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23B-1

GROUP 23B

AUTOMATICTRANSMISSIONOVERHAUL

CONTENTS

HOW TO USE THIS MANUAL . . . . . . 23B-2

GENERAL INFORMATION . . . . . . . . 23B-4

GENERAL SPECIFICATIONS . . . . . . 23B-5

SERVICE SPECIFICATIONS . . . . . . . 23B-6

SNAP RING, SPACER,THRUST WASHER, THRUST RACEAND PRESSURE PLATEFOR ADJUSTMENT . . . . . . . . . . . . . . 23B-7

TORQUE SPECIFICATIONS . . . . . . . 23B-10

SEALANTS . . . . . . . . . . . . . . . . . . . . 23B-11

SPECIAL TOOLS . . . . . . . . . . . . . . . . 23B-12

TRANSMISSION . . . . . . . . . . . . . . . . 23B-16TRANSMISSION DISASSEMBLY ANDREASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-16

OIL PUMP . . . . . . . . . . . . . . . . . . . . . 23B-40OIL PUMP DISASSEMBLY ANDREASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-40

UNDERDRIVE CLUTCH AND INPUTSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 23B-41

UNDERDRIVE CLUTCH AND INPUT SHAFTDISASSEMBLY AND REASSEMBLY . . . . . 23B-41

REVERSE AND OVERDRIVECLUTCH . . . . . . . . . . . . . . . . . . . . . . . 23B-43

REVERSE AND OVERDRIVE CLUTCHDISASSEMBLY AND REASSEMBLY . . . . . 23B-43

PLANETARY CARRIER ASSEMBLY 23B-46PLANETARY CARRIER ASSEMBLYDISASSEMBLY AND REASSEMBLY . . . . . 23B-46

LOW-REVERSE BRAKE . . . . . . . . . . 23B-48

LOW-REVERSE BRAKE DISASSEMBLYAND REASSEMBLY . . . . . . . . . . . . . . . . . . 23B-48

SECOND BRAKE . . . . . . . . . . . . . . . . 23B-49SECOND BRAKE DISASSEMBLY ANDREASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-49

OUTPUT SHAFT . . . . . . . . . . . . . . . . . 23B-50OUTPUT SHAFT DISASSEMBLY ANDREASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-50

DIFFERENTIAL . . . . . . . . . . . . . . . . . . 23B-52DIFFERENTIAL DISASSEMBLY ANDREASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-52

VALVE BODY . . . . . . . . . . . . . . . . . . . 23B-54VALVE BODY DISASSEMBLY ANDREASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-54

DRIVE SHAFT OIL SEAL . . . . . . . . . . 23B-57DRIVE SHAFT OIL SEAL DISASSEMBLYAND REASSEMBLY . . . . . . . . . . . . . . . . . . 23B-57

http://gr00003900-23.pdf/http://gr00003900-23.pdf/http://gr00003900-23.pdf/http://gr00003900-23.pdf/

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HOW TO USE THIS MANUALAUTOMATIC TRANSMISSION OVERHAUL23B-2

HOW TO USE THIS MANUALM12330350

This manual describes service procedures performed after removal of the transmission from the vehicle.For removal of the transmission from the vehicle, installation of the transmission in the vehicle, and on-vehicle inspectionand service of the transmission, please use the separate Workshop Manuals prepared for the vehicle.

(1) A component part drawing is shown at the beginning of each section to enable the technician to ascer tain the installed conditi- on of the component parts.(2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such,

and tightening torques are shown. ·Removal steps: The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence. ·Installation steps: Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse. ·Disassembly steps: The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence.

·Reassembly steps: Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

HOW TO USE THIS MANUAL

How to Read Explanations

Scope of Service Explanations

Service steps

Classification of Service PointsKey service points, service standards, and instructionsfor using special tools are collated as service points andexplained in detail.

: Outward-pointing brackets denote removal service pointsor disassembly service points.

>>A

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HOW TO USE THIS MANUALAUTOMATIC TRANSMISSION OVERHAUL 23B-3

Disassembly steps >>D>C>B>A>A>A>A>A

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GENERAL INFORMATIONAUTOMATIC TRANSMISSION OVERHAUL23B-4

GENERAL INFORMATIONM1233000

AUTOMATIC TRANSMISSION MODELS

SECTIONAL VIEW

Transmission model Combined engine Vehicle model

F4A4A-1-N2Z 4G18-S4-MPI CS3A/CS3W

AK301223

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GENERAL SPECIFICATIONSAUTOMATIC TRANSMISSION OVERHAUL 23B-5

HYDRAULIC CIRCUIT

GENERAL SPECIFICATIONSM1233000200392

AK202010

26

8 9

RNP

D321

18 19 20 2114 15 16

27

1

6

1110

1713

24

23

28

2925

22

7 7 7 7

2 3 4 5

12

AB

1. Reverse clutch2. Low-reverse brake3. Second brake

4. Underdrive clutch5. Overdrive clutch6. Damper clutch7. Accumulator8. Fail-safe valve A9. Fail-safe valve B10. Damper clutch control valve11. Switch valve12. Cooler13. Low-reverse pressure control valve14. Second pressure control valve15. Underdrive pressure control valve

16. Overdrive pressure control valve17. Damper clutch control solenoid valve18. Low-reverse solenoid valve

19. Second solenoid valve20. Underdrive solenoid valve21. Overdrive solenoid valve22. Torque converter pressure control valve23. Regulator valve24. Manual valve25. Oil pump26. Oil strainer27. Oil filter28. Oil pan29. Relief valve

