Disassembly And Assembly: Assembly
CAUTION:
- Never reuse the gasket, O-rings, oil seals, etc. Always replace with new ones when assembling.
- Never use grease other than blue petroleum jelly and white 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.
- Never apply sealant or adhesive to gaskets.
- When replacing a bushing, replace the assembly which it belongs to.
- During the work, always use bare hands or vinyl gloves. Do not use cotton gloves. Use nylon cloth or paper towels when necessary. Do not use shop towels.
- Change the oil in the cooler system.
CAUTION:
Never reuse a gasket.
- Install a new gasket and output shaft support.
- Tighten the eight output shaft support mounting bolts to the specified torque.
- Specified torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
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- Specified torque: 23 +/- 3 N.m (17 +/- 2 ft-lb)
- Install new O-ring on the anchor plug and tighten the anchor plug by specified torque.
- Specified torque: 98 +/- 15 N.m (71 +/- 11 ft-lb)
CAUTION: Insert the anchor bracket hole of the brake band to the anchor plug tip, and then mount the apply bracket part to the hole of reduction brake piston adjust rod. - Install the reduction brake band.
- Install the thrust bearing number 13.
CAUTION: Make sure the thrust bearing number 13 is mounted in the correct direction.CAUTION: Take care that the reduction brake band does not come off the anchor rod and the hole of the reduction brake piston adjust rod.
- Install the direct clutch.
- Install the reduction brake spring.
- Tighten the reduction brake piston adjust rod into the reduction brake piston manually to the full.
- Install new seal ring on the piston.
- Press the reduction brake piston into the transmission case, and then install the snap ring.NOTE: Set the open end of the snap ring at indicated location.
- Fully tighten the reduction brake piston adjust rod manually.
- Adjust the reduction brake piston by following procedure.
- Mount the special tool so that the reduction brake piston does not rotate.
- Mount the torque wrench to the special tool (Socket), and after repeatedly tightening and turning back with the torque of 10 N. m (87 in - lb) twice, tighten the reduction brake piston adjust rod by the specified torque. Then turn the reduction brake piston adjust rod 5 1/2 to 5 3/4 turns backwards.
- Specified torque: 5.0 N.m (44 in-lb)
- Remove the special tool and tighten the reduction brake piston nut manually.
- Tighten the reduction brake piston nut to the specified torque using the special tool (wrench) with the special tool (Socket) so it does not rotate.
- Specified torque: 18+/- 3 N.m (13+/- 2 ft-lb)
- Install a new O-ring on the reduction brake piston cover, and then install the cover and the snap ring on the transmission case.
- Install new seal rings (two large pieces and two small pieces) onto the direct planetary carrier.
- Install the direct planetary carrier into the output shaft support.
- Apply vase line or petroleum jelly on the thrust bearing number 12, and then install on the front end of the direct planetary carrier.
CAUTION: Make sure thrust bearing number 12 is mounted in the correct direction.CAUTION: Confirm that the thrust bearing number 10 in the direct annulus gear is still at specified location.
- Insert the direct annulus gear.
- Apply Vaseline or petroleum jelly on the thrust bearing number 9, and then install on the direct annulus gear.
CAUTION: Make sure thrust bearing number 9 is mounted in the correct direction.CAUTION: Measure and record the thickness of the thrust race number 8 to be assembled.
- Apply Vaseline or blue petroleum jelly on the thrust race number 8 being used, and then install it on the rear side of the center support.
CAUTION:
- Install the center support so that the oil holes shown in the illustration face the lower side of the transmission case.
- Make sure that the thrust race number 8 attached to the rear side of the center support does not fall off.
- Install the center support.
CAUTION: Install the cable bracket together with special tool.
- Using the Transfer case adapter bolt, install special tool MB991603.
- Select the thrust race number 8 with the following procedure:
- Fix a dial gauge to special tool MB991603.
- Push the direct planetary carrier, and the direct annulus gear in alternately, and then measure the end play of direct planetary carrier.NOTE: When pushing the direct planetary carrier in, take care that the center support does not move.NOTE: When pushing the direct annulus gear in, use the special tool MB998304.
