Remanufactured A/T Replacement Procedures

If diagnosis reveals that the automatic transmission must be replaced with a remanufactured unit, follow the steps to obtain a replacement unit and return the core.

NOTE:
This process supersedes the process described in TSB 91-23-014 dated July 1991 for the KM175 automatic transaxle.

1. Place an order with your facing PDC for a remanufactured transmission.

2. When the reman unit arrives, verify that it is identical to the one being removed.

3. Remove the old transmission (core) and install the remanufactured unit into the vehicle as described in Section 23 of the appropriate service manual.





4. Reverse flush the A/T oil cooler and lines as follows. This will prevent the replacement transmission from overheating and from becoming contaminated with the old automatic transmission fluid (ATF), which could contain debris (e.g., metal particles, sludged oil).

a. A transmission cooler flusher (Mitsubishi Equipment # MLR6906 or equivalent) is recommended. Follow the manufacturer's operating instructions.

b. Locate the ATF cooler lines at the top of the transaxle housing. The outlet (pressure) line is secured to the nipple closest to the radiator. The inlet (return) line is secured to the nipple closest to the bulkhead.

c. Remove the ATF cooler line closest to the radiator and place it into a container large enough to collect 2-3 quarts of ATF.

d. Remove the other ATF cooler line and install it into the nipple closest to the radiator. This will back flush the ATF oil cooler.





e. With the parking brake set, the engine off, and the gear selector in neutral, add ATF to bring the ATF level to the HOT mark on the A/T dipstick.

f. Start the engine, allow to idle for five seconds, then immediately turn the key to OFF. Add ATF to bring the ATF level back to the HOT dipstick mark.

g. Repeat step e. until there are approximately 2-3 quarts of ATF in the container.

h. Reconnect the oil cooler lines to their original locations.

i. Add ATF to bring the ATF level back to the HOT dipstick mark.

j. With the gear selector still in neutral, start the engine and allow to idle until the ATF reaches operating temperature of 65-82°C (150-180°F).

k. Apply the service brakes and move the gear selector through every gear position. This will fill each of the A/T hydraulic circuits with ATF. Then return the gear selector to neutral.

l. Add ATF as necessary to bring the ATF level back to the HOT dipstick mark.





5. If the core is equipped with dowel pins, remove them and install them onto the back of the engine block.

6. Drain all fluids from the removed transmission.

7. Install the torque converter and converter retention bracket. Be sure to use the proper bolts to install the torque converter to the flex plate. Depending the model and transmission production date, two different thread pitches are used (1.25 mm and 1.5 mm).

8. Install the original dipstick and tube to the core. Do not attempt to install the core's dipstick into the replacement unit.

9. Install all shipping plugs to prevent residual fluid leakage.

10. Place the core into the case in which the remanufactured transmission was shipped.





11. Ensure that all components are returned and attached properly to the core, e.g. dipstick, dipstick tube, inhibitor switch, pulse generators, etc. Cores received at the remanufacturing facility with missing and/or disassembled components will result in a warranty claim debit to the dealer. The chart lists the debit amounts that will be incurred if the core is not returned properly.

12. Complete the Diagnostic Worksheet/Core Tag included with the remanufactured transmission and attach it to the core's bell housing. Maintain a copy of the Diagnostic Worksheet/Core Tag for your records.

13. Prepare the shipping carton for shipment to the Remanufacturing Facility.

14. Using the supplied and pre-addressed shipping label and bill of lading, ship the core to the remanufacturing facility:

Component Remanufacturing Specialists
400 Corporate Drive
Mahwah, NJ 07430

You must use the designated carrier for your area.

NOTE:
The core must be returned as soon as possible. Do not wait for a letter from MMSA for a warranty claim number. You have 30 days from the date of repair to return the core whether or not it was replaced under warranty. The entire claim will be debited if C.R.S. does not receive the core within 30 days of the repair.

15. Install the remanufactured unit into the vehicle. Then fill it with ATF as described in Steps 4e. and 4f. before starting the engine.