Transmissionmodel

Drive system Number ofspeed

Damper clutch Low-reverseone-way clutch

Final gear ratio

F4A4A-1-N2Z 2WD 4 speed Provided Provided 4.406

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SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION OVERHAUL23B-6

VALVE BODY SPRING IDENTIFICATION TABLE

SERVICE SPECIFICATIONSM1233000

Item F4A4A

Torque converter Type 3-element, 1-stage, 2-phase

Transmission Type 4-speed forward, 1-speed reverse

Gear ratio 1st 2.842

2nd 1.529

3rd 1.000

4th 0.712

Reverse 2.480

Number of underdrive clutch discs 3

Number of overdrive clutch discs 3

Number of reverse clutch discs 2

Number of low-reverse brake discs 4

Number of second brake discs 2

Spring Wirediametermm

Coildiametermm

Freelengthmm

Number loops

Regulator valve spring 1.8 15.7 86.7 24

Underdrive pressure control valve spring 0.7 7.6 37.7 25

Overdrive pressure control valve spring 0.7 7.6 37.7 25

Low-reverse pressure control valve spring 0.7 7.6 37.7 25

Second pressure control valve spring 0.7 7.6 37.7 25

Torque converter valve spring 1.6 11.2 34.4 12.5

Damper clutch control valve spring 0.7 5.9 28.1 19

Fail-safe valve A spring 0.7 8.9 21.9 9.5Damping valve spring 1.0 7.7 35.8 17

Line relief valve spring 1.0 7.0 17.3 10

Orifice check ball spring 0.5 4.5 17.2 15

Item Standard value

Brake reaction plate end play 0 − 0.16 mmSecond brake end play 0.49 − 0.95 mm

Low-reverse brake end play 1.05 − 1.51 mm

Output shaft preload 0.01 − 0.09 mm

Underdrive sun gear end play 0.25 − 0.45 mm

Input shaft end play 0.70 − 1.45 mm

Differential case preload 0.045 − 0.105 mm

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SNAP RING, SPACER THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENTAUTOMATIC TRANSMISSION OVERHAUL 23B-7

SNAP RING, SPACER THRUST WASHER, THRUST RACE ANDPRESSURE PLATE FOR ADJUSTMENT

M1233023000247

SNAP RING (FOR ADJUSTMENT OF BRAKE REACTION PLATE END PLAY)

PRESSURE PLATE (FOR ADJUSTMENT OF LOW-REVERSE BRAKE END PLAY AND SECOND BRAKEEND PLAY)

SPACER (FOR ADJUSTMENT OF OUTPUT SHAFT PRELOAD)

Underdrive clutch piston end play 1.2 − 1.4 mm

Overdrive clutch return spring retainer end play 0 − 0.09 mm

Overdrive clutch end play 1.2 − 1.4 mm

Reverse clutch end play 1.5 − 1.7 mm

Backlash between differential gear and pinion 0.025 − 0.150 mm

Item Standard value

Thickness mm Identification symbol

2.2 Blue

2.3 Brown

2.4 None

2.5 Blue


1.6 L

1.8 1

2.0 0

2.2 2

2.4 42.6 6

2.8 8

3.0 D


1.88 88

1.92 92

1.96 96

2.00 002.04 04

2.08 08

2.12 12

2.16 16

2.20 20

2.24 24

2.28 28

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SNAP RING, SPACER THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENTAUTOMATIC TRANSMISSION OVERHAUL23B-8

THRUST RACE (FOR ADJUSTMENT OF UNDERDRIVE SUN GEAR END PLAY)

THRUST WASHER (FOR ADJUSTMENT OF INPUT SHAFT END PLAY)

SPACER (FOR ADJUSTMENT OF DIFFERENTIAL CASE PRELOAD)

2.32 32

2.36 36

2.40 40

2.44 44

2.48 48

2.52 52

2.56 56

2.60 60

2.64 64

2.68 68

2.72 72

2.76 76


1.6 −1.7 −

1.8 −

1.9 −

2.0 −

2.1 −

2.2 −

2.3 −

2.4 −

2.5 −

2.6 −


1.8 18

2.0 20

2.2 22

2.4 24

2.6 26

2.8 28


1.10 J

1.19 L

1.28 N

1.37 P

1.46 R


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SNAP RING, SPACER THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENTAUTOMATIC TRANSMISSION OVERHAUL 23B-9

SNAP RING (FOR ADJUSTMENT OF UNDERDRIVE CLUTCH PISTON END PLAY AND OVERDRIVECLUTCH END PLAY)

SNAP RING (FOR ADJUSTMENT OF OVERDRIVE CLUTCH RETURN SPRING RETAINERS END PLAY)

SNAP RING (FOR ADJUSTMENT OF REVERSE CLUTCH END PLAY)

1.55 T

1.64 V

1.73 X

1.82 Z


1.6 None

1.7 Blue

1.8 Brown

1.9 None

2.0 Blue

2.1 Brown

2.2 None

2.3 Blue2.4 Brown

2.5 None

2.6 Blue

2.7 Brown

2.8 None

2.9 Blue

3.0 Brown


1.48 Brown

1.53 None

1.58 Blue

1.63 Brown


1.6 None

1.7 Blue

1.8 Brown

1.9 None

2.0 Blue

2.1 Brown

2.2 None

2.3 Blue

2.4 Brown

2.5 None


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TORQUE SPECIFICATIONSAUTOMATIC TRANSMISSION OVERHAUL23B-10

SPACER (FOR ADJUSTMENT OF BACKLASH BETWEEN DIFFERENTIAL SIDE GEARS AND PINION)

