.3 - 1.5 (0.051 - 0.059) 2.0 (0.079) D
    1.5-1.7 (0.059 - 0.067) 2.2 (0.087) C
    1.7-1.9 (0.067 - 0.075) 2.4 (0.094) B
    1.9-2.1 (0.075 - 0.083) 2.6 (0.102) A
    2.1 - 2.3 (0.083-0.091) 2.8 (0.110) 0
    Fig 9: Selecting Pressure Plate According To Movement Amount
    G02390728Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 MB991632 and measure its movement.

    • Standard value of end play (Reference): 
    • 1.65 - 2.11 mm (0.050 - 0.0831 inch) 
    Fig 10: Installing Special Tool MD998913 & Measuring Movement Of Special Tool MB991632
    G02390729Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below (see PRESSURE PLATE SPECIFICATIONS ).
    PRESSURE PLATE SPECIFICATIONS

    MOVEMENT AMOUNT mm (in)  THICKNESS mm (in)  ID SYMBOL 
    1.0-1.2 (0.039 - 0.047) 1.6 (0.063) F
    1.2-1.4 (0.047 - 0.055) 1.8 (0.071) E
    1.4-1.6 (0.055 - 0.063) 2.0 (0.079) D
    1.6-1.8 (0.063-0.071) 2.2 (0.087) C
    1.8-2.0 (0.071 - 0.079) 2.4 (0.094) B
    2.0-2.2 (0.079 - 0.087) 2.6 (0.102) A
    2.2-2.4 (0.087 - 0.094) 2.8 (0.110) 0
    2.4-2.6 (0.094-0.102) 3.0 (0.118) 1
    Fig 11: Selecting Pressure Plate According To Movement Amount
    G02390730Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  20. Remove all parts and special tools that were installed to take the measurements in steps  12 to  18. Remove and separate the pressure plate and snap ring chosen in previous steps.
  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 12: Tapping Output Shaft Bearing Outer Race
    G02390731Courtesy 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: 
      • 54 +/- 5 N.m (40 +/- 4 ft-lb) 
    Fig 13: Tightening Mounting Bolts Of Output Shaft Bearing Retainer
    G02390732Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
    Fig 14: Installing Collar And Taper Roller Bearing
    G02390733Courtesy 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: 170 +/- 10 N.m (126 +/- 7 ft-lb) 
    NOTE: The jam nut is reverse threaded.
    Fig 15: Tightening Jam Nut
    G02390734Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Move the output shaft to measure the end play and record the measurement value.
    Fig 16: Measuring End Play
    G02390735Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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  27 and select a spacer of the same thickness. Adjustment spacer sizes are all listed in 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  22.
    • ** 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  29.
  31. Stake the jam nut with a punch (two places).
    Fig 17: Staking Jam Nut With Punch
    G02390736Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 18: Installing Cap
    G02390737Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 19: Inserting Parking Pawl Shaft
    G02390738Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the parking roller support, and then insert the two parking roller support shafts.
    Fig 20: Inserting Two Parking Roller Support Shafts
    G02390739Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 21: Locating Thrust Bearing, Thrust Races, And Thrust Washers (1 Of 2)
    G02390740Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 22: Locating Thrust Bearing, Thrust Races, And Thrust Washers (2 Of 2)
    G02390741Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. Install the planetary carrier assembly.
    Fig 23: Installing Planetary Carrier Assembly
    G02390742Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the planetary reverse sun gear.
    Fig 24: Installing Planetary Reverse Sun Gear
    G02390743Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the wave spring on the low-reverse brake piston.
    Fig 25: Installing Wave Spring On Low-Reverse Brake Piston
    G02390744Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the pressure plate that was selected in steps  18 and  19. Next, install six brake discs and five brake plates, one on top of the other.
    Fig 26: Installing Pressure Plate, Brake Discs & Brake Plates
    G02390745Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install the snap ring.
    Fig 27: Installing Snap Ring
    G02390746Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the reaction plate.
    Fig 28: Installing Reaction Plate
    G02390747Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install the snap ring that was selected in step  12.
    Fig 29: Installing Snap Ring
    G02390748Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  42. Install four brake discs and three brake plates, one on top of the other. Next, install the pressure plate that was selected in steps  16 and  17.
    Fig 30: Installing Four Brake Discs And Three Brake Plates
    G02390749Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Install the return spring and second brake piston.
    Fig 31: Installing Return Spring And Second Brake Piston
    G02390750Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Install the snap ring.
    Fig 32: Installing Snap Ring
    G02390751Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    45. CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
    Fig 33: Installing Thrust Bearing Number 5 On Hub Of Planetary Reverse Sun Gear
    G02390752Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use care to install the thrust bearing in the proper direction.
  45. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
  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 34: Attaching Thrust Bearing Number 6 To Inside Of Overdrive Clutch Hub
    G02390753Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Install the reverse and overdrive clutch.
    48. CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
    Fig 35: Installing Thrust Bearing Number 7 On Reverse Clutch Retainer
    G02390754Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 36: Tapping Input Shaft Rear Bearing In Rear Cover
    G02390755Courtesy 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 +/- 3 N.m (17 +/- 2 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) 

