A/T - Case Replacement

91mitsubishi05

NO. TSB-91-23-013

DATE May, 1991

MODEL 1985-1987 Galant


SUBJECT: KM175 TRANSAXLE CASE REPLACEMENT



TSB Revision TSB 91-23-013

PURPOSE

To reduce vehicle down time and save unnecessary labor and expense, the dealer should inspect the kickdown servo bore in the transaxle case before disassembling the transaxle to repair it. If the bore is worn beyond the service limit, the transaxle should be replaced with a remanufactured one rather than replacing the case.

The same logic applies if the case is otherwise damaged; replace the transaxle with a remanufactured unit rather than replacing the damaged case.

This bulletin lists the kickdown servo bore service limits and provides a summary of the kickdown servo bore inspection and measurement procedure.





PROCEDURE

1. With the transaxle out of the vehicle, remove the kickdown servo cover snap ring, then remove the kickdown servo switch.





2. Install two screws into the kickdown servo cover, then use two screwdrivers to pry off the cover as shown.





3. Push the kickdown servo inward and remove the snap ring, then remove the kickdown servo piston and spring.





4. Inspect the servo bore for wear.

Install the original servo piston seal ring back into the servo bore at the second orifice as shown. This is an area of the bore that does not wear. The original servo piston seal ring has an end gap. Use a feeler gauge to measure the end gap and record the result. This measurement will serve as a reference and will be called measurement A.

Measurement A

Now move the servo piston seal ring to the wear area (farther into the bore) and measure the end gap again and record the result. This measurement will be called measurement B.

Measurement B

Subtract measurement A from measurement B and divide the result by 3 to determine the servo bore wear.

(B _______ - A ________) divided by 3 = ____

The result is the servo bore wear.





5. If the wear is between .001 and .023" (.025 and .575 mm), use the kickdown piston repair kit MD728665. The kit contains a new style D-ring to replace the original servo piston seal ring. The new style D-ring is a rubber material and does not have an end gap. Replace the other O-rings and D-rings included in the kit prior to reassembly.

If the wear is greater than .023", do not repair the transaxle. REPLACE IT WITH A REMANUFACTURED UNIT.





6. Lubricate all components with ATF. Reassemble the kickdown servo piston and spring into the transaxle case,




7. Push the kickdown servo assembly inward, then install the snap ring, flat edge out.

Note: If the transaxle has more than 30,000 miles on it, follow the Kickdown Servo Adjustment procedure outlined In the appropriate Service Manual.





8. Reinstall the cover, snap ring and the kickdown switch.