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Disassembly And Assembly: Disassembly

CAUTION: Do not disassemble parts other than those described in this volume.
  1. Remove the transfer from the transaxle. < W6AJ >
  2. Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.
  3. Remove the harness bracket from the transaxle.
  4. Remove the oil filler tube and oil level gage from the transaxle.
  5. Remove the control cable bracket and breather hose from the transaxle.
  6. Remove the torque converter from the transaxle.
    Fig 1: Removing Torque Converter From Transaxle
    G05431775Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  7. Remove the vehicle speed sensor from the transaxle case.
  8. Remove the O-ring from the vehicle speed sensor.
    Fig 2: Identifying O-Ring And Vehicle Speed Sensor
    G05431776Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Remove the turbine sensor from the transaxle case.
  10. Remove the O-ring from the turbine sensor.
    Fig 3: Identifying O-Ring And Turbine Sensor
    G05431777Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  11. Remove the park/neutral position switch.
    Fig 4: Identifying Park/Neutral Position Switch
    G05431778Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  12. Remove the water-cooled transmission fluid cooler from the transaxle case.
    Fig 5: Identifying Water-Cooled Transmission Fluid Cooler
    G05431779Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Remove the O-ring from the water-cooled transmission fluid cooler.
    Fig 6: Identifying O-Ring And Water-Cooled Transmission Fluid Cooler
    G05431780Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. Remove the pressure test port bolt from the transaxle case.
  15. Remove the O-ring from the pressure test port bolt.
    Fig 7: Identifying O-Ring And Pressure Test Port Bolt
    G05431781Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Remove the baffle plate from the converter housing.
  17. Remove the O-ring from the baffle plate.
    Fig 8: Identifying O-Ring And Baffle Plate
    G05431782Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  18. Remove stud bolts from the transaxle case.
    Fig 9: Identifying Stud Bolts
    G05431783Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  19. Remove the cooler tube (IN) from the side cover.
    Fig 10: Identifying Cooler Tube (IN) And Side Cover
    G05431784Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  20. Remove the cooler tube (OUT) from the side cover.
    Fig 11: Identifying Cooler Tube (OUT) And Side Cover
    G05431785Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful not to break the terminal body.
  21. Remove the snap ring from the terminal body and push the terminal body into the transaxle case.
    Fig 12: Identifying Snap Ring
    G05431786Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  22. Remove the control valve cover from the transaxle case.
    BOLTS TABLE

    No. of bolts 16
    Fig 13: Locating Control Valve Cover Bolts
    G05431787Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  23. Remove the control valve cover gasket from the transaxle case.
    Fig 14: Identifying Control Valve Cover Gasket
    G05431788Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION:
    • Mounting bolt A is a hexagon head bolt.
    • Mounting bolt B is a hexagon socket head bolt.
  24. Remove control valve assembly mounting bolts A and B.
    BOLT CODE TABLE

    Bolt code A B
    Shank length mm (in) 71.5 (2.82) 58.0 (2.28)
    No. of bolts 5 4
    Fig 15: Identifying Control Valve Assembly Mounting Bolts
    G05431789Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Remove the control valve assembly by pulling it straight.
  25. Remove the control valve assembly from the transaxle case.
    Fig 16: Removing Control Valve Assembly From Transaxle Case
    G05431790Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Be careful not to drop the manual valve.
  26. Remove the manual valve from the control valve.
    Fig 17: Identifying Manual Valve
    G05431791Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Remove the oil temperature sensor and bracket from the control valve.
  28. Remove the bracket from the oil temperature sensor.
    Fig 18: Identifying Bracket And Oil Temperature Sensor
    G05431792Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  29. Remove the terminal assembly from the control valve.
    Fig 19: Identifying Terminal Assembly
    G05431793Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  30. Remove the detent spring.
    Fig 20: Identifying Detent Spring
    G05431794Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  31. Remove lip seals from the transaxle case.
    Fig 21: Identifying Seals
    G05431795Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not damage the manual shaft oil seal mounting surface of the transaxle case when removing the manual shaft oil seal.
  32. Using a flat-head screwdriver or equivalent, remove the manual shaft oil seal from the transaxle case.
    Fig 22: Removing Manual Shaft Oil Seal Using Flat-Head Screwdriver
    G05431796Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Remove the transmission fluid adjusting bolt from the transaxle case.
  34. Remove the O-ring from the ATF adjusting bolt.
    Fig 23: Identifying O-Ring And ATF Adjusting Bolt
    G05431797Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Mounting bolts are Torx E20 bolts.
  35. Remove converter housing mounting bolts.
    BOLT TABLE