- Reinstall by selecting the thrust race number 8 installed by the procedure (19) so that the end play of direct planetary carrier becomes the standard value.NOTE: Refer to the thickness recorded in step 12.
- Standard value: 0.25 - 0.71 mm (0.0098 - 0.0278 inch)
- Measure the end play again, and confirm that it is within the standard value.
NOTE: Carry this step out with special tool MB991603 and dial gauge installed. - Using the following steps, select the snap ring for fixing the center support.
- Install the snap ring used for fixing the center support used.
- After pushing the direct planetary carrier, and the center support in alternately, and then measure the end play of center support.NOTE: When pushing the direct planetary carrier in, be sure to push them in to the point where the center support touches the snap ring.
- Select the snap ring for fixing the center support installed in step 23 (1) so that the end play of the center support is at the standard value. Then, reassemble.
- Standard value: 0-0.16 mm (0 - 0.0063 inch)
- Measure the end play again, and confirm that it is within the standard value.
- Using the following steps, select the snap ring for adjusting the brake reaction plate end play and second brake end play, and the pressure plate for adjusting the low/reverse brake end play.
- Install the wave spring onto the low/reverse brake piston.
- Install special tool MB991632 onto the position shown in the illustration instead of the pressure plate for the low/reverse brake. Install the brake disc, brake plate and snap ring.
CAUTION: Pay close attention to the assembly direction of the reaction plate.
- Install the reaction plate and snap ring that was used.
- Install a dial gauge onto special tool MD998913 so that the end contacts the brake reaction plate. Measure the end play by moving special tool MB991632.
- Select the snap ring installed in step 24 (3) so that the end play is within the standard value. Then, reassemble.
- Standard value: 0-0.16 mm (0 - 0.0063 inch)
- Measure the end play again, and confirm that it is within the standard value.CAUTION: Pay close attention to the shape and assembly direction of the brake plate A installation.
- Next, install special tool MB991632 instead of the pressure plate for the second brake. Install the four brake discs and three brake plates.
- Install the return spring, second brake and snap ring.
- Install a dial gauge onto special tool MD998913 so the end contacts the special tool. Move special tool MB991632 and measure the moving amount. Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
- Standard value: 1.49 -1.95 mm (0.0587 - 0.0768 inch)
- Remove the snap ring, second brake, return spring and special tool MB991632 installed in step (8).
- Install the pressure plate selected in step (9), and install the return spring, second brake and snap ring again.
- Install a dial gauge onto special tool MD998913 so the end contacts the special tool. Move special tool MB991632 and measure the moving amount. Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
- End play standard value (reference)
- : 1.65 - 2.11 mm (0.0650 - 0.0831 inch)
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- Remove the parts installed in steps 24 (1) to (12).
CAUTION: Make sure thrust bearing number 7 is mounted in the correct direction. - Apply Vaseline or petroleum jelly on the thrust bearing number 7, and then install on the rear side of the low/reverse annulus gear.
CAUTION: Make sure that thrust bearing number 7 attached to the rear side of the low/reverse annulus gear does not fall off.
- Install the low/reverse annulus gear.
- Install the reverse sun gear.
- Install the wave spring to the low/reverse brake piston.
- Install the pressure plate, brake disc and brake plate selected in step 24 (12).
- Install the snap ring.
CAUTION: Make sure the reaction plate in the proper direction.
- Install the reaction plate.
- Install the snap ring selected in step 24 (5).
CAUTION: Make sure the brake plate (reaction plate side) is installed in the proper direction.
- Install the brake disc, brake plate and pressure plate selected in step 24 (9).
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CAUTION: Install the return spring end coil side so that it faces the back of the transmission. (Only for one side end coil type) - Install the return spring and second brake.
- Install the snap ring.
CAUTION: Make sure thrust bearing number 4 is installed in the proper direction.
- Apply Vaseline or petroleum jelly on the thrust bearing number 4, and then install on the reverse sun gear.
