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Home >> Mitsubishi >> 2005 >> Outlander Limited, 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. Use petroleum jelly (i.e. Vaseline).
  • Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse new clutch discs or brake discs 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
    G02483290Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. 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
    G02483291Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
    Fig 3: Installing Low-Reverse Brake Piston, Return Spring, And Spring Retainer
    G02483292Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Fit a new O-ring into the groove of one-way clutch inner race.
    Fig 4: Installing O-Ring
    G02483293Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 5: Installing One-Way Clutch Inner Race
    G02483294Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998903 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.
    Fig 6: Installing Special Tools
    G02483295Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 7: Installing Wave Spring
    G02483296Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Install the brake discs (six pieces), brake plates (five pieces) and snap ring as shown in the illustration.
    NOTE: Do not install the pressure plate at this time.
  10. Install special tool MB991631 on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991631 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 8: Measuring End Play Of Reaction Plate
    G02483297Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Install the brake discs (three pieces) and brake plates (two pieces) as shown in the illustration.
    NOTE: Do not install the pressure plate at this time.
  14. Place special tool MB991631 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
    G02483298Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Move special tool MB991631 and measure its movement.
    • Standard value of end play (Reference): 
    • 0.79 - 1.25 mm (0.0311 - 0.0492 inch) 
  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

    PRESSURE PLATE FOR SECOND BRAKE 

    PRESSURE PLATE FOR SECOND BRAKE THICKNESS CHART

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    0.6 - 0.8 (0.024 - 0.031) 1.6 (0.063) L
    0.8 - 1.0 (0.031 - 0.039) 1.8 (0.071) 1
    1.0 - 1.2 (0.039 - 0.047) 2.0 (0.079) 0
    1.2 - 1.4 (0.047 - 0.055) 2.2 (0.087) 2
    1.4 - 1.6 (0.055 - 0.063) 2.4 (0.094) 4
    1.6 - 1.8 (0.063 - 0.071) 2.6 (0.102) 6
    Fig 10: Measuring Movement
    G02483299Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 11: Measuring Movement Amount
    G02483300Courtesy 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 MB991631 and measure its movement.

    • Standard value of end play (Reference): 
    • 1.65 - 2.11 mm (0.0649 - 0.0831 inch) 
    Fig 12: Installing Special Tool
    G02483301Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 13: Measuring Movement Amount
    G02483302Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

    PRESSURE PLATE FOR LOW-REVERSE BRAKE 

    PRESSURE PLATE FOR LOW-REVERSE BRAKE THICKNESS CHART

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.3 - 1.5 (0.051 - 0.059) 1.6 (0.063) L
    1.5 - 1.7 (0.059 - 0.067) 1.8 (0.071) 1
    1.7 - 1.9 (0.067 - 0.075) 2.0 (0.079) 0
    1.9 - 2.1 (0.075 - 0.083) 2.2 (0.087) 2
    2.1 - 2.3 (0.083 - 0.091) 2.4 (0.094) 4
    2.3 - 2.5 (0.091 - 0.098) 2.6 (0.102) 6
    2.5 - 2.7 (0.098 - 0.106) 2.8 (0.110) 8
    2.7 - 2.9 (0.106 - 0.114) 3.0 (0.118) D
    CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
  20. Remove all 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.
  21. Install the snap ring into the groove of transaxle case output shaft bore.
  22. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.
    Fig 14: Tapping Output Shaft Bearing Outer Race In Transaxle Case
    G02483303Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not reuse the bolt, as it has had sealant applied.
  23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
    • Tightening torque: 
    • 29 +/- 2 N.m (21 +/- 1 ft-lb) 
    Fig 15: Tightening Mounting Bolts
    G02483304Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
    Fig 16: Installing Collar And Taper Roller Bearing
    G02483305Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  25. 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 17: Tightening Jam Nut
    G02483306Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  26. Move the output shaft to measure the end play and record the measurement value.
  27. Remove the parts that were installed in steps 22 to 25.
  28. Select a spacer whose thickness corresponds to the measured amount of movement from the following table.
    Fig 18: Measuring End Play
    G02483307Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    SPACER FOR OUTPUT SHAFT 