      Fig 37: Measuring End Play Of Underdrive Sun Gear
      G02390756Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    6. After taking the measurements in steps (1) to (4), take out the installed parts.
  52. Install the three O-rings.
    Fig 38: Installing O-Rings
    G02390757Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step  50 from the table below (see THRUST RACE NUMBER 8 SPECIFICATIONS ). Install it on thrust bearing number 7.
    THRUST RACE NUMBER 8 SPECIFICATIONS

    MEASUREMENT VALUE mm (in)  THICKNESS mm (in) 
    0.3-0.4 (0.012-0.016) 1.6 (0.063)
    0.4-0.5 (0.016-0.020) 1.7 (0.067)
    0.5 - 0.6 (0.020 - 0.024) 1.8 (0.071)
    0.6 - 0.7 (0.024 - 0.028) 1.9 (0.075)
    0.7-0.8 (0.028-0.031) 2.0 (0.079)
    0.8 - 0.9 (0.031 - 0.035) 2.1 (0.083)
    0.9 - 1.0 (0.035 - 0.039) 2.2 (0.087)
    1.0 - 1.1 (0.039-0.043) 2.3 (0.091)
    1.1 - 1.2 (0.043-0.047) 2.4 (0.094)
    1.2 - 1.3 (0.047-0.051) 2.5 (0.098)
    1.3 - 1.4 (0.051-0.055) 2.6 (0.102)
  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 39: Applying Bead Of Sealant
    G02390758Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  55. 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 the oil for approximately one hour.
    Fig 40: Tightening Mounting Bolts
    G02390759Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 41: Installing Underdrive Clutch Hub
    G02390760Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    57. CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
    Fig 42: Installing Thrust Bearing Number 2 On Underdrive Clutch Hub
    G02390761Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
  58. Hold the input shaft, and install the underdrive clutch.
    Fig 43: Installing Underdrive Clutch
    G02390762Courtesy 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 44: Placing Two Beads Of Solder On Underdrive Clutch Retainer
    G02390763Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  60. Install special tool MD998412 as shown in illustration.
    Fig 45: Installing Special Tool MD998412
    G02390764Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 +/- 2 N.m (21 +/- 1 ft-lb) 
  63. Remove the oil pump mounting bolts.
  64. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 46: Removing Oil Pump And Crushed Solders
    G02390765Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
    Fig 47: Measuring Thickness Of Crushed Solder Beads
    G02390766Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  66. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below (see THRUST WASHER NUMBER 1 SPECIFICATIONS ).
    THRUST WASHER NUMBER 1 SPECIFICATIONS