TORQUE SPECIFICATIONSM1233023

2.6 Blue

2.7 Brown

2.8 None


0.75 − 0.82 −

0.83 − 0.92 −

0.93 − 1.00 −

1.01 − 1.08 −

1.09 − 1.16 −


Item N ⋅mTRANSMISSION

Roll stopper bracket bolts 70 ± 10

Wiring harness bracket bolts 23 ± 3

Control cable bracket bolts 23 ± 3

Eye bolt 24 ± 3

Oil cooler feed tube clamp bolts 11 ± 1

Input shaft speed sensor 11 ± 1

Output shaft speed sensor 11 ± 1

Manual control lever mounting nuts 22 ± 3

Inhibitor switch mounting bolts 11 ± 1

Sealing cap mounting bolts 5.0 ± 1.0

Valve body cover bolts 11 ± 1

Manual control shaft detent mounting bolts 6.0 ± 1.0

Valve body mounting bolts 11 ± 1

Fluid temperature sensor mounting bolts 11 ± 1

Converter housing mounting bolts 48 ± 6

Oil pump mounting bolts 29 ± 2

Transfer drive gear mounting bolts 34 ± 2

Rear cover mounting bolts 23 ± 3Output shaft lock nuts 170 ± 10

Output shaft bearing retainer mounting bolts 29 ± 2

COMPONENTS

Differential drive gear bolts 135 ± 5

Valve body fastening bolts 11 ± 1

Solenoid valve support mounting bolts 6.0 ± 1.0

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SEALANTSAUTOMATIC TRANSMISSION OVERHAUL 23B-11

SEALANTSM1233000500218

FORM-IN-PLACE GASKET (FIPG)This transmission has several areas where the form-in-place gasket (FIPG) is used for sealing. To ensurethat the FIPG fully serves its purpose, it is necessaryto observe some precautions when applying it. Beadsize, continuity and location are of paramountimportance.Too thin a bead could cause leaks. Too thick a bead,on the other hand, could be squeezed out of location,causing blocking or narrowing of fluid passages. Toprevent leaks or blocking of passages, therefore, it isabsolutely necessary to apply the FIPG evenlywithout a break, while observing the correct beadsize.FIPG hardens as it reacts with the moisture in theatmospheric air, and it is usually used for sealingmetallic flange areas.

DisassemblyParts sealed with a FIPG can be easily removedwithout need for the use of a special method. Insome cases, however, the FIPG in joints may have tobe broken by tapping parts with a mallet or similartool.

Surface PreparationThoroughly remove all substances deposited on theFIPG application surface, using a gasket scraper.Make sure that the FIPG application surface is flatand smooth. Also make sure that the surface is freefrom oils, greases and foreign substances. Do not failto remove old FIPG that may remain in the fastenerfitting holes.

FIPG ApplicationApplied FIPG bead should be of the specified sizeand free of any break. FIPG can be wiped awayunless it has completely hardened. Install the matingparts in position while the FIPG is still wet (in lessthan 10 minutes after application). Do not allow FIPGto spread beyond the sealing areas duringinstallation. Avoid operating the transmission orletting oils or water come in contact with the sealedarea before a time sufficient for FIPG to harden(approximately one hour) has passed.FIPG application method may vary from location tolocation. Follow the instruction for each particularcase described later in this manual.

Item Specified sealant

Rear cover Mitsubishi genuine sealant Part No. MD974421 or equivalent

Converter housing Mitsubishi genuine sealant Part No. MD974421 or equivalent

Valve body cover Mitsubishi genuine sealant Part No. MD974421 or equivalent

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SPECIAL TOOLSAUTOMATIC TRANSMISSION OVERHAUL23B-12

SPECIAL TOOLSM1233000

Tool Number Name Application

MD998333 Oil pump remover Removal of oil pump

MD998903 Spring compressor Removal and installation of one-way clutchinner race snap ring

MD998924 Spring compressorretainer

• Removal and installation of snap ring• Measurement of underdrive clutch,

overdrive clutch and reverse clutch end

plays

MB990607 Torque wrenchsocket

Removal and installation of output shaftlock nut

MB991625 Special socket (41) Removal and installation of output shaftlock nut

MD998412 Guide Installation of transfer drive gear and oilpump

MB991631 Clearance dummyplate

Measurement of brake reaction plate,second brake and low-reverse brake endplays

MD998913 Dial gaugeextension

Measurement of low-reverse brake endplays

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SPECIAL TOOLSAUTOMATIC TRANSMISSION OVERHAUL 23B-13

MB990930 Installer adapter Installation of output shaft taper rollerbearing outer race

MB990938 Handle • Use with installer adapter• Installation of input shaft rear bearing

MD998350 Bearing installer Installation of output shaft taper rollerbearing

MB990931 Installer adapter Installation of cap

MD998334 Oil seal installer Installation of oil pump oil seal

MD998907 Spring compressor Removal and installation of underdriveclutch snap ring

MB991628 Spring compressor Measurement of underdrive clutch andoverdrive clutch end plays

