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.

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
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Tighten the eight mounting bolts of the transfer drive gear bearing to the specified torque.
Tightening torque: 33.5 ± 2.5 N.m (25 ± 1 ft-lb)

Fig 2: Removing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
Fit a new O-ring into the groove of one-way clutch inner race.
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: Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Put the snap ring on the inner race.
Set special tools MD998338 and MD998924 as shown in the illustration, and then compress the one-way clutch inner race and install the snap ring.

Fig 4: Using Special Tools MD998338 And MD998924
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring onto the low-reverse brake piston.

Fig 5: Installing Wave Spring Onto Low-Reverse Brake Piston
Courtesy 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.
Install the five brake discs, five brake plates and snap ring as shown in the illustration.
NOTE: Do not install the pressure plate at this time.

Fig 6: Installing Five Brake Discs, Five Brake Plates And Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MB991632, brake disc, reaction plate and used snap ring.

Fig 7: Installing Special Tool MB991632, Brake Disc And Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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)

(For brake reaction plate end play)
Install the four brake discs and four brake plates.

Fig 8: Measuring End Play Of Reaction Plate By Moving Special Tool
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Place special tool MB991632 on top of the brake disc in place of the pressure plate.
Install the return spring, second brake piston and snap ring.

Fig 9: Installing Return Spring, Second Brake Piston And Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move special tool MB991632 and measure its movement.
Standard value (Reference):

1.09 - 1.55 mm (0.0429 - 0.0610 inch)

(For second brake end play)

Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

Fig 10: Measuring Special Tool Movements Using Dial Indicator

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE

PRESSURE PLATE 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

Fig 11: Checking Standard Value Of End Play

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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 (Reference):

1.65 - 2.11 mm (0.050 - 0.0831 inch)

(For low-reverse brake end play)

Fig 12: Special Tool Installation Position
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

Fig 13: Checking Standard Value Of End Play Using Special Tool

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

PRESSURE PLATE

PRESSURE PLATE THICKNESS

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

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.
Install the snap ring into the groove of transaxle case output shaft bore.
Install the thinnest output shaft preload adjustment spacer [thickness 1.88 mm (0.0740 in); part number MD756579].
Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.

Fig 14: Taping Output Shaft Bearing Outer Race In Transaxle Case
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not reuse the bolt, as it has had sealant applied.
Tighten the mounting bolts of the output shaft to the specified torque.
Tightening torque: 54 ± 5 N.m (40 ± 4 ft-lb)

Fig 15: Removing Output Shaft Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MD998323 to install the collar and taper roller bearing on the output shaft.

Fig 16: Installing Collar And Taper Roller Bearing On Output Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Apply ATF to a new locking nut, and use special tools MB990607 and MB991625 to tighten the locking 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 locking nut is reverse threaded.

Fig 17: Removing Output Shaft Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Move the output shaft to measure the end play and record the measurement value.
Standard value (reference):

0.01 - 0.09 mm (0.0004 - 0.0035 inch)

(For output shaft end play)
Remove the parts that were installed in steps 21 to 25.

Fig 18: Measuring Output Shaft End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
NOTE: * is the thickness of the spacer installed in step 21. ** is the preload of the output shaft.
Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 27.
Stake the locking nut with a punch (two places).

Fig 19: Staking Jam Nut
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.

Fig 20: Installing Cap With Special Tools MB990931 And MB990938
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

Fig 21: Installing Parking Pawl Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the parking roller support, and then insert the two parking roller support shafts.

Fig 22: Installing Parking Roller Support Shafts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

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

Fig 23: Thrust Bearing, Thrust Races And Thrust Washers

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SYMBOL REFERENCE

SYMBOL	OD mm (in)	ID mm (in)	THICKNESS mm (in)
NO. 1	59 (2.32)	47 (1.85)	1.8 (0.071)
	59 (2.32)	47 (1.85)	2.0 (0.079)
	59 (2.32)	47 (1.85)	2.2 (0.087)
	59 (2.32)	47 (1.85)	2.4 (0.094)
	59 (2.32)	47 (1.85)	2.6 (0.102)
	59 (2.32)	47 (1.85)	2.8 (0.110)
NO. 2	49 (1.93)	34 (1.34)	3.6 (0.142)
NO. 3	57 (1.93)	38.5 (1.34)	4.12 (0.142)
NO. 4	55.4 (1.783)	38.5 (1.22)	3.31 (0.130)
NO. 5	57 (1.93)	38.5 (1.34)	4.12 (0.142)
NO. 6	57 (1.93)	38.5 (1.34)	4.12 (0.142)
NO. 7	59 (2.32)	37 (1.46)	2.8 (0.110)
NO. 8	48.9 (1.925)	37 (1.46)	1.6 (0.063)
	48.9 (1.925)	37 (1.46)	1.7 (0.067)
	48.9 (1.925)	37 (1.46)	1.8 (0.071)
	48.9 (1.925)	37 (1.46)	1.9 (0.075)
	48.9 (1.925)	37 (1.46)	2.0 (0.079)
	48.9 (1.925)	37 (1.46)	2.1 (0.083)
	48.9 (1.925)	37 (1.46)	2.2 (0.087)
	48.9 (1.925)	37 (1.46)	2.3 (0.091)
	48.9 (1.925)	37 (1.46)	2.4 (0.094)
	48.9 (1.925)	37 (1.46)	2.5 (0.098)
	48.9 (1.925)	37 (1.46)	2.6 (0.102)

Install the planetary carrier assembly.

Fig 24: Removing Planetary Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the planetary reverse sun gear.

Fig 25: Removing Planetary Reverse Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the wave spring on the low-reverse brake piston.