    MEASUREMENT VALUE mm (in)  THICKNESS mm (in)  ID SYMBOL 
    2.25 - 2.45 (0.089 - 0.096) 1.8 (0.071) 18
    2.45 - 2.65 (0.096-0.104) 2.0 (0.079) 20
    2.65 - 2.85 (0.104-0.112) 2.2 (0.087) 22
    2.85 - 3.05 (0.112-0.120) 2.4 (0.094) 24
    3.05 - 3.25 (0.120-0.128) 2.6 (0.102) 26
    3.25 - 3.45 (0.128-0.136) 2.8 (0.110) 28
  67. Install thrust washer number 1 that was selected in steps  65 and  66 on the underdrive clutch retainer.
    Fig 48: Installing Thrust Washer Number 1
    G02390767Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Install special tool MD998412 as shown in the illustration.
    Fig 49: Installing Special Tool MD998412
    G02390768Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 +/- 2 N.m (21 +/- 1 ft-lb) 
  71. Make sure that the input shaft end play meets the standard value.
    Fig 50: Measuring End Play
    G02390769Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch) 
  72. Install the oil filter.
    Fig 51: Installing Oil Filter
    G02390770Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 52: Tapping Differential Bearing Outer Race In Transaxle Case
    G02390771Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  74. Install the differential.
    Fig 53: Installing Differential
    G02390772Courtesy 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 54: Placing Two Beads Of Solder On Torque Converter Housing
    G02390773Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  76. Use special tools MB990936 and MB990938 to press in the differential bearing outer race into the torque converter housing.
    Fig 55: Pressing In Differential Bearing Outer Race Into Torque Converter Housing
    G02390774Courtesy 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 +/- 6 N.m (35 +/- 4 ft-lb) 
    Fig 56: Tightening Mounting Bolts
    G02390775Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  78. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
  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 57: Measuring Thickness Of Crushed Solder Beads
    G02390776Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. Install the spacer selected in step 79 to the torque converter housing.
  81. Use special tools MB990936 and MB990938 to press the outer race into housing.
    Fig 58: Pressing Outer Race Into Housing
    G02390777Courtesy 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 in the illustration.
    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 59: Applying Bead Of Sealant To Torque Converter Housing
    G02390778Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  83. Install the two O-rings.
    Fig 60: Installing O-Rings
    G02390779Courtesy 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 +/- 6 N.m (35 +/- 4 ft-lb) 
    Fig 61: Tightening Mounting Bolts
    G02390780Courtesy 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 as shown in illustration. Insert the manual control lever shaft roller into hole "A."
    Fig 62: Installing Manual Control Lever Shaft And Parking Pawl Rod
    G02390781Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  88. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
  89. 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 63: Identifying Accumulator Spring
    G02390782Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    ACCUMULATOR SPRING IDENTIFICATIONS

    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 64: Inserting Accumulator Springs & Pistons
    G02390783Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  90. Install the strainer and second brake retainer oil seal.
    Fig 65: Installing Strainer And Second Brake Retainer Oil Seal
    G02390784Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  91. Insert a new O-ring to the groove of the solenoid valve harness connector.
  92. 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 66: Securing Snap Ring To Solenoid Valve Harness Connector Groove
    G02390785Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  93. 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 67: Installing Valve Body And Gasket To Transaxle Case
    G02390786Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  95. Install the 27 valve body mounting bolts, and tighten to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb) 
    Fig 68: Installing Valve Body Mounting Bolts
    G02390787Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  96. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
    Fig 69: Attaching Solenoid Valve Harness To Valve Body
    G02390788Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 70: Solenoid Valve Harness Connections
    G02390789Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  97. Install the manual control shaft detent and tighten the bolt to the specified torque.
    • Tightening torque: 6.0 +/- 1.0 N.m (52 +/- 8 in-lb) 
    Fig 71: Installing Manual Control Shaft Detent
    G02390790Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  98. 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 in the illustration.
    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 72: Applying Bead Of Sealant To Valve Body Cover
    G02390791Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  99. Install the valve body cover, and then tighten its mounting bolts to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb) 
    Fig 73: Tightening Mountings Bolts
    G02390792Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  100. Install the Sealing cap and tighten the bolt to the specified torque.
    • Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 8 in-lb) 
    Fig 74: Installing Sealing Cap
    G02390793Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  101. Install the park/neutral position switch and tighten the bolt to specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb) 
  102. Install the manual control lever and tighten the nut to specified torque.
    Fig 75: Installing Park/Neutral Position Switch & Manual Control Lever
    G02390794Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
  103. 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 +/- 8 in-lb) 
    Fig 76: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
    G02390795Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  104. Press Face "A" of the air breather to be even with Face "B" of the transmission case as shown in the illustration.
    Fig 77: Pressing Face "A" Of Air Breather To Be Even With Face "B" Of Transmission Case
    G02390796Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  105. 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) 
  106. Tighten the oil cooler feed pipe clamp bolt to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 8 in-lb) 
  107. Install the oil dipstick.
  108. Install the cable support bracket.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
  109. Install the roll stopper brackets.
    • Tightening torque: 70 +/- 10 N.m (51 +/- 7 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.
  110. Install the torque converter, and secure it so that the shown dimension "A" (see Fig 78) meets the reference value.
    • Reference value: 
      • Approximately 9.4 mm (0.37 inch) 
    Fig 78: Installing Torque Converter
    G02390797Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  111. Install the transfer together with new o-ring and tighten the bolts to the specified torque < W4A5A >
    • Tightening torque: 69 +/- 9 N.m (51 +/- 6 ft-lb) 
scientia non olet · About LEMON Manuals