MD999590 Spring compressor Removal and installation of overdriveclutch snap ring


B990938

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SPECIAL TOOLSAUTOMATIC TRANSMISSION OVERHAUL23B-14

MB991790 Spring compressor Measurement of reverse clutch end play

MD998917 Bearing remover Removal of output shaft transfer drivengear

MD998801 Bearing remover • Removal of output shaft taper rollerbearing

• Removal of differential taper rollerbearing

MD998812 Installer cap Use with installer and installer adapter

MD998814 Installer 200 Use with installer cap and installer adapter

MD998823 Installer adapter(48)

Installation of output shaft taper rollerbearing and transfer driven gear

MB990936 Installer adapter Installation of output shaft taper rollerbearing outer race


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SPECIAL TOOLSAUTOMATIC TRANSMISSION OVERHAUL 23B-15

MD998813 Installer 100 Use with installer cap and installer adapter

MD998819 Installer adapter(40)

Installation of differential ball bearing

MD998800 Oil seal installer Installation of drive shaft oil seal


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TRANSMISSIONAUTOMATIC TRANSMISSION OVERHAUL23B-16

TRANSMISSIONDISASSEMBLY AND REASSEMBLY

M1233001000335

AK301024

Apply automatictransmission fluidto all moving partsbefore installation.

1

2

3

14

11

13

12

5

4

2

6

15

16

7

810

9

70 ± 10 N·m

70 ± 10 N·m

5.0 ± 1.0 N·m

6.0 ± 1.0 N·m

23 ± 3 N·m

23 ± 3 N·m

24 ± 3 N·m11 ± 1 N·m

11 ± 1 N·m

22 ± 3 N·m

11 ± 1 N·m

11 ± 1 N·m

1. Torque converter2. Roll stopper bracket3. Harness bracket4. Harness bracket5. Control cable support bracket6. Oil level gauge7. Eye bolt8. Oil cooler feed tube

9. Air breather10. Input shaft speed sensor11. Output shaft speed sensor12. Manual control lever13. Inhibitor switch14. Sealing cap15. Valve body cover16. Manual control shaft detent

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TRANSMISSIONAUTOMATIC TRANSMISSION OVERHAUL 23B-17

AK301025


17

19

20

2122

2627

29

28

18

23

24

25

11 ± 1 N ·m11 ± 1 N · m

11 ± 1 N ·m

AB

17. Valve body18. Gasket19. Snap ring20. Solenoid valve harness21. Strainer22. Second brake retainer oil seal23. Accumulator piston

24. Accumulator spring25. Accumulator spring26. Manual control lever shaft roller27. Parking pawl rod28. O-ring29. Manual control lever shaft

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AK30102648 ± 6 N ·m

29 ± 2 N · m

30

32

33

37

3840

31

34

39

3536


30. Converter housing31. O-ring32. Differential33. Spacer34. Oil filter35. Oil pump

36. Gasket37. Thrust washer #138. Underdrive clutch and input shaft39. Thrust bearing #240. Underdrive clutch hub

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AK301027 AB


41

42

78

4344

46

4748

54

5556

5758

5960

61

62

6566

67

68

69

7071

72

7374

7982

83

84

86

85

80

8175

7677

63

6453

52

50 5145

29 ± 2 N · m

34 ± 2 N ·m

170 ± 10 N ·m

23 ± 3 N · m

49

41. Parking pawl shaft42. Spacer43. Parking pawl spring44. Parking roller support shaft45. Parking pawl46. Parking roller support47. Rear cover48. Thrust race #849. Seal ring50. Input shaft rear bearing51. O-ring52. Thrust bearing #753. Reverse and overdrive clutch54. Thrust bearing #655. Overdrive clutch hub56. Thrust bearing #557. Planetary reverse sun gear

58. Snap ring59. Second brake60. Return spring61. Pressure plate62. Second brake disc63. Second brake plate

64. Planetary carrier assembly65. Snap ring66. Reaction plate67. Snap ring68. Low-reverse brake disc69. Low-reverse brake plate70. Pressure plate71. Wave spring72. Snap ring73. One-way clutch inner race74. O-ring75. Spring retainer76. Return spring77. Low-reverse brake78. Transfer drive gear79. Cap80. Lock nut

81. Output shaft82. Taper roller bearing83. Outer race84. Spacer85. Snap ring86. Transmission case

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DISASSEMBLY

! CAUTION• The automatic transmission includes many

high-precision parts. Handle these partsextremely carefully not to scratch or damagethem during disassembly and reassembly.

• Work bench should be covered with a rubber

mat and keep it clean at all times.• Do not wear any cloth gloves and do not useany rags during disassembly. Use only nyloncloth or paper towels if necessary.

• All removed parts must be washed clean.Metal parts may be washed in an ordinarysolvent, but they should be dried completelyusing compressed air.

• Clutch discs, plastic thrust plates and rubberparts should be washed in automatictransmission fluid (ATF) and keep them freeof dirt after washing.

• If the transmission has been found damagedand repaired, also disassemble and clean theATF cooler system.

1. Remove the torque converter.

2. Use a dial gauge to measure the input shaft endplay.

3. Remove each bracket.4. Remove the oil level gauge.5. Remove the oil cooler feed tube.

6. Remove the input shaft speed sensor and outputshaft speed sensor.

7. Remove the air breather.

! CAUTIONBe sure to remove the manual control levermounting nut before removing the valve body. Ifthe removal sequence is reversed, the inhibitorswitch could be broken.8. Remove the manual control lever, then remove

the inhibitor switch.