CAUTION: Make sure thrust bearing number 3 is mounted in the correct direction.
- Apply Vaseline or petroleum jelly on the thrust bearing number 3, and then install on the overdrive clutch hub.
- Install the overdrive clutch hub.
CAUTION: Make sure thrust bearing number 2 is mounted in the correct direction.
- Install the reverse and overdrive clutch.
- Apply Vaseline or petroleum jelly on the thrust bearing number 2, and then install on the reverse and overdrive clutch.
- Apply Vaseline or petroleum jelly on the thrust race number 1 being used, and then install on the oil pump.
CAUTION: Never reuse a gasket.
- Install special tool MD998412 at the position shown in the illustration, and using this as a guide, install the oil pump and gasket.
- Tighten the ten oil pump mounting bolts to the specified torque.
- Specified torque: 23+/- 3 N.m (17 +/- 2 ft-lb)
- Using special tool MD998316, set a dial gauge as shown in the illustration. Measure the end play of the input shaft, and select the thrust race installed in step 28 so that the end play is at the standard value. Then, reassemble.
- Standard value: 0.25 - 0.81 mm (0.0098 - 0.0319 inch)
- Measure the end play again, and confirm that it is within the standard value.
CAUTION: Evenly squeeze out the sealant so that it is not insufficient or excessive.
- Apply the sealant MITSUBISHI genuine sealant part number MR166584 or equivalent on the converter housing.
- Install the converter housing.
- Tighten the eight converter housing mounting bolts to the specified torque.
- Specified torque: 48 +/- 6 N.m (35 +/- 4 ft-lb)
- Install the parking roller rod to the detent lever.
- Install two new O-rings to the manual control shaft, and assemble onto the transmission case together with the detent lever and parking roller rod.
- Install the pin.
- Hammer in so that the slit section of the spring valve is perpendicular to the axial direction of the manual control shaft.
- Install a new seal ring onto each accumulator piston.
- Install each accumulator piston, spring and snap ring, accumulator cover, and O-ring.NOTE: Identification colors are applied on the spring as shown below. Assemble following this table.NOTE: Install the accumulator pistons to the original positions following the identification tags attached when removed.
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CAUTION: Pay close attention to the installation direction of the oil seal. - Install the oil strainer and two new oil seals. Install the oil seals so that the notched section is oriented as shown in the illustration.
- Install the solenoid valve harness, and then secure the snap ring into connector groove.NOTE: Install the harness so that it is oriented as shown in the illustration.
- Install the new O-ring into the transmission case at the position shown in the illustration.
- Install the valve body while inserting the manual valve pin into the detent lever groove.
- Tighten the twenty valve body mounting bolts to the specified torque.TORQUE SPECIFICATION
BOLT LENGTH mm (in) A 25 (1.0) B 30 (1.2) C 40 (1.6) D 45 (1.8) E 55 (2.2) - Specified torque: 11 +/- 1 N.m (97 +/- 9 in-lb)
- Install the oil temperature sensor.
- Connect the connector to the valve body.
- Install the detent spring.
- Tighten the detent spring mounting bolt to the specified torque.
- Specified torque: 6.0 +/- 1 N.m (52 +/- 9 in-lb)
- Install the oil filter and a new O-ring.
- Install the magnet.CAUTION: Evenly squeeze out the sealant so that it is not insufficient or excessive.
- Apply the sealant MITSUBISHI genuine sealant part number MR166584 or equivalent on the oil pan.
- Install the oil pan.
- Tighten the oil pan mounting bolts to the specified torque.
- Specified torque: 11 +/- 1 N.m (97 +/- 9 in-lb)
CAUTION:- Install the parking gear so that the side without the spline cut faces the transmission side.
- Heat the parking gear to 160 - 180°C (320 - 356°F) and shrink fit up to the stepped section of the output shaft. (Only the type with three identification grooves.) Do not heat for longer than necessary at this time.
- Install the parking gear and snap ring.
- Install the park/neutral position switch and manual control lever.
- Install the output shaft speed sensor.
- Install the input shaft speed sensor.