Part 2

ASSEMBLY (continued)

50. Tighten the anchor plug to the specified torque.

Tightening torque: 98 ± 15 Nm (72 ± 11 ft-lb)





51. Install the direct planetary carrier assembly.





52. Install the reduction brake spring and piston in position in the transmission case, then install the snap ring.





53. Adjust the reduction brake piston using the following procedure:
1) Remove the nut from the reduction brake piston.
2) Install the stopper of the special tool MB991633 to hold the reduction brake piston against rotation.





3) Using a torque wrench fitted with the socket of the special tool MB991633, tighten the adjusting rod to 10 Nm (89 in-lb), then loosen it. Repeat this operation twice. Tighten the adjusting rod to 5 Nm (43 in-lb), then turn it back 5-1/2 (180 degrees) to 5-3/4 (270 degrees) turns.





4) Install the nut on the adjusting rod and tighten the nut to 19 ± 3 Nm (14 ± 2 ft-lb) using the wrench of the special tool MB991633.





54. Install the reduction brake piston cover and snap ring.





55. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.





56. Install the parking roller support, and then insert the parking roller support shafts (two pieces).





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

CAUTION
Be sure to install the thrust bearing in the correct direction as shown.





58. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.





59. Hold the input shaft, and install the underdrive clutch.
60. Adjustment of input shaft end play and select the thrust washer number 1.





61. Install special tool MD998412 as shown.
62. Install the new oil pump gasket on the transaxle case.
63. Install the oil pump and tighten the six mounting bolts to the specified torque.

Tightening torque: 29 ± 2 Nm (21 ± 1 ft-lb)





64. Make sure that the input shaft end play meets the standard value.

Standard value of end play: 0.70 - 1.45 mm (0.028 - 0.057 inch)





65. Install the pipe clamp bolts (two places), and tighten to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)





66. Install the oil filter.





67. Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.





68. Install the differential.
69. Adjustment of differential case preload and select the spacer.





70. Install the selected spacer to the torque converter housing.





71. Use special tools MB990936 and MB990938 to tap the differential bearing outer race in the transaxle case.





72. Use special tools MB991445 to press the outer race into housing.





73. Apply a 1.6 mm (0.06 inch) diameter bead of sealant to the torque converter housing in the area shown.

Specified sealant: Mitsubishi Part No. MD974421 or equivalent

NOTE: Be sure to install the case quickly while the sealant is wet (with 15 minutes). Leaks will occur if the rear cover is installed after the sealant dries.

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





74. Install the O-rings (two pieces).





75. Install the torque converter housing and then tighten its mounting bolts (twenty pieces) to the specified torque.

Tightening torque: 48 ± 6 Nm (35 ± 4 ft-lb)

76. Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
77. Install the manual control lever shaft and parking pawl rod.





78. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A."
79. Insert the new seal rings in the grooves of the accumulator pistons.

NOTE: The piston and seal ring are common parts.





80. Install the piston and spring of the reduction brake accumulator, then install the accumulator cover.





81. 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.











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





83. Insert a new O-ring to the groove of the solenoid valve harness connector.
84. 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.





85. Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
86. 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.





87. Install the valve body mounting bolts (twenty seven pieces), and tighten to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)





88. Attach the solenoid valve harness to the valve body by connecting all the connectors.
89. Install the fluid temperature sensor to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)








90. Install the manual control shaft detent and tighten the bolt to the specified torque.

Tightening torque: 6.0 ± 1.0 Nm (53 ± 9 in-lb)





91. Apply a 2.4 - 2.6 mm (0.09 - 0.10 inch) diameter bead of sealant or equivalent) to the valve body cover in the area shown.
Specified sealant: Mitsubishi Part No. MD974421 or equivalent

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 ATF for approximately one hour.





92. Install the valve body cover, and then tighten its mounting bolts to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)





93. Press Face "A" of the air breather to be on the same plane as the Face "B" of the transaxle case as shown in the illustration.





94. Install the park/neutral position switch and tighten the bolt to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)

95. Install the manual control lever and tighten the nut to the specified torque.

Tightening torque: 22 ± 3 Nm (16 ± 2 ft-lb)





96. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)

97. 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 Nm (18 ± 2 ft-lb)

98. Tighten the oil cooler feed tube clamp bolt to the specified torque.

Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)

99. Install the oil dipstick.
100. Install the control cable support brackets to the specified torque.

Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)

101. Install the roll stopper brackets.

Tightening torque: 70 ± 10 Nm (52 ± 7 ft-lb)

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.





102. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value.

Reference value: Approximately 9.4 mm (0.37 inch)

ADJUSTMENT OF TRANSAXLE

THRUST WASHER SELECTION FOR ADJUSTMENT OF INPUT SHAFT END PLAY

[Measurement using a Solder]

CAUTION
^ If solder is not available, select the thrust washer in accordance with Plastigage method.
^ If the thrust washer appropriate for the standard value cannot be selected using solder, select the thrust washer in accordance with Plastigage method.





1. Put solders (1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long) in the illustrated positions of the underdrive clutch retainer.
2. Install the adjusting thrust washer having minimum thickness.

CAUTION
Never use a gasket that has been tightened.





3. Use the special tool MD998412 to install a new oil pump gasket and the oil pump. Tighten the oil pump mounting bolts to the specified torque.

Tightening torque: 29 ± 2 Nm (21 ± 2 in-lb)

4. Remove the oil pump mounting bolts.





5. Using special tools MD998333, remove the oil pump and then take out crushed solders.
6. If the solders have not crushed, use thicker thrust washer and repeat steps 3 to 5.





7. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
8. Select the thrust washer, calculated by the following formula, in the table.
T = T1 + T2
T: Clearance mm
T1: The crushed solder thickness mm
T2: The thrust washer thickness used for measurement mm

Available thrust washer





[Measurement using Plastigage]





1. Put Plastigage (about 10 mm (0.039 inch) long) in the illustrated positions of the underdrive clutch retainer.
2. Install the adjusting thrust washer having the minimum thickness.

CAUTION
Never use a gasket that has been tightened.





3. Use the special tool MD998412 to install a new oil pump gasket and the oil pump. Tighten the oil pump mounting bolts to the specified torque.

Tightening torque: 29 ± 2 Nm (21 ± 1 ft-lb)

4. Remove the oil pump mounting bolts.





5. Using special tools MD998333, remove the oil pump and then take out crushed Plastigages.
6. If the Plastigages have not crushed, use thicker adjusting thrust washer and repeat steps 3 to 5.





7. Measure the width of the crushed Plastigage at its widest part using a scale printed on the Plastigage package.
8. Select the thrust washer, calculated by the following formula, in the table.
T = T3 + T2
T: Clearance mm
T3: The crushed Plastigage thickness mm
T2: The thrust washer thickness used for measurement mm

Available thrust washer





SPACER SELECTION FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD

[Measurement using a Solder]

CAUTION
^ If solder is not available, select the spacer in accordance with Plastigage method.
^ If the spacer appropriate for the standard value cannot be selected using solder, select the spacer in accordance with Plastigage method.





1. Put solders (1.0 mm (0.039 inch) diameter, about 10 mm (0.39 inch) long) in the illustrated positions of the converter housing.





2. Use special tools MB991445 to press the outer race into housing.





3. 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-lb)

4. Remove the bolts and converter housing, and take out the solder pieces.
5. If the solders have not crushed, use thicker solders (1.6 mm (0.063 inch) diameter, about 10 mm (0.39 inch) long) and repeat steps 2 to 4.





6. Measure the thickness of the crushed solder with a micrometer, and then select a spacer that will provide the standard value.

Spacer thickness: (T1 - 0.045 mm (0.0018 inch) to (T1 - 0.105 mm (0.0041 inch)
T1: The crushed solder thickness mm (inch)

Standard value of preload: 0.045 - 0.105 mm (0.0018 - 0.0041 inch)

[Measurement using Plastigage]





1. Put Plastigage (about 10 mm (0.39 inch) long) in the illustrated positions of the converter housing.
2. Install the adjusting spacer having the minimum thickness.





3. Use special tools MB991445 to press the outer race into housing.





4. 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-lb)

5. Remove the bolts and converter housing, and take out crushed Plastigage.
6. If the Plastigages have not crushed, replace the spacer with a thicker one and repeat steps 3 to 5.





7. Measure the width of the crushed Plastigage at its widest part using a scale printed on the Plastigage package, and then select a spacer that will provide the standard value.

Spacer thickness: (T3 - 0.045 mm (0.0018 inch) to (T3 - 0.105 mm (0.0041 inch)
T3: The crushed Plastigage thickness mm (inch)

Standard value of preload: 0.045 - 0.105 mm (0.0018 - 0.0041 inch)