9. Remove the sealing cap.

AK301061ABInput shaft

AK300218AC

Output shaft speed sensorInput shaft speed sensor

AK301296

AK300219 AC

Inhibitor switch

Manual control lever

AK300220

AK300221

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10.Remove the valve body cover.

11.Remove the manual control shaft detent.

12.Disconnect the solenoid valve harness from thevalve body by undoing the fruid temperaturesensor and all the connectors.

13.Remove the valve body mounting bolts (twentysix pieces) .

! CAUTIONBe careful not to lose the steel balls (two pieces).14.Remove the valve body, gasket and the steel

balls (two pieces).

15.Remove the snap ring from the connector, thenpush the connector into the transmission case toremove the solenoid valve harness.

16.Remove the strainer and second brake retaineroil seal.

17.Remove the accumulator pistons and theirsprings.

NOTE: Put tags to the removed accumulatorpistons and springs so that you will be able toreinstall them in the correct positions.

AK300222AC

Manual control shaft detent

AK300224ACFluid temperature sensor

AK300225

AK300226AC

Steel balls

No. Accumulator1 For low-reverse brake

2 For underdrive clutch

3 For second brake

4 For overdrive clutch

AK300227AC

Snap ring

Connector

AK300228

Strainer

AC

Second brakeretainer oil seal

AK300229AC

21 3 4

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18.Remove the manual control lever shaft roller.19.Remove the manual control lever shaft and the

parking pawl rod.

20.Remove the converter housing mounting bolts,then remove the converter housing.

21.Remove the O-rings (two pieces).

22.Remove the differential and spacer.

23.Remove the oil filter.

24.Remove the oil pump mounting bolts.

25.Use special tool oil pump remover (MD998333) inposition shown in the drawing.

26.Screw the special tools Oil pump remover(MD998333) evenly to remove the oil pump.

27.Remove the oil pump gasket.

28.Remove the thrust washer #1.

AK300230

Parking pawl rodManual controllever shaft roller

Manual controllever shaft

AC

AK301084

AK300232

AK301085AB

DifferentialSpacer

AK300234

AK300235

AK300236AC

MD998333

AK300237

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29.Holding the input shaft, remove the underdriveclutch and input shaft.

30.Remove the thrust bearing #2.

31.Remove the underdrive clutch hub.

32.Pull out the parking pawl shaft, then remove thespacer and spring.

33.Remove the parking roller support shafts (twopieces), then remove the parking pawl andparking roller support.

34.Remove the rear cover.35.Remove the thrust race #8.36.Remove the seal rings (four pieces).37.Remove the input shaft rear bearing.

38.Remove the O-rings (three pieces).

39.Remove the reverse and overdrive clutch and thethrust bearing #7.

AK300238

AK300239

AK300240

AK300241

AK300242

AK300463

AK300464

AK300465

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48.Remove the reaction plate and brake disc.

49.Remove the snap ring.

50.Remove the brake plates (three pieces), brakediscs (four* pieces) and pressure plate (onepiece).NOTE: *Includes the brake discs removed in step48.

51.Remove the wave spring.

52.Use the special tools to press down the one-wayclutch inner race, then remove the snap ring.

• Spring compressor (MD998903)• Spring compressor retainer (MD998924)

53.Remove the one-way clutch inner race, O-ring,spring retainer, return spring, and low-reversebrake.

54.Remove the four or three of the transfer drivegear mounting bolts. Then turn the gear 1/8 of a

turn (45 ° ) and remove the remaining three or fourbolts.

55.Remove the transfer drive gear.

AK300474

AK300475

AK301089

AK300477

AK300478

MD998903MD998924

AC

AK300479

AK300480

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REASSEMBLY! CAUTION

• Never reuse any gasket, O-ring, and oil seal.Always replace them with new ones.

• Never use any product other than bluepetrolatum jelly or white Vaseline to lubricateor hold parts during assembly.

• Apply ATF to friction elements, rotating parts,and sliding parts before installation.Soak newclutch discs or brake discs in ATF for at leasttwo hours before installing them.

• Never apply sealant or adhesive to gaskets.• When a bushing requires replacement,

replace the assembly of which the bushingforms a part.

• Never use any cloth gloves or any rags duringreassembly. Use only nylon cloth or papertowels if necessary.

• Change also the ATF in the cooler circuit.

1. Use the special tool Guide (MD998412) to installthe transfer drive gear.

2. Tighten the transfer drive gear mounting bolts to

the specified torque of 34 ± 2 N ⋅m .3. Install the low-reverse brake, return spring and

spring retainer.4. Fit a new O-ring in the groove in the one-way

clutch inner race.

5. Locate the identification notches on the one-wayclutch inner race, then install the one-way clutchinner race in the transfer drive gear bearing withthe notches aligned with the A-A line as shown inthe drawing.

6. Use the special tools to hold down the one-wayclutch inner race, then fit the snap ring in position.

• Spring compressor retainer (MD998924)• Spring compressor (MD998903)

AK301090 AB

MD998412

AK300489

AK301091

Transmission case

Identificationnotches

ABA

A

AK300478

MD998903MD998924

AC

AK300477

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7. Install the wave spring on the low-reverse brakepiston.

8. Install the brake discs (four pieces), brake plates(three pieces), and snap ring for the low-reversebrake .NOTE: Do not install the pressure plate yet.

9. Install the special tool on the stack of the brake

discs.10.Install the reaction plate and the snap ring thatwas removed during disassembly.

11.Move up the special tool Clearance dummy plate(MB991631) to check whether the end play of thereaction plate is within the standard value range.If necessary, remove the snap ring that has beeninstalled in step 10 and install another appropriatesnap ring.

