Disassembly And Assembly: Disassembly

CAUTION:

Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
Work on a rubber mat and keep it clean at all times.
Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
If the transaxle body has been damaged, disassemble and clean the cooler system.

Remove the transfer and O-ring < W4A42 >.
Remove the torque converter.
Remove each bracket.
Remove the dipstick.
Remove the eye bolt gauge, gaskets and the oil cooler feed tube.
Remove the air breather
Remove the input shaft speed sensor and output shaft speed sensor.

Fig 1: Identifying Input Shaft Speed Sensor And Output Shaft Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.

Fig 2: Identifying Park/Neutral Position Switch And Manual Control Lever

G01863138

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Loosen the manual control lever tightening nut, and then remove the manual control lever and the park/neutral position switch.
Remove the Sealing cap and o-ring.

Fig 3: Locating Sealing Cap
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Remove the valve body cover.

Fig 4: Identifying Valve Body Cover
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Remove the manual control shaft detent.

Fig 5: Locating Manual Control Shaft Detent
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Disconnect the solenoid valve harness from the valve body by disconnecting the fluid temperature sensor and all the connectors.

Fig 6: Identifying Valve Body
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CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See step 8.

Fig 7: Removing Valve Body Mounting Bolts

G01863143

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the valve body mounting bolts (27 pieces).

CAUTION: Do not lose the two steel balls.

Fig 8: Removing Steel Balls

G01863144

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Remove the valve body, gasket, and the two steel balls.
Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.

Fig 9: Removing Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the strainer and the second brake retainer oil seal.

Fig 10: Removing Strainer And The Second Brake Retainer Oil Seal For Removal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove each accumulator piston and spring.

Fig 11: Removing Accumulator Piston And Spring
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Fig 12: Accumulator Piston And Spring Number Description Chart
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the manual control lever shaft roller.
Remove the manual control lever shaft and the parking pawl rod.

Fig 13: Removing Parking Pawl Rod, Manual Control Lever Shaft And Manual Control Lever Shaft Roller
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the torque converter housing mounting bolts (18 bolts), and then remove the torque converter housing.

Fig 14: Locating Torque Converter Housing
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Remove the differential bearing outer race and spacer from the torque converter housing.
Remove the two O-rings.

Fig 15: Removing O-Rings
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Remove the differential < F4A42> or center differential < W4A42 >.
Remove the differential bearing outer race from the transaxle case.

Fig 16: Removing Differential Bearing Outer Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil filter.

Fig 17: Removing Oil Filter
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Remove the oil pump mounting bolts (six bolts).
Install special tool MD998333 in hole "A".

Fig 18: Locating Hole For Installing Special Tool
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Turn special tools MD998333 to remove the oil pump.
Remove the oil pump gasket.

Fig 19: Screwing Special Tool To Remove Oil Pump & Gasket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust washer number 1.

Fig 20: Removing Thrust Washer #1
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Holding the input shaft, remove the underdrive clutch and input shaft.

Fig 21: Removing Underdrive Clutch And Input Shaft
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Remove thrust bearing number 2.

Fig 22: Removing Thrust Bearing Number 2
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Remove the underdrive clutch hub.

Fig 23: Removing Underdrive Clutch Hub
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Remove the rear cover and input shaft rear bearing.
Remove thrust race number 8.
Remove the seal rings (four pieces).

Fig 24: Removing Rear Cover, Input Shaft Rear Bearing, Thrust Race Number 8 And Seal Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the three O-rings.

Fig 25: Locating O-Rings (3 Pieces)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 26: Removing Reverse And Overdrive Clutch And Thrust Bearing #7
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove overdrive clutch hub and trust bearing number 6.

Fig 27: Removing Overdrive Clutch Hub And Thrust Bearing #6
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove thrust bearing number 5.

Fig 28: Removing Thrust Bearing #5
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Remove the planetary reverse sun gear.

Fig 29: Removing Planetary Reverse Sun Gear
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Remove the snap ring.

Fig 30: Removing Snap Ring
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Remove the second brake piston and the return spring.

Fig 31: Removing Second Brake Piston And Return Spring
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Remove the brake plates (two pieces), brake discs (three pieces) and pressure plate.

Fig 32: Removing Pressure Plate, Brake Discs And Brake Plates
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Remove the planetary carrier assembly.

Fig 33: Removing Planetary Carrier Assembly
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Remove the snap ring.

Fig 34: Removing Snap Ring
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Remove the reaction plate and the brake disc.

Fig 35: Removing Reaction Plate And Brake Disc
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Remove the snap ring.

Fig 36: Removing Snap Ring
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Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.

Fig 37: Removing Brake Plates, Brake Discs And Pressure Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the wave spring.

Fig 38: Removing Wave Spring
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Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 39: Removing Parking Pawl Shaft
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Remove the two parking roller support shafts, and then remove the parking pawl and parking roller support.

Fig 40: Removing Parking Roller Support Shafts, Parking Pawl & Parking Roller Support
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998903 and MD998924, compress the one-way clutch inner race.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
Fig 41: Removing One-Way Clutch Inner Race & Low-Reverse Brake Piston Using SST
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the three transfer drive gear bearing mounting bolts.
Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

Fig 42: Removing Transfer Drive Gear Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the transfer drive gear.

Fig 43: Removing Transfer Drive Gear
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Remove the cap by jabbing a screw driver into the center of the cap and prying it up.

Fig 44: Removing Cap
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Using a chisel, straighten the staked portions from the output shaft nut.

Fig 45: Straightening Staked Portions Of Output Shaft Lock Nut
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CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 46: Removing Output Shaft Jam Nut Using SST
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing retainer mounting bolt.

Fig 47: Removing Bearing Retainer Mounting Bolt
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Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 48: Removing Output Shaft, Taper Roller Bearing And Collar
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Tap out the outer race and the spacer.
Remove the snap ring.

Fig 49: Removing Snap Ring
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