Part 1
TRANSAXLEDISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
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, rotating parts, and sliding parts before installation. 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.
1. 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.
2. Tighten the mounting bolts (eight pieces) of the transfer drive gear bearing to the specified torque.
Tightening torque: 34 ± 2 Nm (25 ± 1 ft-lb)
3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
4. Fit a new O-ring into the groove of one-way clutch inner race.
5. 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.
6. Put the snap ring on the inner race.
7. Set special tools MD999577 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.
8. Install the wave spring onto the low-reverse brake piston.
9. Install the brake discs (six pieces), brake plates (five pieces) and snap ring as shown in the figure.
NOTE: Do not install the pressure plate at this time.
10. Install special tool MB991632 on the brake disc.
11. Install the reaction plate and the used snap ring.
12. 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)
13. Install the brake discs (four pieces) and brake plates (three pieces) as shown in the figure.
NOTE: Do not install the pressure plate at this time.
14. Place special tool MB991632 on top of the brake disc in place of the pressure plate.
15. Install the return spring, second brake piston and snap ring.
16. Move special tool M B991632 and measure its movement.
Standard value of end play (Reference): 1.09 -1.55 mm (0.0429 -0.0610 inch)
17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
PRESSURE PLATE FOR SECOND BRAKE:
PRESSURE PLATE FOR SECOND BRAKE
18. 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 of end play (Reference): 1.65 -2.11 mm (0.0649 -0.0831 inch)
19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.
PRESSURE PLATE FOR LOW-REVERSE BRAKE (Part 1):
PRESSURE PLATE FOR LOW-REVERSE BRAKE (Part 2):
PRESSURE PLATE FOR LOW-REVERSE BRAKE
CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.
20. Remove all parts and special tools that were installed to take the measurements in steps 9 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.
21. Install the needle bearing as shown in the illustration.
22. Install the two seal rings.
23. Install the snap ring into the groove of transaxle case output shaft bore.
24. Install the snap ring.
25. Install the planetary carrier assembly.
26. Install the planetary reverse sun gear.
27. Install the wave spring on the low-reverse brake piston.
28. Install the pressure plate that was selected in step 19. Next, install brake discs (six pieces) and brake plates (five pieces), one on top of the other.
29. Install the snap ring.
30. Install the reaction plate.
31. Install the snap ring that was selected in step 12.
32. Install second brake discs (four pieces) and second brake plates (three pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.
33. Install the return spring and second brake piston.
34. Install the snap ring.
IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS (Part 1):
IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS (Part 2):
IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS
CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
35. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
CAUTION: Use care to install the thrust bearing in the proper direction.
36. 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.
37. Install the reverse and overdrive clutch.
CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
38. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
39. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
40. Install the seal rings (four pieces) in the grooves of the rear cover.
41. 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-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)
(6) After taking the measurement in steps (5), take out the installed parts in steps (1) through (4).
42. Install the O-rings (six pieces).
43. Install the direct clutch accumulator piston and spring and then install the O-ring.
NOTE: Accumulator spring is identified as shown in the illustration.
44. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 40 from the table above. Install it on thrust bearing number 7.
45. 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). Leaks will occur if the rear cover is installed after the sealant dries.
46. Install the rear cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
NOTE: After installation, keep the sealed area away from ATF for approximately one hour.
CAUTION: Install the thrust bearing with the indicated side facing down.
47. Install the thrust race number 12 and thrust bearing number 11.
48. Finger-tighten the anchor plug and a new O-ring, then install the reduction brake band and direct clutch simultaneously.
49. Make sure that the direct clutch can be rotated only in the direction indicated in the illustration.
NOTE: If the clutch can be rotated in the other direction, remove and reinstall it correctly.
