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Home >> Mitsubishi >> 2003 >> Outlander LS, AWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle Overhaul >> Transaxle >> Disassembly And Assembly >> Assembly

Disassembly And Assembly: 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 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.
    Fig 1: Installing Special Tool MD998412
    G01863186Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  2. Tighten the seven mounting bolts of the transfer drive gear bearing to the specified torque.

    Tightening torque: 34 +/- 2 N.m (25 +/- 1 ft-lb) 

    Fig 2: Tightening Mounting Bolts Of Transfer Drive Gear Bearing
    G01863187Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
    Fig 3: Installing Low-Reverse Brake Piston, Return Spring, And Spring Retainer
    G01863188Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  4. Fit a new O-ring into the groove of one-way clutch inner race.
    Fig 4: Fitting New O-Ring
    G01863189Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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.
    Fig 5: Checking Placement Of Identification Notches
    G01863190Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. Put the snap ring on the inner race.
  7. Set special tools MD998903 and MD998924 as shown, and then compress the one- way clutch inner race and install the snap ring.
    Fig 6: Installing Snap Ring Using SST
    G01863191Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. Install the wave spring onto the low-reverse brake piston.
    Fig 7: Installing Wave Spring
    G01863192Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. Install the six brake discs, five brake plates and snap ring as shown in the figure.
    NOTE: Do not install the pressure plate at this time.
  10. Install special tool MB991631 on the brake disc.
  11. Install the reaction plate and the used snap ring.
  12. Move special tool MB991631 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) 

    Fig 8: Measuring End Play
    G01863193Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. Install the brake discs (three pieces) and brake plates (two pieces) as shown in the figure.
    NOTE: Do not install the pressure plate at this time.
  14. Place special tool MB991631 on top of the brake disc in place of the pressure plate.
  15. Install the return spring, second brake piston and snap ring.
    Fig 9: Installing Return Spring, Second Brake Piston And Snap Ring
    G01863194Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. Move special tool MB991631 and measure its movement.
    1. Standard value of end play (Reference) : 
      1. 0.79 - 1.25 mm (0.311 - 0.0492 inch) 
    Fig 10: Moving Special Tool And Measuring Its Movement
    G01863195Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
    Fig 11: Pressure Plate Specification Chart For Second Brake
    G01863196Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 12: Identifying Movement Amount
    G01863197Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  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 MB991631 and measure its movement.

    Standard value of end play (Reference): 1.65 - 2.11 mm (0.050 - 0.0831 inch) 

    Fig 13: Installing Special Tool In Dial Gauge
    G01863198Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.
    Fig 14: Pressure Plate Specification Chart For Low Reverse Brake
    G01863199Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 15: Measuring Movement Amount
    G01863200Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    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 snap ring into the groove of transaxle case output shaft bore.
  22. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.
    Fig 16: Tapping Output Shaft Bearing Outer Race In Transaxle Case
    G01863201Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  23. CAUTION: Do not reuse the bolt, as it has had sealant applied.
    Fig 17: Identifying Mounting Bolt Of Output Shaft Bearing Retainer
    G01863202Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  24. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
    1. Tightening torque : 
      1. 29 +/- 2 N.m (21 +/- 1 ft-lb) 
  25. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
    Fig 18: Installing Collar And Taper Roller Bearing On Output Shaft
    G01863203Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  26. Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.

    Tightening torque: 170 +/- 10 N.m (125 +/- 7 ft-lb) 

