Campaign - A/T KM175 End Clutch Service
87mitsubishi05SUBJECT:
1987 GALANT KM175 END CLUTCH SERVICE CAMPAIGN
NO. STB-87-21-028
DATE December, 1987
MODEL 1987 Galant
PURPOSE
This bulletin provides a detailed procedure for replacing the end clutch thrust washer in the automatic transaxles of certain 1987 Galant vehicles (see Affected Vehicles below). The transaxles in these vehicles were assembled with incorrect end clutch thrust washers that must be replaced to prevent potential transaxle damage. The existing thrust washer may cause the transaxle to exhibit excessive noise and/or harsh shifts. Customers of all affected vehicles have been sent letters telling them to return their vehicles to a Mitsubishi dealer to have the thrust washer replaced. A copy of the letter is shown on page 6 of this bulletin.
In addition, all KM175 transaxle assemblies (P/N MD996102) in dealer stock that fail within the Affected Transaxle Assembly Serial Number Range listed below should have the thrust washer replaced as described below. Again, only those T/A assemblies that fall within the Affected Transaxle Assembly Serial Number Range listed below should be repaired.
AFFECTED VEHICLES
This campaign applies only to 1987 Galant vehicles equipped with the automatic transaxle which were built within the following VIN range. Enclosed with this bulletin is a VIN listing of all vehicles sold by your dealership that are included in this service campaign.
MODEL AFFECTED VIN RANGE
1987 Galant JA3BB46L( )HY - 011983 through 013289
( ) = Check Digit
AFFECTED TRANSAXLE ASSEMBLY SERIAL NUMBER RANGE
T/A PART NUMBER AFFECTED T/A SERIAL NUMBER RANGE
MD996102 CW2209 through DT1843
WARRANTY INFORMATION
Customer Vehicle
Submit a normal warranty claim over your Diamond Network terminal using warranty menu option E-2 for the repair of the affected vehicle (in-stock or customer).
Enter the replacement thrust washer part number and the operation listed below on LINE "A" (first line) of the related claim. Any other needed repair and replacement parts may be entered on the same claim but must be on the lower lines (line B and below).
Labor Operation Code: 21310391
Time Allowance: 0.6 hr.
Dealer Parts Stock Of Transaxle Assemblies Claims for replacing thrust washers on affected transaxle assemblies in your dealership's parts stock should be submitted on a paper warranty claim form (MSSF103D00) using the thrust washer part number and labor operation and time below. Also enter the serial number of the repaired transaxle assembly in the space labeled "Failed Part Serial Number". Use your dealership's five digit dealer code number and the pre-printed claim number as the "VIN" and enter a mileage of "1".
Labor Operation Code: 21310392
Time Allowance: 0.3 hr.
PARTS INFORMATION
A new thrust washer is required to complete the repair procedure. No automatic distribution of parts for this campaign will be made to dealers. Please order parts directly from your facing Parts Distribution Center.
PART DESCRIPTION PART NUMBER QUANTITY REQUIRED
PER TRANSAXLE
End Clutch Thrust Washer MD715877 1
SERVICE PROCEDURE
IMPORTANT: The transaxle assembly does not have to be removed from the vehicle to complete this procedure. Perform all of the following steps if transaxle is in the vehicle. Perform only steps 3 through 12 if transaxle is not in the vehicle (in dealer parts stock).
FIGURE 1:
1. Lift the vehicle on a hoist and turn the wheels fully to the right.
2. Remove the right side under cover panel (4 bolts and 5 clips) (Figure 1).
FIGURE 2:
3. Clean any dirt or grease from the end clutch cover and then remove the cover (Figure 2). If necessary, pull down on the transaxle assembly to allow the cover to clear the vehicle body.
FIGURE 3:
4. Remove the end clutch assembly (Figure 3).
FIGURE 4:
5. Remove the end clutch spring washer if it is still on the end of the clutch shaft (Figure 4).
FIGURE 5:
6. Remove the end clutch hub (Figure 5). When removing the hub, try not to let the end clutch shaft come out with it. The shaft can be difficult to re-insert properly.
FIGURE 6:
7. Remove the thrust washer (Figure 6). If the removed washer is broken into two or more pieces, the transaxle should be removed, disassembled, inspected and repaired as necessary.
The torque converter should only be replaced if major damage is evident when the transaxle is disassembled.
8. Install the new thrust washer (P/N MD715877) over the clutch shaft with the brass side facing out (oil grooves visible) (Figure 6).
FIGURE 7:
9. Install the end clutch spring washer in the gutter of the end clutch (Figure 7). Install the clutch hub to the end clutch. Apply clean automatic transmission fluid to the outside edge of the end clutch pack.
FIGURE 8:
FIGURE 9:
10. Inspect the O-ring inside the clutch cover (Figure 8) and the O-ring on the oil pipe (Figure 9). Replace these parts if damaged.
FIGURE 10:
11. Install the end clutch assembly to the end clutch shaft (Figure 10). Make sure the clutch assembly is installed fully on the shaft or else the clutch cover cannot be installed property.
FIGURE 11:
12. Apply clean ATF to the outer diameter of the end clutch cover. Install the end clutch cover and torque the two bolts and nut to 4-6 ft-lb (6-8 N-m) (Figure 11). Put a black paint mark on the cover outer diameter at the 12 o'clock position to show that the campaign has been completed.
13. Lower the vehicles and drive for approximately 1.5 miles.
14. Raise the vehicle and check for fluid leakage around the end clutch cover. If fluid is evident, remove the clutch cover and inspect the O-rings as described in Step 10. Replace the O-rings if damaged.
15. Install the fight side under cover panel and lower the vehicle.
16. Check the ATF level and add fluid as necessary.
December 21, 1987
Dear Mitsubishi Galant Owner, Mitsubishi Motor Sales of America, Inc. ("MMSA") would like to thank you for your recent purchase of our Galant vehicle. We hope that you are enjoying the many technological features that have been incorporated into this model to enhance your driving pleasure.
We have discovered that a small number of 1987 Galants were produced with an incorrect thrust washer in the transmission. This may cause the transmission to exhibit excessive noise or harsh shifting. We urge you to contact your Mitsubishi Motors Dealer to arrange for an appointment to have this condition corrected free of charge. Your Dealer should be able to answer any questions concerning this notification.
We regret any inconvenience this notification might cause and may we wish you many enjoyable driving miles in your Galant.