Disassembly And Assembly: Assembly

CAUTION: Never reuse the outer race.

Using the special tool MB991550, Install the outer race of the differential side bearing on the transaxle case.

Fig 1: Identifying Special Tool MB991550
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the transaxle case.

Fig 2: Identifying Special Tools MD998812, MD998813 And MD998830
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply transmission fluid to the bearing so that the interference can be adjusted in a smooth condition.
- Measure the end play at more than two locations and obtain the average of the measurements.
Measure an interference (A) of the reduction gear assembly in the following procedure. Refer to SERVICE DATA for the interference of the reduction gear assembly.

Fig 3: Identifying Reduction Gear And Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Install the reduction gear assembly on the transaxle case.
  
  Fig 4: Identifying Reduction Gear Assembly
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Set the outer race on the reduction gear bearing.
  
  Fig 5: Identifying Outer Race On Reduction Gear Bearing
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L1 from the outer race to the end face of the transaxle case.
  
  Fig 6: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Place a block on the end face of the converter housing and measure distance L2 to the reduction gear taper bearing shim mounting surface.
5. Calculate distance L3 from the end face of the converter housing to the outer race of the reduction gear assembly from the following formula.
  L3 = L2 - Height of block
6. Calculate the thickness of the reduction gear taper bearing shim from the following formula.
  Thickness of reduction gear taper bearing shim = L3 - L1 + Interference
  
  Standard value: 0. 16 - 0. 22 mm (0. 006 - 0. 009 in)
  
  (For reduction gear preload)
  
  Fig 7: Measuring Distance L2
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  CAUTION: Never reuse the reduction gear taper bearing shim.
Install a selected reduction gear taper bearing shim on the converter housing. Refer to SERVICE DATA for selecting the reduction gear taper bearing shim.

Fig 8: Identifying Reduction Gear Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the converter housing.

Fig 9: Identifying Special Tools MD998812, MD998813 And MD998830
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply transmission fluid to the bearing so that the interference can be adjusted in a smooth condition.
- Measure the end play at more than two locations and obtain the average of the measurements.
Measure an interference (A) of the differential assembly in the following procedure. Refer to SERVICE DATA for the interference of the differential assembly.

Fig 10: Identifying Interference Of Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Install the differential assembly on the transaxle case.
  
  Fig 11: Identifying Differential Assembly
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Set the outer race on the differential side bearing.
  
  Fig 12: Locating Outer Race On Differential Side Bearing
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L1 from the outer race to the end face of the transaxle case.
  
  Fig 13: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Measure distance L2 from the end face of the converter housing to the differential taper bearing shim mounting surface of the converter housing.
5. Calculate the thickness of the differential taper bearing shim from the following formula.
  Thickness of differential taper bearing shim = L2 - L1 + Interference
  
  Standard value: 0. 19 - 0. 25 mm (0. 008 - 0. 010 in)
  
  (For differential preload)
  
  Fig 14: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  CAUTION: Never reuse the differential taper bearing shim.
Install a selected differential taper bearing shim on the converter housing. Refer to SERVICE DATA for selecting the differential taper bearing shim.

Fig 15: Identifying Differential Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Never reuse the outer race.
Using the special tool MB991550 < F1CJA > or MB991445 < W1CJA >, Install the outer race of the differential side bearing on the converter housing.

Fig 16: Identifying Special Tool MB991550 - F6AJ
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 17: Identifying Special Tool MB991550 - W6AJ
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 18: Identifying O-Ring And Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E18 bolts.
Install the output gear set. Refer to the following or the exploded view for the tightening torque.
BOLT TABLE

No. of bolts 10

Tightening torque: 41 N.m (30 ft-lb)

Fig 19: Identifying Output Gear Set Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the D-rings.
- Apply transmission fluid to the D-rings before installation.
Install D-rings on the low-reverse brake piston.

Fig 20: Identifying D-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply transmission fluid to the low-reverse brake piston before installation.
Install the low-reverse brake piston on the transaxle case.

Fig 21: Identifying Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the diaphragm spring.

Fig 22: Identifying Diaphragm Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the diaphragm spring retainer.

Fig 23: Identifying Diaphragm Spring Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the special tool MB992195, install the snap ring.

Fig 24: Identifying Special Tool MB992195
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.