Standard value: 0 − 0.16 mm12.Install the brake discs (two pieces) and brake

plate (one piece) for the second brake.NOTE: Do not install the pressure plate yet.

13.Install the special tool Clearance dummy plate

(MB991631).14.Install the return spring, second brake piston, andsnap ring.

15.Move the special tool Clearance dummy plate(MB991631) to measure the amount ofmovement. Select a pressure plate whosethickness corresponds to the measured amount ofmovement from the following table.

Standard value (reference): 0.49 − 0.95 mAvailable pressure plates

16.Turn the transmission upside down.

AK301092

Reaction plate

Snap ring

MB991631

AB

AK301093AB

Second brake pistonSnap ring

MB991631

Returnspring

Amount ofmovement mm

Thicknessmm

Identificationmark

0.3 − 0.5 1.6 L

0.5 − 0.7 1.8 1

0.7 − 0.9 2.0 0

0.9 − 1.1 2.2 2

1.1 − 1.3 2.4 4

1.3 − 1.5 2.6 6

01.91.8

1.7

1.6

1.5

1.4

1.31.2

1.11.0 .9 .8

.7

.6

.5

.4

.3

.2.12.0

AK202295AE

MB991631

AK301094 AB

Amount ofmovement

AK301095AB

Amount ofmovement

MD998913

MB991631

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17.Move the special tool Clearance dummy plate(MB991631) and measure the amount ofmovement using a dial gauge fitted with thespecial tool Dial gauge extension (MD998913).Select a pressure plate whose thicknesscorresponds to the measured amount ofmovement from the following table.

Standard value of low-reverse brake endplay (reference):1.05 − 1.51 mmAvailable pressure plates

18.Remove all the parts has been installed in steps7. through 17.

19.Install the snap ring in the groove formed in theoutput shaft hole in the transmission case.

20.Install the thinnest spacer (thickness: 1.88mm) foradjusting the output shaft preload.

21.Use the special tool to drive the output shaftbearing outer race into the transmission case.

• Installer adapter (MB990930)• Handle (MB990938)

! CAUTIONDo not reuse the output shaft bearing retainermounting bolts as they are pre-coated with asealant.22.Install the output shaft bearing retainer mounting

bolts and tighten them to the specified torque of29 ± 2 N ⋅m.

23.Use the special tool Bearing installer (MD998350)to install the taper roller bearing on the outputshaft.

! CAUTION

The lock nut thread is left-handed.24.Apply ATF to a new lock nut, and use the special

tool to tighten the lock nut to the specified torqueof 170 ± 10 N ⋅m. Then loosen the nut one turn,then tighten it again to the specified torque of 170± 10 N ⋅m.

• Torque wrench socket (MB990607)• Special socket (MB991625)

Amount ofmovement mm

Thicknessmm

Identificationmark

0.7 − 0.9 1.6 L

0.9 − 1.1 1.8 1

1.1 − 1.3 2.0 0

1.3 − 1.5 2.2 2

1.5 − 1.7 2.4 4

1.7 − 1.9 2.6 6

1.9 − 2.1 2.8 8

2.1 − 2.3 3.0 D

AK300492AC

MB990938

MB990930

AK300493

AK300494AC

MD998350

AK300484AC

MB990607MB991625

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25.Move the output shaft and to measure the amountof movement record the measurement.

26.Remove all the parts having installed in steps 20.through 24.

27.Select and install a spacer whose thickness isequivalent to the sum of the measurementrecorded in step 25., 1.88mm (the thickness of thespacer installed in step 20.), and an amountbetween 0.01 and 0.09mm (output shaft preload).

28.Repeat steps 21. through 24. to reinstall the parts.

29.Stake the lock nut (at two places).

30.Use the special tools to install the cap as shownin the drawing.• Installer adapter (MB990931)• Handle (MB990938)

31.Install the planetary carrier assembly.

32.Install the planetary reverse sun gear.

33.Install the wave spring on the low-reverse brakepiston.

34.Install the pressure plate (one piece) that hasbeen selected in step 17. Then install the brakediscs (four pieces) and brake plates (threepieces).

AK300495

AK300496

AK301096

MB990938MB990931

AB

2.5 – 3.0 mm

AK300498

AK300499

AK300500

AK301097

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35.Install the snap ring.

36.Install the reaction plate.

37.Install the snap ring that has been selected instep 11.

38.Install the brake discs (two pieces), brake plate(one piece), and the pressure plate (one piece)that has been selected in step 15.

39.Install the return spring and second brake.

40.Install the snap ring.

! CAUTIONBe sure to install the thrust bearing with theindicated side facing down.41.Install the thrust bearing #5.

AK300502

AK301098

AK300504

AK301099

AK300506

AK300507

AK301100AB

Install withthis side down

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IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

AK202491

No.8 No.7 No.6 No.5 No.4 No.3 No.2 No.1

O.D. mm I.D. mm Thicknessmm

Marking O.D. mm I.D. mm Thicknessmm

Marking

59 47 1.8 #1 48.9 37 1.6 #82.0 1.7

2.2 1.8

2.4 1.9

2.6 2.0

2.8 2.1

49 34 3.6 #2 2.2

49 34 3.6 #3 2.3

46 31 3.3 #4 2.4

49 34 3.6 #5 2.5

49 34 3.6 #6 2.6

59 37 2.8 #7

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! CAUTIONBe sure to install the thrust bearing with theindicated side facing down.42.Install the overdrive clutch hub and thrust bearing

#6 in the reverse and overdrive clutch.

