Part 2 of 2

REASSEMBLY

CAUTION:
^ Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
^ Do not use grease, use petroleum jelly (i.e. Vaseline).
^ Apply ATF to friction components, rooting parts, and sliding parts before inflation. Immerse new clutch discs or brake discs 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.





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 Nm (17 ± 2 ft. lbs.)
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)
6. After taking the measurement in step (5), take out the installed parts in steps (1) through (4).





52. Install the three O-rings.








53. Select a number 8 thrust race whose thickness corresponds to the measured values taken in step 51 from the table. Install it on thrust bearing number 7.





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) or leaks will occur if the rear cover is installed after the sealant dries.





55. Install the rear cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)

NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.





56. Install the underdrive clutch hub to the underdrive sun gear.





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.





58. Hold the input shaft, and install the underdrive clutch.





59. Place two beads of solder [each 10 mm (0.39 inch) in length, 3.5 mm (0.14 inch) in diameter] on the underdrive clutch retainer as shown in the illustration.





60. Install special tool MD998412 in the illustrated place.
61. Install the oil pump to the transaxle case.

NOTE: Do not install the oil pump gasket at this time.

62. Tighten the oil pump mounting bolts (six pieces) to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)





63. Remove the oil pump mounting bolts.
64. Using special tools MD998333, remove the oil pump and the crushed solders.








65. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
66. Select a thrust washer number 1 whose thickness corresponds to the measured value from table.





67. Install thrust washer number 1 that was selected in step 66 on the underdrive clutch retainer.





68. Install special tool MD998412 in the illustrated place.
69. Install the new oil pump gasket on the transaxle case.
70. Install the oil pump and tighten the mounting bolts (six pieces) to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)





71. Make sure that the input shaft end play meets the standard value.
Standard value: 0.70 - 1.45 mm (0.028 - 0.057 inch)





72. Install the oil triter.





73. Use special tools MB990935 and MB990938 to tap the differential bearing outer race in the transaxle case.





74. Install the differential.





75. Place two beads of solder [each 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter] on the torque converter housing as shown in the illustration.





76. Use special tools MB990935 and MB990938 to press in the differential bearing outer race into the torque converter housing.





77. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.
Tightening torque: 48 ± 6 Nm (35 ± 4 ft. lbs.)
78. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.





79. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value. Add 0.045 to 0.105 mm (0.0018 to 0.0041 inch)* to the measured value and select a spacer with the corresponding thickness. Adjustment spacer sizes. Select the most suitable one from among those listed.

NOTE: * is the thickness for the differential case preload.





80. Install the spacer selected in step 79 to the torque converter housing.
81. Use special tools MB990935 and MB990938 to press the outer race into housing.





82. 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) or leaks will occur if the rear cover is installed after the sealant dries.

NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.





83. Install the two O-rings.





84. Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque.
Tightening torque: 48 ± 6 Nm (35 ± 4 ft. lbs.)





85. Insert the two O-rings into the grooves of the manual control lever shaft.
86. Install the manual control lever shaft and parking pawl rod.
87. Align hole "A" with the groove in the manual control lever shaft. insert the manual control lever shaft roller into hole "A".
88. Insert the new seal rings in the grooves of the accumulator pistons.

NOTE: The piston and seal ring are common parts.











89. 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.





90. Install the strainer and second brake retainer oil seal.





91. Insert a new O-ring to the groove of the solenoid valve harness connector.
92. 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.





93. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
94. 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.





95. Install the 27 valve body mounting bolts, and tighten to the specified torque.
Tightening torque: 11 ± 1 Nm (95 ± 9 ft. lbs.)








96. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.





97. Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6 ± 1 Nm (52 ± 9 inch lbs.)





98. 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) or leaks will occur if the rear cover is installed after the sealant dries.

NOTE: After installation, keep the sealed area away from the ATF for approximately one hour.





99. Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Tightening torque: 11 ± 1 Nm (95 ± 9 inch lbs.)





100. Install the Sealing cap and tighten the bolt to the specified torque.
Tightening torque: 5 ± 1 Nm (43 ± 9 inch lbs.)





101. Install the park/neutral position switch and tighten the bolt to specified torque.
Tightening torque: 11 ± 1 Nm (95 ± 9 inch lbs.)





102. Install the manual control lever and tighten the nut to specified torque.
Tightening torque: 22 ± 3 Nm (16 ± 2 ft. lbs.)
103. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
Tightening torque: 11 ± 1 Nm (95 ± 9 inch lbs.)
104. Install the oil cooler feed tube together with new gaskets and tighten the eye bolts to the specified torque.
Tightening torque: 30 ± 3 Nm (22 ± 2 ft. lbs.)
105. Tighten the oil cooler feed pipe clamp bolt.
Tightening torque: 11 ± 1 Nm (95 ± 9 inch lbs.)
106. Install the oil dipstick.
107. Install the cable support bracket.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)
108. Install the roll stopper brackets.
Tightening torque: 69 ± 10 Nm (51 ± 7 ft. lbs.)





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.

109. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value.
Reference value: Approximately 12.2 mm (0.48 inch)