    NOTE: The jam nut is reverse threaded.
    Fig 19: Tightening Jam Nut
    G01863204Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  27. Move the output shaft to measure the end play and record the measurement value.
  28. Remove the parts that were installed in steps 21 to 25.
  29. Add 0.01 to 0.09 mm (0.0004 to 0.0035 inch)** to the measured value in step 26 and select a spacer of the same thickness. Adjustment spacer sizes are all listed on SERVICE SPECIFICATIONS . Select the most suitable one from among those listed.
    NOTE: * is the thickness of the spacer installed in step 21. ** is the preload of the output shaft.
    Fig 20: Measuring End Play Of Output Shaft
    G01863206Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 21: Spacer Specification For Output Shaft (1 Of 2)
    G01863205Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 22: Spacer Specification For Output Shaft (2 Of 2)
    G01863207Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  30. Repeat steps 22 to 26 again, installing each part and using the appropriate adjustment spacer determined in step 27.
  31. Stake the jam nut with a punch (two places).
    Fig 23: Staking Jam Nut
    G01863208Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  32. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
    Fig 24: Installing Cap
    G01863209Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.
    Fig 25: Installing Parking Pawl Shaft
    G01863210Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  34. Install the parking roller support, and then insert the two parking roller support shafts.
    Fig 26: Installing Parking Roller Support Shafts
    G01863211Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 27: Identifying Thrust Bearing, Thrust Race, And Thrust Washer Specifications (1 Of 2)
    G01863212Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 28: Identifying Thrust Bearing, Thrust Race, And Thrust Washer Specifications (2 Of 2)
    G01863213Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 29: Identifying Thrust Bearing, Thrust Races, And Thrust Washers
    G01863214Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  35. Install the planetary carrier assembly.
    Fig 30: Installing Planetary Carrier Assembly
    G01863215Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  36. Install the planetary reverse sun gear.
    Fig 31: Installing Planetary Reverse Sun Gear
    G01863216Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  37. Install the wave spring on the low-reverse brake piston.
    Fig 32: Installing Wave Spring On Low-Reverse Brake Piston
    G01863217Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  38. Install the pressure plate that was selected in step 19. Next, install six brake discs and five brake plates, one on top of the other.
    Fig 33: Installing Pressure Plate, Brake Disc, And Brake Plate
    G01863218Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  39. Install the snap ring.
    Fig 34: Installing Snap Ring
    G01863219Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  40. Install the reaction plate.
    Fig 35: Installing Reaction Plate
    G01863220Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  41. Install the snap ring that was selected in step  12.
    Fig 36: Installing Snap Ring
    G01863221Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  42. Install three brake discs and two brake plates, one on top of the other. Next, install the pressure plate that was selected in step  17.
    Fig 37: Installing Brake Discs And Brake Plates
    G01863222Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  43. Install the return spring and second brake piston.
    Fig 38: Installing Return Spring And Second Brake Piston
    G01863223Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  44. Install the snap ring.
    Fig 39: Installing Snap Ring
    G01863224Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  45. CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
    Fig 40: Identifying Installation Direction Of Thrust Bearing #5
    G01863225Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  46. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.
  47. CAUTION: Use care to install the thrust bearing in the proper direction.
    Fig 41: Attaching Thrust Bearing Number 6 To Inside Of Overdrive Clutch Hub
    G01863226Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  48. 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.
  49. Install the reverse and overdrive clutch.
  50. CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
    Fig 42: Identifying Installation Direction Of Thrust Bearing Number 7
    G01863227Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  51. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.
  52. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
  53. Install the four seal rings in the grooves of the rear cover.
    Fig 43: Tapping Input Shaft Rear Bearing In Rear Cover
    G01863228Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  54. 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 N.m (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) 

      Fig 44: Measuring End Play Of Under Drive Sun Gear
      G01863229Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    6. After taking the measurement in steps (5), take out the installed parts in steps (1) through (4).
  55. Install the three O-rings.
    Fig 45: Installing Three O-Rings
    G01863230Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  56. Select a thrust race number 8 whose thickness corresponds to the measured values taken in step 50 from the table below. Install it on thrust bearing number 7.
    Fig 46: Thrust Race Number 8 Thickness Chart
    G01863231Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 47: Installing Thrust Race Number 8 On Thrust Bearing Number 7
    G01863232Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  57. 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.
    Fig 48: Identifying Points Of Rear Cover For Applying Sealant
    G01863233Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  58. Install the rear cover, and tighten its mounting bolts to the specified torque.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