! CAUTIONBe sure to install the thrust bearing with theindicated side facing down.43.Install the reverse and overdrive clutch and thrust

bearing #7.

44.Use the special tool Handle (MB990938) to press-

fit the input shaft rear bearing into the rear cover.45.Install the four seal rings.

46.Measure the end play of the underdrive sun gearusing the following procedure to select a thrustrace #8 of proper thickness.(1) Install the thinnest thrust race #8 (thickness:

1.6mm) on the thrust bearing #7.(2) Install the rear cover on the transmission and

tighten the bolts to the specified torque of 23 ± 3 N ⋅m.

(3) Turn the transmission upside down, thus

making the torque converter housing mountingend face up.

(4) Install the underdrive clutch hub on theunderdrive sun gear.

(5) Measure the end play of the underdrive sungear and record the measurement.

Standard value (reference): 0.25 − 0.45 mm(6) Remove all the parts installed in substeps (1)

through (4).

47.Install the O-rings (three places).48.Select a thrust race #8 whose thickness

corresponds to the measurement recorded insubstep (5) of step 46. from the table below and

install the thrust race on the thrust bearing #7.

AK301225

Thrust bearing #6

AB

AK301224

Thrust bearing #7Install withthis side down

AB

AK300511AC

MB990938

Measurement mm Thickness mm

0.3 − 0.4 1.6

0.4 − 0.5 1.7

0.5 − 0.6 1.8

0.6 − 0.7 1.9

0.7 − 0.8 2.0

AK300512AC

Underdrive clutch hub

AK300464

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49.Apply an approx. 1.6 mm diameter bead of form-in-place gasket (FIPG) to the rear cover along itscircumference as shown in the drawing.

Specified sealant:Mitsubishi genuine sealant Part No. MD974421

or equivalent

50.Install the rear cover and tighten its mountingbolts to the specified torque of 23 ± 3 N ⋅m .

51.Install the parting pawl, spacer and spring inposition, then install the parking pawl shaft.

52.Install the parking roller support, then install thetwo parking roller support shafts.

53.Install the underdrive clutch hub.

! CAUTIONInstall the thrust bearing with the indicated sidefacing down.54.Install the thrust bearing #2.

55.Install the underdrive clutch holding the inputshaft.

0.8 − 0.9 2.1

0.9 − 1.0 2.2

1.0 − 1.1 2.3

1.1 − 1.2 2.4

1.2 − 1.3 2.5

1.3 − 1.4 2.6

Measurement mm Thickness mm

AK301245AB

AK300463

AK300513

AK300514

AK300240

AK301246 AB

Install with this side down

AK300238

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56.Install the thinnest thrust washer #1 for adjustingthe input shaft end play (thickness: 1.8mm) on theunderdrive clutch retainer.

! CAUTIONNever use a gasket that has been tightened.57.Use the special tool Guide (MD998412) to install

a new oil pump gasket and the oil pump.58.Tighten the oil pump mounting bolts to the

specified torque of 29 ± 2 N ⋅m .

59.Measure the end play of the input shaft. Select athrust washer #1 of the thickness corresponding

to the measurement and replace with it the thrustwasher that has been installed in step 56.

Standard value (reference): 0.70 − 1.45mm

60.Install the oil filter.

61.Install the differential.

62.Place two pieces of about 10mm long, 3mmdiameter solder on the differential at the locationsindicated in the drawing.

63.Install the converter housing on the transmissioncase without applying FIPG. Tighten the mountingbolts to the specified torque of 48 ± 6 N ⋅m .

64.Remove the bolts and converter housing, andtake out the solder pieces.

AK300237

AK301247AB

MD998412

AK300517

AK300234

AK301312

AK301248AB

Solder

AK301084

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65.Use a micrometer to measure the thickness of thecrashed solder.

66.Select a spacer of the thickness equivalent to themicrometer reading plus the standard preloadvalue.

Standard preload value: 0.045 − 0.165mm

67.Install the spacer selected in the above step.

68.Apply an approx. 1.6 mm diameter bead of from-in-place gasket (FIPG) to the converter housingalong its circumference as shown in the drawing.


or equivalent

69.Install the two O-rings (two pieces).

70.Install the converter housing and tighten themounting bolts to the specified torque of 48 ±N⋅m .

71.Install the manual control lever shaft and parkingpawl rod.

72.Install the manual control lever shaft roller.73.Fit a new seal ring to each accumulator piston.

NOTE: All the four accumulator pistons and sealrings are identical.

AK301249

AK301085AC

Spacer

AK301252AB

AK300232

AK301084

AK300520

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74.Identify the accumulator spring for eachaccumulator and install it in the correct hole in thetransmission case together with the piston.NOTE: The accumulator springs are identified asshown in the table below.

75.Install the strainer and second brake retainer oilseal as shown in the drawing.

76.Fit a new O-ring into the groove in the solenoidvalve harness connector.

77.Insert the solenoid valve harness connector intothe hole in the transmission case from inside thecase. After making sure that the connector ispositioned as shown in the drawing, fit the snapring snugly into the connector groove.

78.Install the steel balls one each in the two holes on

the top of the valve body (outside valve body).79.Install the valve body and gasket. Make sure that

the pin of the manual valve is in place in thedetent plate groove in the manual control levershaft.

