Part 3

DISASSEMBLY AND ASSEMBLY (Continued)

49. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 47 from the table below. Install it on thrust bearing number 7.









50.
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 1.6 mm (0.06 inch) diameter bead of sealant to the illustrated position of the rear cover.
Specified sealant:
Mitsubishi Part No. MD974421 or equivalent
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.





51. Install the rear cover, and tighten its mounting bolts to the specified torque.
Tightening torque: 23± 3Nm (17± 2 ft-lb)
NOTE:
After installation, keep the sealed area away from ATF for approximately one hour.





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





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





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





55.
CAUTION:
Be sure to install the thrust bearing in the correct direction as shown.

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





56. Hold the input shaft, and install the underdrive clutch.
57. Adjustment of input shaft end play and select the thrust washer number 1. (Refer to adjustment of transaxle - thrust washer selection for adjustment of input shaft end play Adjustment of Transaxle.)





58. Install special tool MD998412 as shown.
59. Install the oil pump to the transaxle case.
NOTE:
Do not install the oil pump gasket at this time.

60. Tighten the six oil pump mounting bolts to the specified torque.
Tightening torque: 29± 2Nm (21± 1 ft-lb)






61. 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)






62. Install the oil filter.





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





64. Install the differential.
65. Adjustment of differential case preload and select the spacer. (Refer to adjustment of transaxle - spacer selection for adjustment of differential case preload Adjustment of Transaxle.)





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





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





68.
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 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.





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





70. Install the torque converter housing and then tighten its mounting bolts (eighteen pieces) to the specified torque.
Tightening torque: 48± 6Nm (35± 4 ft-lb)
71. Insert the O-rings (two pieces) into the grooves of the manual control lever shaft.
72. Install the manual control lever shaft and parking pawl rod.





73. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".





74. Insert the new seal rings in the grooves of the accumulator pistons.
NOTE:
The piston and seal ring are common parts.





75. 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.










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





77. Insert a new O-ring to the groove of the solenoid valve harness connector.
78. 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.





79. Install the steel balls into each of the two holes in the top face of the valve body (outside valve body).
80. 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.





81. 82. Install the valve body mounting bolts (twenty seven pieces), and tighten to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)






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





84. Install the fluid temperature sensor to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)






85. Install the manual control shaft detent and tighten the bolt to the specified torque.
Tightening torque: 6.0± 1.0Nm (53± 9 in-lb)






86.
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 2.5 mm (0.1 inch) diameter bead of sealant 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.





87. Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)






88. Install the park/neutral position switch and tighten the bolt to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)
89. Install the manual control lever and tighten the nut to the specified torque.
Tightening torque: 22± 3Nm (16± 2 ft-lb)






90. Install a new O-ring on the input shaft speed sensor and output shaft speed sensor.
91. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)






92. 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.
93. 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± 3Nm (18± 2 ft-lb)
94. Tighten the oil cooler feed tube clamp bolt to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)
95. Install the oil dipstick.
96. Install the control cable support brackets to the specified torque.
Tightening torque: 23± 3Nm (17± 2 ft-lb)
97. Install the harness bracket to the specified torque.
Tightening torque: 11± 1Nm (97± 9 in-lb)
98. Install the roll stopper brackets.
Tightening torque: 90± 10Nm (66± 7 ft-lb)






99.
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 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)