    SPACER FOR OUTPUT SHAFT THICKNESS CHART

    MOVEMENT AMOUNT mm (in) THICKNESS mm (in) ID SYMBOL
    1.81 - 1.85 (0.0713 - 0.0728) 1.88 (0.0740) 88
    1.85 - 1.89 (0.0728 - 0.0744) 1.92 (0.0756) 92
    1.89 - 1.93 (0.0744 - 0.0760) 1.96 (0.0772) 96
    1.93 - 1.97 (0.0760 - 0.0776) 2.00 (0.0787) 00
    1.97 - 2.01 (0.0776 - 0.0791) 2.04 (0.0803) 04
    2.01 - 2.05 (0.0791 - 0.0807) 2.08 (0.0819) 08
    2.05 - 2.09 (0.0807 - 0.0823) 2.12 (0.0835) 12
    2.09 - 2.13 (0.0823 - 0.0839) 2.16 (0.0850) 16
    2.13 - 2.17 (0.0839 - 0.0854) 2.20 (0.0866) 20
    2.17 - 2.21 (0.0854 - 0.0870) 2.24 (0.0882) 24
    2.21 - 2.25 (0.0870 - 0.0886) 2.28 (0.0898) 28
    2.25 - 2.29 (0.0886 - 0.0902) 2.32 (0.0913) 32
    2.29 - 2.33 (0.0902 - 0.0917) 2.36 (0.0929) 36
    2.33 - 2.37 (0.0917 - 0.0933) 2.40 (0.0945) 40
    2.37 - 2.41 (0.0933 - 0.0949) 2.44 (0.0961) 44
    2.41 - 2.45 (0.0949 - 0.0965) 2.48 (0.0976) 48
    2.45 - 2.49 (0.0965 - 0.0980) 2.52 (0.0992) 52
    2.49 - 2.53 (0.0980 - 0.0996) 2.56 (0.1008) 56
    2.53 - 2.57 (0.0996 - 0.1012) 2.60 (0.1024) 60
    2.57 - 2.61 (0.1012 - 0.1028) 2.64 (0.1039) 64
    2.61 - 2.65 (0.1028 - 0.1043) 2.68 (0.1055) 68
    2.65 - 2.69 (0.1043 - 0.1059) 2.72 (0.1071) 72
    2.69 - 2.73 (0.1059 - 0.1075) 2.76 (0.1087) 76
  29. Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 28.
  30. Stake the jam nut with a punch (two places).
    Fig 19: Staking Jam Nut With Punch
    G02483308Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 20: Installing Cap
    G02483309Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Install the planetary carrier assembly.
    Fig 21: Installing Planetary Carrier Assembly
    G02483310Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the planetary reverse sun gear.
    Fig 22: Installing Planetary Reverse Sun Gear
    G02483311Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the wave spring on the low-reverse brake piston.
    Fig 23: Installing Wave Spring On Low-Reverse Brake Piston
    G02483312Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. 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 24: Installing Pressure Plate
    G02483313Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the snap ring.
    Fig 25: Installing Snap Ring
    G02483314Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the reaction plate.
    Fig 26: Installing Reaction Plate
    G02483315Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the snap ring that was selected in step 12.
    Fig 27: Installing Snap Ring
    G02483316Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. 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 28: Installing Brake Discs
    G02483317Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the return spring and second brake piston.
    Fig 29: Installing Return Spring And Second Brake Piston
    G02483318Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install the snap ring.
    Fig 30: Installing Snap Ring
    G02483319Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS 

    Fig 31: Identifying Identification Of Thrust Bearing, Thrust Races, And Thrust Washers Location
    G02483320Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  42. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
    Fig 32: Checking Installation Direction Of Thrust Bearing Number 5
    G02483321Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use care to install the thrust bearing in the proper direction.
  43. 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 33: Attaching Thrust Bearing Number 6
    G02483322Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  44. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
    Fig 34: Checking Installation Direction Of Thrust Bearing Number 7
    G02483323Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  45. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
  46. Install the seal rings (four pieces) in the grooves of the rear cover.
    Fig 35: Tapping Input Shaft Rear Bearing
    G02483324Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. 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) 

      Fig 36: Measuring End Play
      G02483325Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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 measurement in steps (5), take out the installed parts in steps (1) through (4).
  48. Install the O-rings (three pieces).
    Fig 37: Installing O-Rings
    G02483326Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  49. 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.
    UNDERDRIVE SUN GEAR THRUST THICKNESS CHART

    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)
  50. 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 38: Applying Bead Of Sealant
    G02483327Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  51. 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 39: Tightening Mounting Bolts
    G02483328Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  52. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 40: Inserting Parking Pawl
    G02483329Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Install the parking roller support, and then insert the parking roller support shafts (two pieces).
    Fig 41: Inserting Parking Roller Support Shafts
    G02483330Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 42: Installing Underdrive Clutch Hub
    G02483331Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  55. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
    Fig 43: Checking Installation Direction Of Thrust Bearing Number 2
    G02483332Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Hold the input shaft, and install the underdrive clutch.
    Fig 44: Installing Underdrive Clutch
    G02483333Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. 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 45: Placing Two Beads Of Solder
    G02483334Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Install special tool MD998412 as shown.
  59. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
  60. Tighten the six oil pump mounting bolts to the specified torque.
    • Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb) 
    Fig 46: Tightening Oil Pump Mounting Bolts
    G02483335Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Remove the oil pump mounting bolts.
  62. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 47: Removing Oil Pump And Crushed Solders
    G02483336Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  63. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
  64. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.
    THRUST WASHER NUMBER 1 THICKNESS CHART