    NOTE: After installation, keep the sealed area away from ATF for approximately one hour.
    Fig 49: Installing Rear Cover
    G01863234Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  59. Install the underdrive clutch hub to the underdrive sun gear.
    Fig 50: Installing Underdrive Clutch Hub To Underdrive Sun Gear
    G01863235Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  60. CAUTION: Be sure to install the thrust bearing in the correct direction as shown.
    Fig 51: Identifying Installation Direction Of Thrust Bearing Number 2
    G01863236Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  61. Check the installation direction of thrust bearing number 2, and install it on the underdrive clutch hub.
  62. Hold the input shaft, and install the underdrive clutch.
    Fig 52: Installing Underdrive Clutch
    G01863237Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  63. 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.
    Fig 53: Placing Beads Of Solder On Underdrive Clutch Retainer
    G01863238Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  64. Install special tool MD998412 as shown.
    Fig 54: Installing Special Tool
    G01863239Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  65. Install the oil pump to the transaxle case.
    NOTE: Do not install the oil pump gasket at this time.
  66. Tighten the six oil pump mounting bolts to the specified torque.

    Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb) 

  67. Remove the oil pump mounting bolts.
  68. Using special tools MD998333, remove the oil pump and the crushed solders.
    Fig 55: Removing Oil Pump And Crushed Solders
    G01863240Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  69. Use a micrometer to measure the thickness of the crushed solder beads and record the measured value.
  70. Select a thrust washer number 1 whose thickness corresponds to the measured value from table below.
    Fig 56: Measuring Thickness Of Crushed Solder Beads
    G01863242Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 57: Crushed Solder Beads Thickness Chart
    G01863241Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  71. Install thrust washer number 1 that was selected in step 65 on the underdrive clutch retainer.
    Fig 58: Installing Thrust Washer Number 1
    G01863243Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  72. Install special tool MD998412 as shown.
    Fig 59: Installing Special Tool
    G01863244Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  73. Install the new oil pump gasket on the transaxle case.
  74. Install the oil pump and tighten the six mounting bolts to the specified torque.

    Tightening torque: 29 +/- 2 N.m (21 +/- 1 ft-lb) 

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

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

    Fig 60: Measuring Input Shaft End Play
    G01863245Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  76. Install the oil filter.
    Fig 61: Installing Oil Filter
    G01863246Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  77. Use special tools MB990935 and MD990938 to tap the differential bearing outer race in the transaxle case.
    Fig 62: Tapping Differential Bearing Outer Race In Transaxle Case
    G01863247Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  78. Install the differential < F4A42> or center differential < W4A42 >.
    Fig 63: Installing Differential (F4A42) Or Center Differential (W4A42)
    G01863248Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  79. 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.
    Fig 64: Placing Solder Beads On Torque Converter Housing
    G01863249Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  80. Use special tools MB990935 and MB990938 to press in the differential bearing outer race into the torque converter housing.
    Fig 65: Pressing Differential Bearing Outer Race Into Torque Converter Housing
    G01863250Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  81. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.

    Tightening torque : 48 +/- 6 N.m (35 +/- 4 ft-lb) 

    Fig 66: Installing Torque Converter Housing To Transaxle Case
    G01863251Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  82. Loosen all the bolts, and remove the torque converter housing. Then remove the outer race and the crushed solders.
  83. 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 are all listed on SERVICE SPECIFICATIONS . Select the most suitable one from among those listed.
    NOTE: * is the thickness for the differential case preload.
    Fig 67: Measuring Thickness Of Crushed Solder Beads
    G01863252Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  84. Install the spacer selected in step 78 to the torque converter housing.
  85. Use special tools MB990935 and MB990938 to press the outer race into housing.
    Fig 68: Pressing Outer Race Into Housing
    G01863253Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  86. 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). 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.
    Fig 69: Applying Sealant To Torque Converter Housing
    G01863254Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  87. Install the two O-rings.
    Fig 70: Installing Two O-Rings
    G01863255Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  88. Install the torque converter housing and then tighten its 18 mounting bolts to the specified torque.

