Part 2 of 2
REASSEMBLY
CAUTION:
- Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
- Never use grease other than blue petrolatum jelly and white Vaseline.
- Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
- Never apply sealant or adhesive to gaskets.
- When replacing a bushing, replace the assembly which it belongs to.
- Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something.
- Change the oil in the cooler system.
40. Install the input shaft bearing.
41. Install the four seal rings.
CAUTION: There are two types of seal rings, with and without identification color. Be sure to install them to their correct positions.
42. Install used thrust race #8, and then the rear cover.
43. Measure end play of the underdrive sun gear. Replace the thrust race installed in step (44) to adjust the play to the standard value.
Standard value: 0.25 - 0.45 mm (0.0098 - 0.0177 inch)
NOTE: Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.
44. Squeeze out the liquid gasket and apply it to the shown points of the rear cover.
Liquid gasket: MITSUBISHI genuine sealant Part No. MD974421 or equivalent
NOTE:
- Be sure to install the case quickly while the sealant is wet (with 15 minutes).
- After installation, keep the sealed area away from the oil for approximately 1 hour
45. Install the rear cover, and tighten its mounting bolts to the specified torque.
46. Install the underdrive clutch hub.
47. Install thrust bearing #2.
CAUTION: Be sure to install the thrust bearing in the correct direction.
48. Hold the input shaft, and install the underdrive clutch.
49. Install the used thrust washer #1.
50. Use the special tool to install a new oil pump gasket and oil pump.
CAUTION: Never reuse the old gasket.
51. Tighten the oil pump mounting bolts to the specified torque.
Standard value: 23 Nm (17 ft. lbs.)
52. Measure end play of the input shaft. Replace the thrust washer installed in step (51) to adjust the play to the standard value.
Standard value: 0.70 - 1.45 mm (0.0276 - 0.0569 inch)
53. Install the oil filter.
54. Install the differential.
55. Place solder (approximately 10 mm (0.39 inch) in length, 3 mm (0.12 inch) in diameter) on the torque converter housing as shown in the figure.
56. Install the torque converter housing to the transaxle case without applying sealant. Tighten its mounting bolts to the specified torque.
Standard value: 47 Nm (35 ft. lbs.)
57. Loosen the bolts, and remove the solder.
58. Use a micrometer to measure the thickness of the pressed solder. Select a spacer which thickness is within the following value.
[T + 0.045 mm (0.0018 inch)] to [T + 0.105 mm (0.0041 inch)]
59. Install the spacer selected in the above step.
60. Assemble the spacer selected in step (60) to the torque converter housing. Use the special tool to press in the outer race.
61. Squeeze out the liquid gasket and apply it to the shown area of torque converter.
Liquid gasket: MITSUBISHI genuine sealant Part No. MD974421 or equivalent
NOTE:
- Be sure to install the case quickly while the sealant is wet (with 15 minutes).
- After installation, keep the sealed area away from the oil for approximately 1 hour
62. Install the two O-rings.
63. Install the torque converter, and then tighten its 18 mounting bolts to the specified torque.
Standard value: 47 Nm (35 ft. lbs.)
64. Install the manual control lever shaft and parking pawl rod.
65. Install the manual control lever shaft roller.
66. Install the accumulator pistons, new seal rings, and springs.
NOTE: The accumulator springs are identified as shown in the figure.
67. Install the strainer and second brake retainer oil seal.
68. Install the solenoid valve harness, and then secure the snap ring to the connector groove.
69. Install the valve body, gasket, and two steel balls.
70. Install the fluid temperature sensor.
71. Install the 28 valve body mounting bolts.
72. Connect the valve body connectors.
73. Install the manual control shaft detent.
74. Apply the liquid gasket to the valve body cover.
Liquid gasket: MITSUBISHI genuine sealant Part No. MD974421 or equivalent
NOTE:
- Be sure to install the case quickly while the sealant is wet (with 15 minutes).
- After installation, keep the sealed area away from the oil for approximately 1 hour.
75. Install the valve body cover, and then tighten its mounting bolts to the specified torque.
Standard value: 11 Nm (8.0 ft. lbs.)
76. Install the speedometer gear.
77. Install the park/neutral position switch and manual control lever.
78. Install the input shaft speed sensor and output shaft speed sensor.
79. Apply a small amount of ATF to the oil filter gasket. Tighten the filter to the specified torque.
Standard value: 12 Nm (8.7 ft. lbs.)
80. Install the eye bolt, a new gasket, and the oil cooler feed tube.
81. Install the oil dipstick.
82. Install the brackets.
83. Install the torque converter, and secure it so that the shown dimension (A) meets the reference value.
Reference value: approximately 9.4 mm (0.37 inch)
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.