    No. of bolts 19
    Fig 24: Locating Converter Housing Mounting Bolts
    G05431798Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Lightly tap the converter housing with a plastic hammer or equivalent to remove.
    Fig 25: Tapping Converter Housing With Plastic Hammer
    G05431799Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not damage the converter housing when removing the side oil seal.
  37. Remove the side oil seal from the converter housing using a pin punch or equivalent. < F6AJ >
    Fig 26: Removing Side Oil Seal From Converter Housing
    G05431800Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the converter housing.
    Fig 27: Identifying Special Tools MB992039 And MB990590
    G05431801Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Remove the reduction gear taper bearing shim from the converter housing.
    Fig 28: Identifying Reduction Gear Taper Bearing Shim
    G05431802Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the converter housing.
    Fig 29: Identifying Special Tools MB992039 And MB990590
    G05431803Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Remove the differential taper bearing shim from the converter housing.
    Fig 30: Identifying Differential Taper Bearing Shim
    G05431804Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  42. Remove the O-ring from the input shaft.
    Fig 31: Locating O-Ring And Input Shaft
    G05431805Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Remove the oil pump assembly and oil strainer as one unit.
    BOLT TABLE

    No. of bolts 7
    Fig 32: Identifying Oil Pump Assembly And Oil Strainer
    G05431806Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Remove the oil strainer from the oil pump assembly.
    BOLT CODE TABLE

    Bolt code A B
    Shank length mm (in) 25 (1.0) 16 (0.6)
    No. of bolts 2 1
    Fig 33: Identifying Oil Strainer Bolts
    G05431807Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  45. Remove the magnet from the oil strainer.
    Fig 34: Identifying Magnet
    G05431808Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  46. Remove the O-ring from the transaxle case.
    Fig 35: Identifying O-Ring And Transaxle Case
    G05431809Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  47. Remove the input shaft.
    Fig 36: Identifying Input Shaft
    G05431810Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  48. Remove the bearing race and needle bearing from the 3-5 reverse clutch drum.
    Fig 37: Identifying Bearing Race And Needle Bearing
    G05431811Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  49. Remove the 3-5 reverse clutch assembly.
    Fig 38: Identifying 3-5 Reverse Clutch Assembly
    G05431812Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  50. Remove the needle bearing from the FR sun gear.
    Fig 39: Identifying Needle Bearing
    G05431813Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  51. Remove the FR sun gear.
    Fig 40: Identifying FR Sun Gear
    G05431814Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  52. Remove the needle bearing from the FR sun gear.
    Fig 41: Identifying Needle Bearing And FR Sun Gear
    G05431815Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  53. Remove the FR internal gear and FR carrier as one unit.
    Fig 42: Identifying FR Internal Gear And FR Carrier
    G05431816Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. Remove the FR internal gear and needle bearing from the FR carrier.
    Fig 43: Identifying FR Internal Gear And Needle Bearing
    G05431817Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  55. Remove the low clutch assembly.
    Fig 44: Identifying Low Clutch Assembly
    G05431818Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Remove the thrust washer from the drum support.
    Fig 45: Identifying Thrust Washer
    G05431819Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. Remove the differential assembly.
    Fig 46: Identifying Differential Assembly
    G05431820Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Remove the parking plate.
    Fig 47: Identifying Parking Plate
    G05431821Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Remove the return spring.
    Fig 48: Identifying Return Spring
    G05431822Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  60. Remove the parking shaft.
    Fig 49: Locating Parking Shaft
    G05431823Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Remove the parking pawl.
    Fig 50: Identifying Parking Pawl
    G05431824Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  62. Remove the reduction gear lubrication tube.
    Fig 51: Identifying Reduction Gear Lubrication Tube
    G05431825Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  63. Remove the reduction gear assembly.
    Fig 52: Identifying Reduction Gear Assembly
    G05431826Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Mounting bolts are Torx E16 bolts.
  64. Remove the side cover.
    BOLT TABLE