    Tightening torque: 48 +/- 6 N.m (35 +/- ft-lb) 

    Fig 71: Installing Torque Converter Housing
    G01863256Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  89. Insert the two O-rings into the grooves of the manual control lever shaft.
  90. Install the manual control lever shaft and parking pawl rod.
  91. Align hole "A" with the groove in the manual control lever shaft. Insert the manual control lever shaft roller into hole "A".
    Fig 72: Installing Manual Control Lever Shaft, Parking Pawl Rod And Manual Control Lever Shaft Roller
    G01863257Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  92. Insert the new seal rings in the grooves of the accumulator pistons.
    NOTE: The piston and seal ring are common parts.
  93. 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.
    Fig 73: Identifying Identification Blueing Area Of Accumulator Spring
    G01863259Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 74: Accumulator Springs Identification Chart
    G01863258Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 75: Identifying Accumulator Springs
    G01863260Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  94. Install the strainer and second brake retainer oil seal.
    Fig 76: Installing Strainer And Second Brake Retainer Oil Seal
    G01863261Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  95. Insert a new O-ring to the groove of the solenoid valve harness connector.
  96. 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.
    Fig 77: Securing Snap Ring To Connector Groove
    G01863262Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  97. Install a steel ball into each of the two holes in the top face of the valve body (outside valve body).
    Fig 78: Installing Steel Ball
    G01863263Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  98. 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.
  99. Install the 27 valve body mounting bolts, and tighten to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 79: Installing Valve Body Mounting Bolts
    G01863264Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  100. Attach the solenoid valve harness to the valve body by connecting the fluid temperature sensor and all the connectors.
    Fig 80: Identifying Solenoid Valves
    G01863266Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 81: Solenoid Valve Harness Cable Color And Connector Housing Color Chart
    G01863265Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  101. Install the manual control shaft detent and tighten the bolt to the specified torque.

    Tightening torque: 6 +/- 1 N.m (52 +/- 9 in-lb) 

    Fig 82: Installing Manual Control Shaft Detent
    G01863267Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  102. 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 ATF for approximately one hour.
    Fig 83: Applying Sealant To Valve Body Cover
    G01863268Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  103. Install the valve body cover, and then tighten its mounting bolts to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 84: Installing Valve Body Cover
    G01863269Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  104. Install the Sealing cap and tighten the bolt to the specified torque.

    Tightening torque: 5 +/- 1 N.m (43 +/- 9 in-lb) 

    Fig 85: Installing Sealing Cap
    G01863270Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  105. Install the park/neutral position switch and tighten the bolt to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

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

    Tightening torque: 22 +/- 3 N.m (16 +/- 2 ft-lb) 

    Fig 86: Installing Park/Neutral Position Switch And Manual Control Lever
    G01863271Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  107. Install the input shaft speed sensor and output shaft speed sensor and tighten the bolt to the specified torque.

    Tightening torque: 11 +/- 1 N.m (95 +/- 9 in-lb) 

    Fig 87: Installing Input Shaft Speed Sensor And Output Shaft Speed Sensor
    G01863272Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  108. Install the air breather
  109. Install the oil cooler feed tube together with new gaskets and tighten the eye bolts to the specified torque.

    Tightening torque: 30 +/- 3 N.m (22 +/- 2 ft-lb) 

  110. Tighten the oil cooler feed pipe clamp bolt to the specified torque.

    Tightening torque : 11 +/- 1 N.m (95 +/- 9 in-lb) 

  111. Install the oil dipstick.
  112. Install the cable support brackets to the specified torque.

    Tightening torque: 23 +/- 3 N.m (17 +/- 2 ft-lb) 

  113. Install the roll stopper brackets.

    Tightening torque: 70 +/- 10 N.m (52 +/- 7 ft-lb) 

  114. 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.
  115. Install the torque converter, and align it with the oil pump so that the shown dimension "A" meets the reference value.
    1. Reference value : 
      1. Approximately 12.2 mm (0.48 inch) 
    2. Fig 88: Installing Torque Converter
      G01863273Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  116. Install the transfer together with new o-ring and tighten the blots to the specified torque < W4A42 >.

    Tightening torque: 69 +/- 9 N.m (51 +/- 7 ft-lb)