Part 3
DISASSEMBLY AND ASSEMBLY (Continued)
23. Apply a 1.2 mm (0.0472 inch) diameter bead of sealant as illustrated onto the transaxle case.
Specified sealant:
Mitsubishi Part No. MD974421 or equivalent
24. Before installing the transaxle case, confirm that the reverse idler gear mounting hole is positioned as shown in the illustration.
25. Install the clutch housing to the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 30± 5Nm (22± 4 ft-lb)
26. Extend the hole snap ring and install it on the radial ball bearing.
27. Install stud bolt to the output shaft No.1 sub-assembly.
28. Pull the output shaft No.1 sub-assembly in the direction as shown in the illustration and fit the hole snap ring into the bearing groove.
NOTE:
After installation, keep the sealed area away from oil for approximately one hour.
29. Push the input shaft sub-assembly in the direction as shown in the illustration and fit the hole snap ring into the bearing groove.
30. Lift the output No.1 sub-assembly.
31. Confirm that the dimension between the centers of dia. 2.5 mm (0.335 inch) holes on the hole snap ring is in accordance with the illustration.
32. Check the hole snap ring fits securely into the bearing groove.
33. Install the reverse idler gear mounting bolt and gasket to the specified torque.
Tightening torque: 80± 10Nm (59± 7 ft-lb)
34. 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.
35. Apply a 1.2 mm (0.0472 inch) diameter bead of sealant as illustrated onto the control shaft cover.
Specified sealant:
Mitsubishi Part No. MD974421 or equivalent
36. Install the shift and select lever shaft assembly to the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 19± 3Nm (14± 2 ft-lb)
37. Install the straight pin to the specified torque.
Tightening torque: 30± 9Nm (22± 7 ft-lb)
38. Install the lock ball assembly and tighten to the specified torque.
Tightening torque: 30± 8Nm (22± 6 ft-lb)
39. Install the filler plug and new gasket and tighten to the specified torque.
Tightening torque: 39± 12Nm (29± 9 ft-lb)
40. Install the drain plug and new gasket and tighten to the specified torque.
Tightening torque: 39± 12Nm (29± 9 ft-lb)
41. Using the 27 mm (1.06 inches) socket wrench, Install the new straight screw plug with head and tighten to the specified torque.
Tightening torque: 55± 16Nm (41± 12 ft-lb)
42. Install the straight screw plug with head and tighten to the specified torque.
Tightening torque: 23± 6Nm (17± 4 ft-lb)
43. Apply grease to the hole and the sides of control bell crank dust cover.
Specified grease:
Mitsubishi Part No. 0101011 or equivalent
44. Install the selecting bell crank assembly and control bell crank dust cover to the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 19± 3Nm (14± 2 ft-lb)
45. Install the control cable bracket with transaxle case hanger No.1 to the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 19± 3Nm (14± 2 ft-lb)
46. Install the wiring harness clamp bracket to the clutch housing and tighten the bolt to the specified torque.
Tightening torque: 9.0± 2.0Nm (80± 17 in-lb)
47. Install the lock ball assembly and tighten to the specified torque.
Tightening torque: 39± 12Nm (29± 9 ft-lb)
48. Install the backup light switch assembly and tighten to the specified torque.
Tightening torque: 40± 12Nm (30± 8 ft-lb)
49. Install the new clamp to the transaxle case and tighten the bolt to the specified torque.
Tightening torque: 12± 4Nm (102± 40 in-lb)
50. Connect the backup light switch harness connector to the control cable bracket.
51. Install the vehicle speed sensor to the clutch housing.