    No. of bolts 14
    Fig 53: Identifying Side Cover And Bolts
    G05431827Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Remove the spacer and needle bearing from the side cover.
    Fig 54: Identifying Spacer And Needle Bearing
    G05431828Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  66. Remove the O-ring from the transaxle case.
    Fig 55: Identifying O-Ring And Transaxle Case
    G05431829Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  67. Remove the high clutch assembly.
    Fig 56: Identifying High Clutch Assembly
    G05431830Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  68. Remove the reduction sun gear.
    Fig 57: Identifying Reduction Sun Gear
    G05431831Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  69. Remove the reduction carrier.
    Fig 58: Identifying Reduction Carrier
    G05431832Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  70. Remove the needle bearing from the reduction internal gear.
    Fig 59: Identifying Needle Bearing And Reduction Internal Gear
    G05431833Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Remove the reduction internal gear from the high clutch hub.
    Fig 60: Identifying Reduction Internal Gear
    G05431834Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Remove the needle bearing from the reduction internal gear.
    Fig 61: Identifying Needle Bearing And Reduction Internal Gear
    G05431835Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Remove the high clutch hub.
    Fig 62: Identifying High Clutch Hub
    G05431836Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  74. Remove the needle bearing from the RR sun gear on the rear side.
    Fig 63: Identifying Needle Bearing And RR Sun Gear
    G05431837Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  75. Remove the RR sun gear on the rear side.
    Fig 64: Identifying RR Sun Gear
    G05431838Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  76. Remove the needle bearing from the RR carrier assembly.
    Fig 65: Identifying Needle Bearing And RR Carrier Assembly
    G05431839Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
  77. Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.
    Fig 66: Identifying Brake Retaining Plate, Drive Plate And Driven Plate
    G05431840Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  78. Using a flat-head screwdriver or equivalent, remove the snap ring.
    Fig 67: Removing Snap Ring Using Flat-Head Screwdriver
    G05431841Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  79. Remove the one-way clutch and RR carrier assembly as one unit.
    Fig 68: Identifying One-Way Clutch And RR Carrier Assembly
    G05431842Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. Separate the one-way clutch and RR carrier assembly.
    Fig 69: Identifying One-Way Clutch And RR Carrier Assembly
    G05431843Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  81. Remove the needle bearing from the RR carrier assembly.
    Fig 70: Identifying Needle Bearing And RR Carrier Assembly
    G05431844Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Using a flat-head screwdriver or equivalent, remove the snap ring.
    Fig 71: Removing Snap Ring
    G05431845Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
  83. Remove the low-reverse brake retaining plate, drive plate and driven plate.
    Fig 72: Identifying Low-Reverse Brake Retaining Plate, Drive Plate And Driven Plate
    G05431846Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  84. Remove the RR sun gear on the front side.
    Fig 73: Identifying RR Sun Gear
    G05431847Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  85. Remove the bearing race from the RR sun gear on the front side.
    Fig 74: Identifying Bearing Race And RR Sun Gear
    G05431848Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  86. Remove the needle bearing.
    Fig 75: Identifying Needle Bearing
    G05431849Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  87. Using the special tool MB992195, remove the snap ring.
    Fig 76: Identifying Special Tool MB992195
    G05431850Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  88. Remove the diaphragm spring retainer.
    Fig 77: Identifying Diaphragm Spring Retainer
    G05431851Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Remove the diaphragm spring.
    Fig 78: Identifying Diaphragm Spring
    G05431852Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.
  90. Feed air through the oil hole as indicated below to remove the low-reverse brake piston from the transaxle case.
    Fig 79: Identifying Low-Reverse Brake Piston
    G05431853Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  91. Remove D-rings from the low-reverse brake piston.
    Fig 80: Identifying D-Ring
    G05431854Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Mounting bolts are Torx E18 bolts.
  92. Remove the Output gear set.
    BOLT TABLE

    No. of bolts 10
    Fig 81: Identifying Output Gear Set Bolts
    G05431855Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  93. Remove the O-ring from the transaxle case.
    Fig 82: Identifying O-Ring And Transaxle Case
    G05431856Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    CAUTION: Do not damage the transaxle case when removing the side oil seal.
  94. Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.
    Fig 83: Removing Side Oil Seal From Transaxle Case
    G05431857Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  95. Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the transaxle case equivalent.
    Fig 84: Identifying Special Tools MB992039 And MB990590
    G05431858Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  96. Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the transaxle case.
    Fig 85: Identifying Special Tools MB992039 And MB990590
    G05431859Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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