Steps 1-49
REASSEMBLY
No. of Brake Discs and Plates
CAUTION:
1. Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
2. Never use grease other than blue petrolatum jelly and white Vaseline.
3. 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.
4. Never apply sealant or adhesive to gaskets.
5. When replacing a bushing, replace the assembly, which it belongs to.
6. Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something.
7. Change the oil in the cooler system.
1. Use the special tools to tap the differential bearing outer race in the transaxle case.
2. Use the special tool to install the transfer drive gear.
3. Tighten the seven mounting bolts of the transfer drive gear to the specified torque.
4. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
5. Fit a new O-ring into the groove of one-way clutch inner race.
6. 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.
7. Put the snap ring on the inner race.
8. Set special tools, and then compress the one-way clutch inner race and install the snap ring.
9. Install the wave spring.
10. Install the brake discs, brake plates and snap ring.
NOTE: Do not install the pressure plate at this time.
Number of brake discs and plates
CAUTION: If necessary, take the measurements in steps 10 to 19 after replacing the pressure plate, brake plate and brake disc.
11. Install special tool.
12. Install the reaction plate and the used snap ring.
13. Move the special tool to measure the end play, and then replace the snap ring installed in step (12) to adjust the end play to standard value.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)
14. Install the brake disc and brake plate.
Number of brake discs and plates
15. Install special tool.
NOTE: Do not install the pressure plate at this time.
16. Install the return spring, second brake piston and snap ring.
17. Move the special tool (MB991631) and measure its movement.
Standard value:
0.49 - 0.95 mm (0.0193 - 0.0374 inch)
0.79 - 1.25 mm (0.0311 - 0.0492 inch)
Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
PRESSURE PLATE
PRESSURE PLATE
18. Turn the transaxle over.
19. Install the special tool (MD998913) in a dial gauge, and then move the special tool (MB991631) and measure its movement.
Standard value:
1.05 - 1.51 mm (0.0413 - 0.0594 inch)
1.35 - 1.81 mm (0.0531 - 0.0713 inch)
Select a pressure plate whose thickness corresponds to the measured amount of movement from the table.
PRESSURE PLATE
PRESSURE PLATE
20. Remove all parts and special tools that were installed to take the measurements in steps (9) to (19). Remove and separate the pressure plate and snap ring chosen in steps (13), (17) and (19).
21. Install the snap ring and the thinnest adjustment spacer [1.88 mm (0.0740 inch)].
NOTE: The spacer may have to be replaced Witty one having an adequate thickness after the end play of the output shaft is checked in step (26).
22. Use the special tools to tap the output shaft bearing outer race in the transaxle case.
23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
CAUTION: Do not reuse the bolt, as it is coated with sealant.
24. Install the output shaft in the transaxle case, and then use the special tool to install the collar and taper roller bearing in the output shaft.
25. Apply ATF to a new lock nut, and use the special tool to tighten the lock nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
CAUTION: The lock nut has left-handed threads.
26. Move the output shaft to measure the shaft end play, and then replace the spacer installed in step (21) with a new one which thickness is within the following value.
A = Shaft end play mm (inch)
B = Thickness of spacer assembled in step (21) [1.88 mm (0.0740 inch)]
Metric values: [A + B + 0.01 mm] to [A + B + 0.09 mm]
American values: [A + B + 0.0004 inch] to [A + B + 0.0035 inch]
27. Stake the two places of the lock nut.
28. Install the cap.
29. Install the parking pawl, spacer, and spring. Then install the parking pawl shaft.
30. Install the parking roller support, and then the two parking roller support shafts.
IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS
31. Install the planetary carrier assembly.
32. Install the planetary reverse sun gear.
33. Install the wave spring.
34. Install the pressure plate, brake disc, and brake plate.
Number of brake discs and plates
35. Install the snap ring.
36. Install the reaction plate.
37. Install the snap ring.
38. Install the brake disc, brake plate, and pressure plate.
Number of brake discs and plates
39. Install the return spring and second brake piston.
40. Install the snap ring.
41. Install thrust bearing #5.
CAUTION: Be sure to install the thrust bearing in the correct direction.
42. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.
CAUTION: Be careful about the installation direction of the thrust bearing.
43. Install the reverse and overdrive clutch, and thrust bearing #7.
CAUTION: Be careful about the installation direction of the thrust bearing.
44. Install the three O-rings.
45. Install the input shaft bearing.
46. Install the four seal rings.
47. Install used thrust race #8, and then the rear cover.
48. Measure end play of the underdrive sun gear. Replace the thrust race installed in step (4) to adjust the play to the standard value.
Standard value: 0.25 to 0.45 mm (0.0098 to 0.0177 inch)
NOTE: Installing the underdrive clutch hub makes it easy to measure the end play of the underdrive sun gear.
49. Apply sealant to the mating surface of the rear cover. Be sure to install the transaxle case within 15 minutes after applying sealant.
Specified sealant: MITSUBISHI genuine sealant Part No. MD974421 or equivalent