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Home >> Mitsubishi >> 2006 >> Endeavor 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 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
    G04311515Courtesy 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
    G04311516Courtesy 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.
    Fig 3: Identifying Transaxle Case
    G04311517Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998338 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.
    Fig 4: Installing Snap Ring With Special Tools
    G04311518Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 5: Installing Wave Spring
    G04311519Courtesy 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 illustration.
    NOTE: Do not install the pressure plate at this time.
  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) 

    Fig 6: Installing Reaction Plate
    G04311520Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Install the brake discs and brake plates as shown in the illustration.
  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 And Brake Plates
    G04311521Courtesy 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) 

  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
    Fig 8: Measuring Movement With Special Tool
    G04311522Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    PRESSURE PLATE 

    Fig 9: Measuring Movement Amount Of Pressure Plate
    G04311523Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    THICKNESS CHART

    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
  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: Measuring Movement With Special Tool And Dial Gauge
    G04311524Courtesy 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 

    Fig 11: Measuring Movement Amount Of Pressure Plate
    G04311525Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    THICKNESS CHART

    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
  20. Remove all parts and special tools that were installed to take the measurements in steps  8 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. 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: Taping Output Shaft Bearing Outer Race In Transaxle Case
    G04311526Courtesy 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 to the specified torque.

    Tightening torque: 

    54 +/- 5 N.m(40 +/- 4 ft-lb) 

    Fig 13: Tightening Mounting Bolts
    G04311527Courtesy 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 On Output Shaft
    G04311528Courtesy 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 (125 +/- 7 ft-lb) 

    NOTE: The jam nut is reverse threaded.
    Fig 15: Tightening Jam Nut
    G04311529Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Move the output shaft to measure the end play and record the measurement value.

    Standard value of output shaft end play (reference): 0.01 - 0.09 mm (0.0004 - 0.0035 inch) 

  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  26 and select a spacer of the same thickness. Adjustment spacer sizes are all listed on ADJUSTING PLATE, SNAP RING AND SPACERS  . Select the most suitable one from among those listed.
    Fig 16: Measuring End Play
    G04311530Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: * is the thickness of the spacer installed in step  21.** 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  27.
  31. Stake the jam nut with a punch (two places).
    Fig 17: Staking Jam Nut
    G04311531Courtesy 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 With Special Tools MB990931 And MB990938
    G04311532Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 19: Installing Parking Pawl Shaft
    G04311533Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the parking roller support, and then insert the two parking roller support shafts.
    Fig 20: Installing Parking Roller Support Shafts
    G04311534Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

    IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS mm (in) 

    Fig 21: Identifying Thrust Bearing, Thrust Races, And Thrust Washers Location
    G04311535Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    THICKNESS CHART

    SYMBOL OD mm (in) ID mm (in) THICKNESS mm (in) SYMBOL OD mm (in) ID mm (in) THICKNESS mm (in)
    No. 1 59 (2.32) 47 (1.85) 1.8 (0.071) No. 8 48.9 (1.925) 37 (1.46) 1.6 (0.063)
    59 (2.32) 47 (1.85) 2.0 (0.079) 48.9 (1.925) 37 (1.46) 1.7 (0.067)
    59 (2.32) 47 (1.85) 2.2 (0.087) 48.9 (1.925) 37 (1.46) 1.8 (0.071)
    59 (2.32) 47 (1.85) 2.4 (0.094) 48.9 (1.925) 37 (1.46) 1.9 (0.075)
    59 (2.32) 47 (1.85) 2.6 (0.102) 48.9 (1.925) 37 (1.46) 2.0 (0.079)
    59 (2.32) 47 (1.85) 2.8 (0.110) 48.9 (1.925) 37 (1.46) 2.1 (0.083)
    No. 2 49 (1.93) 34 (1.34) 3.6 (0.142) 48.9 (1.925) 37 (1.46) 2.2 (0.087)
    No. 3 49 (1.93) 34 (1.34) 3.6 (0.142) 48.9 (1.925) 37 (1.46) 2.3 (0.091)
    No. 4 45.3 (1.783) 31 (1.22) 3.3 (0.130) 48.9 (1.925) 37 (1.46) 2.4 (0.094)
    No. 5 49 (1.93) 34 (1.34) 3.6 (0.142) 48.9 (1.925) 37 (1.46) 2.5 (0.098)
    No. 6 49 (1.93) 34 (1.34) 3.6 (0.142) 48.9 (1.925) 37 (1.46) 2.6 (0.102)
    No. 7 59 (2.32) 37 (1.46) 2.8 (0.110)  
  35. Install the planetary carrier assembly.
    Fig 22: Installing Planetary Carrier Assembly
    G04311536Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the planetary reverse sun gear.
    Fig 23: Installing Planetary Reverse Sun Gear
    G04311537Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the wave spring on the low-reverse brake piston.
    Fig 24: Installing Wave Spring
    G04311538Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the pressure plate that was selected in step  18. Next, install six brake discs and five brake plates, one on top of the other.
    Fig 25: Installing Pressure Plate
    G04311539Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install the snap ring.
    Fig 26: Installing Snap Ring
    G04311540Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the reaction plate.
    Fig 27: Installing Reaction Plate
    G04311541Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install the snap ring that was selected in step  12.
    Fig 28: Installing Snap Ring
    G04311542Courtesy 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 step  16.
    Fig 29: Installing Pressure Plate
    G04311543Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Install the return spring and second brake piston.
    Fig 30: Installing Return Spring
    G04311544Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Install the snap ring.
    Fig 31: Installing Snap Ring
    G04311545Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  45. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
    Fig 32: Installing Thrust Bearing Number 5
    G04311546Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Use care to install the thrust bearing in the proper direction.
  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 33: Installing Thrust Bearing Number 6
    G04311547Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Install the reverse and overdrive clutch.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  48. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
    Fig 34: Installing Thrust Bearing Number 7
    G04311548Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 35: Taping Input Shaft Rear Bearing In Rear Cover
    G04311549Courtesy 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.
      Fig 36: Measuring End Play
      G04311550Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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 measurements in steps (1) to (4), take out the installed parts.
  52. Install the three O-rings.
  53. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step  50 from the table below. Install it on thrust bearing number 7.
    Fig 37: Installing O-rings
    G04311551Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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)
  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 38: Applying Sealant
    G04311552Courtesy 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 39: Tightening Mounting Bolts
    G04311553Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 40: Installing Underdrive Clutch Hub To Underdrive Sun Gear
    G04311554Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
  57. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
    Fig 41: Installing Thrust Bearing
    G04311555Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Hold the input shaft, and install the underdrive clutch.
    Fig 42: Holding Input Shaft
    G04311556Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Adjustment of input shaft end play and select the thrust washer number 1. (Refer to THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY  .)
  60. Install thrust washer number 1 that was selected in step (69) on the underdrive clutch retainer.
    Fig 43: Installing Thrust Washer
    G04311557Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Install special tool MD998412 as shown.
  62. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
  63. Tighten the oil pump mounting bolts (six pieces) to the specified torque.