Measure the clearance (A) of the low-reverse brake using the following procedure. Refer to SERVICE DATA for the specified low-reverse brake clearance.

Fig 25: Identifying Clearance Of Low-Reverse Brake

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

While compressing the drive plates, driven plates and retaining plate, measure the thickness L1 of the pack.

COMPRESSION LOAD TABLE

Compression load [N (kgf)]

7056 - 8056 (720 - 822)

Fig 26: Measuring Thickness L1 Of Pack (1 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 27: Measuring Thickness L1 Of Pack (2 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: If there is no appropriate plate, use the special tool, MD998917

Measure thickness L2 of the one-way clutch.

Fig 28: Measuring Thickness L2 Of One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure distance L3 from the end face of the transaxle case to the low-reverse brake piston.

Fig 29: Measuring Distance L3
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Temporarily assemble the snap ring, one-way clutch and snap ring to the transaxle case.
Measure distance L4 from the end face of the transaxle case to the one-way clutch, while pulling up the one-way clutch.
Remove the temporarily assembled snap ring, one-way clutch and snap ring from the transaxle case.
Calculate the clearance using the following formula. Clearance = L3 - (L1 + L2 + L4)
Select an appropriate retaining plate so that the specified clearance is obtained. Refer to SERVICE DATA for selecting the retaining plate.
Standard value: 1. 9 - 2. 2 mm (0. 07 - 0. 09 in)

(For low-reverse brake clearance)

Fig 30: Measuring Distance L3
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.

Install the needle bearing.

Fig 31: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply Vaseline to the bearing race before installation.
Install the bearing race on the RR sun gear on the front side.

Fig 32: Identifying Bearing Race And RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR sun gear on the front side.

Fig 33: Identifying RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR carrier assembly.

Fig 34: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR carrier assembly.

Fig 35: Identifying RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Ensure that the various plates are installed in the correct order.
Install the low-reverse brake drive plate, driven plate and selected retaining plate on the transaxle case.

Fig 36: Identifying Low-Reverse Brake Drive Plate, Driven Plate And Retaining Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, install the snap ring.

Fig 37: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the one-way clutch.

Fig 38: Identifying One-Way Clutch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, install the snap ring.

Fig 39: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.

Measure the clearance (A) of the 2-6 brake using the following procedure. Refer to SERVICE DATA for the specified 2-6 brake clearance.

Fig 40: Identifying Clearance Of 2-6 Brake

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

While compressing the drive plates, driven plates and retaining plate, measure thickness L1 of the pack.

COMPRESSION LOAD TABLE

Compression load [N (kgf)]

800 - 1800 (82 - 184)

Fig 41: Measuring Thickness L1 Of Pack (1 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 42: Measuring Thickness L1 Of Pack (2 Of 2)

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

NOTE: If there is no appropriate plate, use the special tool, MD998917

Measure distance L2 from the end face of the transaxle case to the snap ring.
CAUTION: When measuring L3, use the same straight bar as used when L2 is measured.

Fig 43: Measuring Distance L2
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Measure distance L3 from the end face of the side cover to the 2-6 brake piston.
Calculate the clearance using the following formula.
Clearance = L2 - (L1 + L3)
Select an appropriate retaining plate so that the specified clearance is obtained. Refer to SERVICE DATA for selecting the retaining plate.
Standard value: 1. 9 - 2. 2 mm (0. 07 - 0. 09 in)

(For 2-6 brake clearance)

Fig 44: Measuring Distance L3
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.

Install the needle bearing on the RR carrier assembly.

Fig 45: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the RR sun gear on the rear side.

Fig 46: Identifying RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the RR sun gear on the rear side.

Fig 47: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the high clutch hub.

Fig 48: Identifying High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the reduction internal gear.

Fig 49: Identifying Needle Bearing On Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction internal gear on the high clutch hub.

Fig 50: Identifying Reduction Internal Gear And High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the reduction internal gear.

Fig 51: Identifying Needle Bearing And Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction carrier.

Fig 52: Identifying Reduction Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction sun gear.

Fig 53: Identifying Reduction Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the reduction sun gear end play (A) using the following procedure. Refer to SERVICE DATA for the specified reduction sun gear end play (A).

Fig 54: Identifying Reduction Sun Gear End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.
  
  Fig 55: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 from the reduction carrier to the reduction sun gear.
  