Fig 26: Installing Wave Spring On Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 27: Installing Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 28: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reaction plate.

Fig 29: Installing Reaction Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring that was selected in step 12.

Fig 30: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 31: Installing Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the return spring and second brake piston.

Fig 32: Installing Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the snap ring.

Fig 33: Installing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.

Fig 34: Installing Thrust Bearing Number 5
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Use care to install the thrust bearing in the proper direction.
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 35: Installing Thrust Bearing Number 6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the reverse and overdrive clutch.
CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.

Fig 36: Installing Thrust Bearing Number 7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
Install the four seal rings in the grooves of the rear cover.

Fig 37: Four Seal Rings In Grooves Of Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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.
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)
  
  (For underdrive sun gear end play)
6. After taking the measurements in steps ( 1) to ( 4), take out the installed parts.
  
  Fig 38: Measuring End Play
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the three O-rings.

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.

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)

Fig 39: Removing O-rings

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 2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Part No. 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 40: Applying Sealant Of Rear Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 41: Tightening Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the underdrive clutch hub to the underdrive sun gear.

Fig 42: Removing Underdrive Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown in the illustration.
Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.

Fig 43: Installing Thrust Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Hold the input shaft, and install the underdrive clutch.
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 .)

Fig 44: Removing Underdrive Clutch And Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install thrust washer number 1 that was selected in step ( 69) on the underdrive clutch retainer.

Fig 45: Thrust Washer Number 1
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install special tool MD998412 as shown in the illustration.
Install the oil pump to the transaxle case.
NOTE: Do not install the oil pump gasket at this time.
Tighten the oil pump mounting bolts (six pieces) to the specified torque.
Tightening torque: 29 ± 2 N.m (21 ± 1 ft-lb)

Fig 46: Installing Special Tool MD998412
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Make sure that the input shaft end play meets the standard value.
Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch)

(For input shaft end play)

Fig 47: Measuring End Play
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the oil filter.

Fig 48: Removing Oil Filter
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990936 and MB990938 <F4A5A> or MB990935 and MB990938 <W4A5A> to press the differential bearing outer race into the transaxle case.

Fig 49: Taping Differential Bearing Outer Race In Transaxle Case (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 50: Pressing Differential Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the differential.
Adjustment of differential case preload and select the spacer. (Refer to SPACER SELECTION FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD .)

Fig 51: Removing Differential
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the selected spacer to the torque converter housing.

Fig 52: Locating Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Use special tools MB990936 and MB990938 <F4A5A> or MB991445 <W4A5A> to press the differential bearing outer race into the torque converter housing.

Fig 53: Pressing Differential Bearing Outer Race Into Torque Converter Housing (F4A5A)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 54: Pressing Differential Bearing Outer Race Into Torque Converter Housing (W4A5A)
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 2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Part No. MD974421 or equivalent) to the torque converter housing in the area shown in the illustration.
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 55: Applying Sealant Into Torque Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the two O-rings.

Fig 56: Removing O-rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the torque converter housing and then tighten its 20 mounting bolts to the specified torque.
Tightening torque: 48 ± 6 N.m (35 ± 4 ft-lb)

Fig 57: Removing Torque Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert the two O-rings into the grooves of the manual control lever shaft.
Install the manual control lever shaft and parking pawl rod.
Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A."

Fig 58: Installing Manual Control Lever Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert the new seal rings in the grooves of the accumulator pistons.
NOTE: The piston and seal ring are common parts.

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 59: Accumulator Spring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

ITEM REFERENCE

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 60: Removing Accumulator Piston And Spring

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Install the strainer and second brake retainer oil seal.

Fig 61: Removing Strainer And Second Brake Retainer Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert a new O-ring to the groove of the solenoid valve harness connector.
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 62: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
Install the valve body 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 63: Removing Valve Body
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the 27 valve body mounting bolts, and tighten to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)

Fig 64: Installing Valve Body Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Attach the solenoid valve harness to the valve body by connecting all the connectors.

Fig 65: Attaching Solenoid Valve Harness To Valve Body

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

SOLENOID VALVE HARNESS CHART

NO.	PARTS TO BE CONNECTED	SOLENOID VALVE HARNESS
NO.	PARTS TO BE CONNECTED	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

Install the fluid temperature sensor and then tighten its mounting bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6.0 ± 1.0 N.m (53 ± 9 in-lb)

Fig 66: Removing Manual Control Shaft Detent
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 2 mm (0.08 inch) diameter bead of sealant (Mitsubishi Part No. MD974421 or equivalent) to the valve body cover in the area shown in the illustration.
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 67: Applying Sealant To Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the valve body cover, and then tighten its mounting bolts to the the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)

Fig 68: Removing Valve Body Cover
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Install the park/neutral position switch and tighten the bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the manual control lever and tighten the nut to the specified torque.
Tightening torque: 21.5 ± 3.5 N.m (16 ± 2 ft-lb)

Fig 69: Removing Manual Control Lever
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
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 (97 ± 9 in-lb)

Fig 70: Removing Input Shaft Speed Sensor And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Press Face "A" of the air breather to be even with Face "B" of the transmission case as shown in the illustration.
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)
Tighten the oil cooler feed pipe clamp bolt to the specified torque.
Tightening torque: 11 ± 1 N.m (97 ± 9 in-lb)
Install the oil dipstick.
Install the control cable support bracket.
Tightening torque: 23 ± 3 N.m (17 ± 2 ft-lb)
Install the roll stopper brackets.
Tightening torque: 90 ± 10 N.m (66 ± 7 ft-lb)

Fig 71: Installing Roll Stopper Brackets
Courtesy 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.
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)
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 72: Torque Converter Dimension
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.