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

    Fig 44: Installing Special Tool MD998412
    G04311558Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  64. Make sure that the input shaft end play meets the standard value.

    Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch) 

    Fig 45: Measuring End Play
    G04311559Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Install the oil filter.
    Fig 46: Installing Oil Filter
    G04311560Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  66. Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.
    Fig 47: Taping Differential Bearing Outer Race In Transaxle Case
    G04311561Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Install the differential.
    Fig 48: Installing Differential
    G04311562Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Adjustment of differential case preload and select the spacer. (Refer to SPACER SELECTION FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD  .)
  69. Install the selected spacer to the torque converter housing.
    Fig 49: Installing Selected Spacer To Torque Converter Housing
    G04311563Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  70. Use special tools MB990936 and MB990938 to press in the differential bearing outer race into the torque converter housing.
    Fig 50: Pressing Differential Bearing Outer Race Into Torque Converter Housing With Special Tools
    G04311564Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. 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).
    NOTE: After installation, keep the sealed area away from the oil for approximately one hour.
    Fig 51: Applying Sealant
    G04311565Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Install the two O-rings.
    Fig 52: Installing O-Rings
    G04311566Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. 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 53: Tightening Mounting Bolts
    G04311567Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  74. Insert the two O-rings into the grooves of the manual control lever shaft.
  75. Install the manual control lever shaft and parking pawl rod.
  76. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".
    Fig 54: Installing Manual Control Lever Shaft
    G04311568Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  77. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
  78. 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 55: Identifying Accumulator Spring
    G04311569Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    ACCUMULATOR NUMBER CHART

    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 56: Identifying Accumulator Spring Location
    G04311570Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  79. Install the strainer and second brake retainer oil seal.
    Fig 57: Installing Strainer
    G04311571Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. Insert a new O-ring to the groove of the solenoid valve harness connector.
  81. 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 58: Installing Snap Ring
    G04311572Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
  83. 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 59: Installing Transaxle Case
    G04311573Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  84. Install the 27 valve body mounting bolts, and tighten to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 60: Installing Mounting Bolts
    G04311574Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  85. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
    Fig 61: Installing Connectors
    G04311575Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    VALVE REFERENCE CHART

    NO. PARTS TO BE CONNECTED SOLENOID VALVE HARNESS
    CABLE COLOR CONNECTOR HOUSING COLOR
    1 Underdrive solenoid valve White, red, red Black
    2 Overdrive solenoid valve Orange, red Black
    3 Low-reverse solenoid valve Brown, yellow Milky white
    4 Second solenoid valve Blue, red, red Milky white
    5 Torque converter clutch control solenoid valve Blue, yellow, yellow Black
  86. 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 62: Tightening Bolt
    G04311576Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  87. 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).
    NOTE: After installation, keep the sealed area away from the oil for approximately one hour.
    Fig 63: Applying Sealant
    G04311577Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  88. 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 64: Tightening Mounting Bolts
    G04311578Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Install the Sealing cap and tighten the bolt to the specified torque. < Type with sealing cap >

    Tightening torque: 5.0 +/- 1.0 N.m (43 +/- 9 in-lb) 

    Fig 65: Installing Sealing Cap
    G04311579Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  90. Install the park/neutral position switch and tighten the bolt to specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

  91. Install the manual control lever and tighten the nut to specified torque.

    Tightening torque: 22 +/- 3 N.m (17 +/- 2 ft-lb) 

    Fig 66: Installing Manual Control Lever
    G04311580Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  92. 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 67: Installing Input Shaft Speed Sensor
    G04311581Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  93. Press Face "A" of the air breather to be even with Face "B" of the transmission case as shown in the illustration.
  94. 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) 

  95. Tighten the oil cooler feed pipe clamp bolt to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

  96. Install the oil dipstick.
    Fig 68: Identifying Air Breather Face (A) And Transmission Case Face (B)
    G04311582Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  97. Install the control cable support bracket.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

  98. 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.
  99. Install the torque converter, and secure it so that the shown dimension "A" meets the reference value.

    Reference value: 

    Approximately 9.4 mm (0.37 inch) 

  100. 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) 

    Fig 69: Checking Dimension A
    G04311583Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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