  Fig 56: Measuring Distance L2
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 from the end face of the side cover to the end face of the high clutch support area.
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
5. Select an appropriate spacer so that the specified end play is obtained. Refer to SERVICE DATA for selecting the spacer.
  
  Fig 57: Measuring Distance L3
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  
  Standard value: 0.4 - 0.7 mm (0.02 - 0.03 in)
  
  (For reduction sun gear end play)
  
  CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the side cover end play (A) in the following procedure. Refer to SERVICE DATA for the specified side cover end play (A).

Fig 58: Identifying Side Cover End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 from the reduction carrier to the end face of the transaxle case.
  
  Fig 59: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 from the end face of the side cover to the needle bearing mounting surface.
  
  Fig 60: Measuring Distance L2
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 from the contact surface with the needle bearing of the high clutch drum to the snap ring of the cancel cover in the following procedure.
  
  Fig 61: Measuring Distance L3
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  1. Measure distance L4 from the high clutch drum edge to the snap ring of the cancel cover.
    
    Fig 62: Measuring Distance L4
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Measure height L5 of the high clutch drum.
    
    Fig 63: Measuring Height L5 Of High Clutch Drum
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Measure distance L6 from the underside of the high clutch drum to the contact surface with the needle bearing.
  4. Calculate L3 using the following formula.
    L3 = L5 - (L4 + L6) + Thickness of straight bar
4. Calculate the end play using the following formula.
  End play = L2 - (L1 + L3) - Thickness of needle bearing
5. Select an appropriate needle bearing so that the specified end play is obtained. Refer to SERVICE DATA for selecting the needle bearing.
  Standard value: 0.70 - 1.05 mm (0.028 - 0.041 in)
  
  (For side cover end play)
  
  Fig 64: Measuring Distance L6
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the high clutch assembly.

Fig 65: Identifying High Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Ensure that the various plates are installed in the correct order.
Install the 2-6 brake drive plate, driven plate and selected retaining plate on the transaxle case.

Fig 66: Identifying 2-6 Brake Drive Plate, Driven Plate And Retaining Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 67: Identifying O-Ring And Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the spacer.
- Apply Vaseline to the spacer and needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install an appropriate spacer and the needle bearing on the side cover.

Fig 68: Identifying Spacer And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.

Apply the sealant to the transaxle case mounting surface of the side cover (almost the center line of the surface).

Specified sealant: Three Bond 1216B

SPECIFIED SEALANT TABLE

L1 mm (in)

3 - 5 (0.1 - 0.2)

L2 mm (in)

2.3 (0.09)

Fig 69: Applying Sealant To Transaxle Case Mounting Surface Of Side Cover

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E16 bolts.

Install the side cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.
BOLT TABLE

No. of bolts 14

Tightening torque: 27 N.m (20 ft-lb)

Fig 70: Identifying Side Cover Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the drum support end play (A) using the following procedure. Refer to SERVICE DATA for the specified drum support end play (A).

Fig 71: Identifying Drum Support End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 between the end face of the RR internal gear splines and the oil pump mounting surface of the transaxle case.
  
  Fig 72: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 between the thrust washer mounting surface of the drum support and the oil pump mounting surface of the transaxle case.
  
  Fig 73: Measuring Distance L2
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 using the following procedure.
  
  Fig 74: Identifying FR Carrier And Low Clutch Assembly
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  1. Install the FR carrier on the low clutch assembly.
    CAUTION:
    Apply Vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
  2. Install the needle bearing on the FR carrier.
    
    Fig 75: Identifying Needle Bearing And FR Carrier
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the FR internal gear on the FR carrier.
    CAUTION:
    Apply Vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
    
    Fig 76: Identifying FR Internal Gear And FR Carrier
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Install the needle bearing on the FR sun gear.
    
    Fig 77: Identifying Needle Bearing On FR Sun Gear
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  5. Install the FR sun gear.
    
    Fig 78: Identifying FR Sun Gear
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    Apply Vaseline to the needle bearing before installation.
    
    Ensure that the needle bearing faces the correct direction.
  6. Install the needle bearing on the FR sun gear.
    
    Fig 79: Identifying Needle Bearing And FR Sun Gear
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  7. Install the 3-5 reverse clutch assembly.
    