    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
    Fig 48: Measuring Thickness Of Crushed Solder Beads
    G02483337Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Install thrust washer number 1 that was selected in step 64 on the underdrive clutch retainer.
    Fig 49: Installing Thrust Washer Number 1
    G02483338Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  66. Install special tool MD998412 as shown.
  67. Install the new oil pump gasket on the transaxle case.
  68. 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 50: Tightening Mounting Bolts
    G02483339Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  69. Make sure that the input shaft end play meet's the standard value.
    • Standard value : 0.70 - 1.45 mm (0.028 - 0.057 inch) 
    Fig 51: Measuring End Play
    G02483340Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  70. Install the oil filter.
    Fig 52: Installing Oil Filter
    G02483341Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Use special tools MB990935 and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 53: Tapping Differential Bearing Outer Race
    G02483342Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Install the differential < F4A4B > or center differential < W4A4B >.
    Fig 54: Installing Differential F4A4B Or Center Differential W4A4B
    G02483343Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. 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 55: Placing Two Beads Of Solder
    G02483344Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  74. Use special tools MB990935 and MB990938 < F4A4B > or MB991550 < W4A4B > to press the differential bearing outer race into the torque converter housing.
    Fig 56: Pressing Differential Bearing Outer Race
    G02483345Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  75. 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 (36 +/- 4 ft-lb) 
  76. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
    Fig 57: Loosening Bolts
    G02483346Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  77. 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 58: Measuring Thickness
    G02483347Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  78. Install the spacer selected in step 77 to the torque converter housing.
  79. Use special tools MB990935 and MB990938 < F4A4B > or MB991550 < W4A4B > to press the outer race into housing.
    Fig 59: Pressing Outer Race Into Housing
    G02483348Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. 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). 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 60: Applying Bead Of Sealant
    G02483349Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  81. Install the O-rings (two pieces).
    Fig 61: Installing O-Rings
    G02483350Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Install the torque converter housing and then tighten its mounting bolts (eighteen pieces) to the specified torque.
    • Tightening torque: 48 +/- 6 N.m (36 +/- 4 ft-lb) 
    Fig 62: Tightening Mounting Bolts
    G02483351Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  83. Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
  84. Install the manual control lever shaft and parking pawl rod.
  85. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A."
    Fig 63: Inserting Manual Control Lever Shaft Roller Into Hole
    G02483352Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  86. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
    Fig 64: Inserting New Seal Rings
    G02483353Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  87. 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 IDENTIFICATION

    NO. NAME IDENTIFICATION "BLUEING"
    1 For low-reverse brake None
    2 For underdrive clutch Half
    3 For second brake Whole surface
    4 For overdrive clutch None
    Fig 65: Identifying Accumulator Spring
    G02483354Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  88. Install the strainer and second brake retainer oil seal.
    Fig 66: Installing Strainer And Second Brake Retainer Oil Seal
    G02483355Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Insert a new O-ring to the groove of the solenoid valve harness connector.
  90. 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 67: Installing Snap Ring
    G02483356Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  91. Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
  92. 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 68: Installing Steel Balls
    G02483357Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  93. 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 69: Installing Valve Body Mounting Bolts
    G02483358Courtesy 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.
    Fig 70: Attaching Solenoid Valve Harness
    G02483359Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 71: Cable Reference Chart (1 Of 2)
    G02483360Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 72: Cable Reference Chart (2 Of 2)
    G02483361Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  95. 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 73: Installing Manual Control Shaft Detent
    G02483362Courtesy 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) or 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 74: Applying Bead Of Sealant
    G02483363Courtesy 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 +/- 1 N.m (95 +/- 9 in-lb) 
    Fig 75: Installing Valve Body Cover
    G02483364Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  98. 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 76: Installing Sealing Cap
    G02483365Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  99. Install the park/neutral position switch and tighten the bolt to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
  100. Install the manual control lever and tighten the nut to the specified torque.
    • Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb) 
    Fig 77: Installing Manual Control Lever
    G02483366Courtesy 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.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
    Fig 78: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
    G02483367Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  102. 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 illustration.
  103. 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) 
  104. Tighten the oil cooler feed pipe clamp bolt to the specified torque.
    • Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 
  105. Install the oil dipstick.
  106. Install the cable support brackets to the specified torque.
    • Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 
  107. Install the roll stopper brackets.
    • Tightening torque: 70 +/- 10 N.m (52 +/- 7 ft-lb) 
    Fig 79: Installing Roll Stopper Brackets
    G02483368Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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.
  108. 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) 
  109. Install the transfer together with new o-ring and tighten the blots to the specified torque < W4A4B >.
    • Tightening torque: 69 +/- 9 N.m (51 +/- 7 ft-lb) 
    Fig 80: Tightening Blots
    G02483369Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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