    Fig 80: Identifying 3-5 Reverse Clutch Assembly
    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Measure distance L3 between A and B.
4. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - Thrust washer thickness
5. Select an appropriate thrust washer so that the specified end play is obtained. Refer to SERVICE DATA for selecting the thrust washer.
  Standard value: 0 - 0.35 mm (0 - 0.014 in)
  
  (For drum support end play)
  
  Fig 81: Measuring Distance L3
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear assembly.

Fig 82: Identifying Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reduction gear lubrication tube.

Fig 83: Identifying Reduction Gear Lubrication Tube
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl.

Fig 84: Identifying Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking shaft.

Fig 85: Locating Parking Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring.

Fig 86: Identifying Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking plate. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.9 N.m (70 in-lb)

Fig 87: Identifying Parking Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential gear assembly.

Fig 88: Identifying Differential Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Ensure that the claws on the thrust washer are correctly engaged with the holes in the drum support.
- Apply Vaseline to the thrust washer before installation.
Install an appropriate thrust washer on the drum support.

Fig 89: Identifying Thrust Washer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low clutch assembly.

Fig 90: Identifying Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR carrier on the low clutch assembly.

Fig 91: Identifying FR Carrier And Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR carrier.

Fig 92: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR internal gear on the FR carrier.

Fig 93: Identifying FR Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR sun gear.

Fig 94: Identifying Needle Bearing On FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the FR sun gear.

Fig 95: Identifying FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Apply Vaseline to the needle bearing before installation.
- Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the FR sun gear.

Fig 96: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the 3-5 reverse clutch assembly.

Fig 97: Identifying 3-5 Reverse Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Measure the 3-5 reverse clutch end play (A) using the following procedure. Refer to SERVICE DATA for the specified 3-5 reverse clutch end play (A).

Fig 98: Identifying 3-5 Reverse Clutch End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
1. Measure distance L1 between the oil pump assembly end face and A.
  
  Fig 99: Measuring Distance L1
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
2. Measure distance L2 between A and the bearing race mounting surface.
  
  Fig 100: Measuring Distance L2
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
3. Measure distance L3 between the oil pump mounting surface of the transaxle case and the needle bearing mounting surface of the 3-5 reverse clutch drum.
  
  Fig 101: Measuring Distance L3
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Measure thickness L4 of the needle bearing.
5. Calculate the end play using the following formula.
  End play = L3 - (L1 - L2) - L4 - Bearing race thickness
6. Select an appropriate bearing race so that the specified end play is obtained. Refer to SERVICE DATA for selecting the bearing race.
  Standard value: 0.55 - 0.85 mm (0.022 - 0.034 in)
  
  (For 3-5 reverse clutch end play)
  
  Fig 102: Measuring Distance L4
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  CAUTION:
  - Apply Vaseline to the needle bearing before installation.
  - Ensure that the needle bearing faces the correct direction.
Install the needle bearing on the 3-5 reverse clutch drum.

Fig 103: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the input shaft.

Fig 104: Identifying Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply Transmission fluid to the O-rings before installation.
Install an O-ring on the transaxle case.

Fig 105: Identifying O-Ring And Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the magnets on the oil strainer.

Fig 106: Identifying Magnets On Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the oil strainer.
- Apply transmission fluid to the O-ring of the oil strainer.

Install the oil strainer on the oil pump assembly. Refer to the following or the exploded view for the tightening torque.

BOLT CODE TABLE

Bolt code	A	B
Shank length mm (in)	25 (1.0)	16 (0.6)
No. of bolts	2	1

Tightening torque: 9.4 N.m (83 in-lb)

Fig 107: Identifying Oil Strainer Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Apply Vaseline to the bearing race before installation.

Install an appropriate bearing race on the oil pump assembly.

Fig 108: Identifying Bearing Race On Oil Pump Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
- Apply the transmission fluid as little as possible because too much transmission fluid applied to the O-ring, could cause some confusion over oil leakage.
Install an O-ring on the oil pump.

Fig 109: Identifying O-Ring On Oil Pump
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil pump assembly and oil strainer as one unit. Refer to the following or the exploded view for the tightening torque.
BOLT TABLE

No. of bolts 7

Tightening torque: 21 N.m (15 ft-lb)

Fig 110: Identifying Oil Pump Assembly And Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the input shaft.

Fig 111: Locating O-Ring On Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.
- Make sure the starting point and the ending point are about the middle between the bolts.
- Apply a double bead of sealant in sections A.

Apply the sealant to the transaxle case mounting surface of the converter housing (almost the center line of the surface).

Specified sealant: Three Bond 1216B

SPECIFIED SEALANT TABLE

L1 mm (in)	3 - 5 (0.1 - 0.2)
L2 mm (in)	2.3 (0.09)
L3 mm (in)	1.8 (0.07)

Fig 112: Applying Sealant To Transaxle Case Mounting Surface Of Converter Housing

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E20 bolts.

Install the converter housing on the transaxle case. Refer to the following or the exploded view for the tightening torque.
BOLT TABLE

No. of bolts 19

Tightening torque: 47 N.m (35 ft-lb)

Fig 113: Locating Converter Housing Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Never reuse the side oil seal.
- Apply transmission fluid to the side oil seal before installation.

Using the special tools MB992197 and MB992075, install a side oil seal.

Fig 114: Identifying Special Tools MB992197 And MB992075

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CAUTION:

Ensure that the side oil seal is installed to the specified depth shown in the table below.
Measure the installed depth of the seal at four locations diagonally. Any difference between the measurements should be no more than 0.3 mm.

TRANSAXLE CASE TABLE

On the transaxle case side

Seal depth (A) from case end face: 4.0 ± 0.5 mm (0.2 ± 0.02 in) or less

Fig 115: Identifying Seal Depth Clearance

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CAUTION:

Never reuse the side oil seal.
Apply transmission fluid to the side oil seal before installation.

Using the special tools MB992198 and MB992075, install a side oil seal.< F6AJ >

Fig 116: Identifying Special Tools MB992198 And MB992075

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CAUTION:

Ensure that the side oil seal is installed to the specified depth shown in the table below.
Measure the installed depth of the seal at four locations diagonally. Any difference between the measurements should be no more than 0.3 mm.

SEAL DEPTH REFERENCE

On the converter housing case side

Seal depth (A) from housing end face: 14.0 ± 0.5 mm (0.6 ± 0.02 in) or less

Fig 117: Identifying Seal Depth Clearance

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CAUTION:

Never reuse the O-rings.
Apply transmission fluid to the O-rings before installation.

Install an O-ring on the ATF adjusting bolt.
Install the ATF adjusting bolt on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.4 N.m (65 in-lb)

Fig 118: Identifying O-Ring And ATF Adjusting Bolt
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CAUTION:
- Never reuse the lip seals.
- Apply transmission fluid to the lip seals before installation.
Install the lip seals on the transaxle case.

Fig 119: Identifying Seals On Transaxle Case
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Install the detent spring. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 4.9 N.m (43 in-lb)

Fig 120: Identifying Detent Spring
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Install the bracket on the oil temperature sensor.
Install the oil temperature sensor on the control valve. Refer to the following view for the tightening torque.
Tightening torque: 7.9 N.m (70 in-lb)

Fig 121: Identifying Bracket And Oil Temperature Sensor
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CAUTION: Check the oil pressure switch connectors (each indicated with an arrow) for correct fit.
Install the terminal assembly on the control valve.

Fig 122: Identifying Terminal Assembly On Control Valve
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CAUTION: Apply transmission fluid to the manual valve before installation.
Install the manual valve on the control valve.

Fig 123: Identifying Manual Valve
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Press the terminal body into the transaxle case.

Fig 124: Identifying Terminal Body Into Transaxle Case
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CAUTION: Ensure that the notch in the manual valve is engaged with the lug on the manual plate.

Fig 125: Identifying Manual Valve
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Install the control valve assembly on the transaxle case.

Fig 126: Installing Control Valve Assembly On Transaxle Case
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CAUTION:
- Mounting bolt A is a hexagon head bolt.
- Mounting bolt B is a hexagon socket head bolt.

Install the control valve assembly mounting bolts A and B. Refer to the following or the exploded view for tightening torque.

BOLT CODE TABLE

Bolt code	A	B
Shank length mm (in)	71.5 (2.82)	58.0 (2.28)
No. of bolts	5	4

Tightening torque: 7.9 N.m (70 in-lb)

CAUTION:

Never reuse the control valve cover gasket.
Thoroughly clean the control valve cover gasket mounting surface of the transaxle case so that it is completely free of moisture, lubricant and the old gasket.

Fig 127: Identifying Control Valve Assembly Mounting Bolts
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Install the control valve cover gasket on the transaxle case.

Fig 128: Identifying Control Valve Cover Gasket
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Install the control valve cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.
BOLT TABLE

No. of bolts 16

Tightening torque: 9.0 N.m (80 in-lb)

Fig 129: Locating Control Valve Cover Bolts
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CAUTION: Never reuse the snap ring.
Install a snap ring on the terminal body.

Fig 130: Identifying Snap Ring
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CAUTION: Never reuse the copper washers.
Refer to the following or the exploded view for the tightening torque to install the cooler tube (OUT) onto the side cover.
Eye bolt tightening torque: 39.2 N.m (29 ft-lb)

Bracket tightening torque: 21.6 N.m (16 ft-lb)

Fig 131: Identifying Cooler Tube (OUT) And Side Cover
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CAUTION: Never reuse the copper washers.

Refer to the following or the exploded view for the tightening torque to install the cooler tube (IN) on the side cover.

Tightening torque: 39.2 N.m (29 ft-lb)

Fig 132: Identifying Cooler Tube (IN) And Side Cover

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CAUTION: Ensure that the cooler tube (IN) is against the stop on the side cover.

Fig 133: Identifying Cooler Tube (IN)

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CAUTION: Ensure that the stud bolts protrude from the case as much as indicated in the table below.

STUD BOLT CODE TABLE

Stud bolt code	1	2
Projection amount mm (in)	39.9 (1.57)	61.4 (2.42)

Install stud bolt 1 and 2 on the transaxle case.

Fig 134: Identifying Stud Bolts
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the baffle plate.
Install the baffle plate on the converter housing. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 6.6 N.m (58 in-lb)

Fig 135: Identifying O-Ring And Baffle Plate
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the pressure test port bolt.
Install the pressure test port bolt on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.4 N.m (65 in-lb)

Fig 136: Identifying O-Ring And Pressure Test Port Bolt
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the water-cooled transmission fluid cooler.

Fig 137: Identifying O-Ring And Water-Cooled Transmission Fluid Cooler
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Install the water-cooled transmission fluid cooler on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 4.3 N.m (38 in-lb)

Fig 138: Identifying Water-Cooled Transmission Fluid Cooler
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CAUTION:
- Never reuse the park/neutral position switch.
- When loosely installing the switch, insert it squarely onto the manual shaft. (Do not hold the switch at an angle.)
Install an park/neutral position switch using the following procedure.
1. Loosely install an park/neutral position switch on the manual shaft.
  
  Fig 139: Identifying Park/Neutral Position Switch
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2. Install the shift plate on the manual shaft. Refer to the following or the exploded view for the tightening torque.
  Tightening torque: 22 ± 3 N.m (17 ± 2 ft-lb)
3. Set the manual shaft to Range N.
  
  Fig 140: Identifying Shift Plate
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4. Align the hole in the park/neutral position switch with the hole in the shift plate. With the holes aligned, insert a pin (f5 mm) or equivalent through the holes. Now, tighten the bolt to the specified torque shown in the following or in the exploded view. Refer to the following or the exploded view for the tightening torque.
  Tightening torque: 5.9 N.m (52 in-lb)
  
  Fig 141: Identifying Park/Neutral Position Switch
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  CAUTION:
  - Never reuse the O-rings.
  - Apply transmission fluid to the O-rings before installation.
Install an O-ring on the turbine sensor.
Install the turbine sensor on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 142: Identifying O-Ring And Turbine Sensor
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CAUTION:
- Never reuse the O-rings.
- Apply transmission fluid to the O-rings before installation.
Install an O-ring on the vehicle speed sensor.
Install the vehicle speed sensor on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 N.m (52 in-lb)

Fig 143: Identifying O-Ring And Vehicle Speed Sensor
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CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
Install the torque converter on the transaxle. Ensure that the dimension A is to the specification.
DIMENSION TABLE

Dimension A mm (in) 11.6 (0.46)
Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the oil filler tube and oil level gage on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 11 ± 1 N.m (97 ± 8 in-lb)

Fig 144: Measuring Torque Converter Dimension A
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Install the harness bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the corrugate clamp bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)
Install the transfer on the transaxle. Refer to the following or the exploded view for the tightening torque. < W6AJ >
Tightening torque: 69 ± 9 N.m (51 ± 6 ft-lb)