80.Install the valve body mounting bolts and tightenthem to the specified torque of 11 ± 1 N ⋅m .

No. Accumulator spring Blue inkmarking

1 For low-reverse brake Nomarking

2 For underdrive clutch Half ofsurface

3 For second brake Entiresurface

4 For overdrive clutch Nomarking

AK301313

1 2 3 4

AB

AK300229AC21 3 4

AK300228

Strainer

AC

Second brakeretainer oil seal

AK300227AC

Snap ring

Connector

AK300226AC

Steel balls

AK300225

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81.Install the oil temperature sensor and themconnect the connector to the valve body.

82.Install the manual control shaft detent spring anddetent.

83.Apply an approx. 2.5 mm diameter bead of from-in-place gasket (FIPG) to the valve body coveralong its circumference as shown in the drawing.


or equivalent

84.Install the valve body cover and tighten itsmounting bolts to the specified torque of 11 ±N⋅m .

85.Install the sealing cap.86.Install the inhibitor switch.

87.Install the manual control lever.

No. Solenoid valve Wirecolour

Connectorhousingcolour

1 Underdrivesolenoid valve

White/ red/red

Black

2 Overdrivesolenoid valve

Orange /red

Black

3 Low-reversesolenoid valve

Brown/ yellow

Milky white

4 Second solenoidvalve

Green/ red/red

Milky white

5 Damper clutchcontrol solenoidvalve

Blue/ yellow/ yellow

Black

AK300224ACFluid temperature sensor

AK300222AC

Manual control shaft detent

AK301264 AB

AK300221

AK300220

AK300219AC

Inhibitor switch

Manual control lever

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88.Press Face "A" of the air breather to be on thesame plane as the Face "B" of the transmissioncase as shown in the drawing.

89.Install the input shaft speed sensor and outputshaft speed sensor.

90.Apply Automatic Transmission Fluid on the bothsides of the new gasket and threads of theeyebolt, and then tighten to the specified torque of24 ± 3 N ⋅m .

91.Install the oil level gauge.92.Install the brackets.

! CAUTIONApply ATF to the oil pump drive hub beforeinstalling the torque converter. Be careful not todamage the oil seal lip when installing the torqueconverter.93.Install the torque converter, and secure it so that

the dimension (A) indicated in the drawing meetsthe reference value.

Reference value: 12.2 mm

AK203140 AC

A AB B

AK300218AC

Output shaft speed sensorInput shaft speed sensor AK301263AB

A

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OIL PUMPAUTOMATIC TRANSMISSION OVERHAUL23B-40

OIL PUMPDISASSEMBLY AND REASSEMBLY

M1233001300187

REASSEMBLY SERVICE POINTS>>A>B>B>A

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UNDERDRIVE CLUTCH AND INPUT SHAFTAUTOMATIC TRANSMISSION OVERHAUL 23B-41

UNDERDRIVE CLUTCH AND INPUT SHAFTDISASSEMBLY AND REASSEMBLY

M1233020900111

DISASSEMBLY SERVICE POINTS SNAP RING REMOVAL

Use the special tools to remove the snap ring.• Spring compressor (MD998907)• Spring compressor retainer (MD998924)

AK301265

6

2

15

13

12 14

3

11 15

10 7 4

5

91

8 12

11

9

8

1

45

7

6

2

14

3

13

10

AB


Disassembly steps1. Snap ring2. Input shaft3. Seal ring

>>D>C>C>C>B>A>A>A

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UNDERDRIVE CLUTCH AND INPUT SHAFTAUTOMATIC TRANSMISSION OVERHAUL23B-42

REASSEMBLY SERVICE POINTS>>A>B>C>D

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REVERSE AND OVERDRIVE CLUTCHAUTOMATIC TRANSMISSION OVERHAUL 23B-43

REVERSE AND OVERDRIVE CLUTCHDISASSEMBLY AND REASSEMBLY

M1233021200148

AK301275

3

1 2

4

56

8

17

7

18

19

910

12

11 16

14

15

13

3 7

11 16

14

18

12

19

5

6

17

15

10

9

131

2

4 8

Apply automatic

transmission fluidto all moving partsbefore installation.

AB

Disassembly steps>>G>F>F>F>E>D>D>D>C>A>A>B>A>A>A

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REVERSE AND OVERDRIVE CLUTCHAUTOMATIC TRANSMISSION OVERHAUL23B-44

DISASSEMBLY SERVICE POINTS SNAP RING REMOVAL

Use the special tools to remove the snap ring.• Spring compressor retainer (MD998924)• Spring compressor (MD999590)

REASSEMBLY SERVICE POINTS

>>A>B>C>D

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REVERSE AND OVERDRIVE CLUTCHAUTOMATIC TRANSMISSION OVERHAUL 23B-45

! CAUTIONSoak the clutch discs in ATF before installingthem.1. Assemble the clutch plates, clutch discs, and

clutch reaction plate with their non-toothedportions (A in the drawing) aligned with the hole(B in the drawing) formed in a crest of the reverse

clutch piston.

2. Orient the clutch reaction plate as shown in thedrawing when it is installed.

>>E>F>G

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PLANETARY CARRIER ASSEMBLYAUTOMATIC TRANSMISSION OVERHAUL23B-46

3. Check the clearance between the snap ring andthe clutch reaction plate. If the clearance is notwithin the standard value range, make adjustmentby selecting a snap ring of an appropriatethickness.

Standard value: 1.5 − 1.7 mm

PLANETARY CARRIER ASSEMBLYDISASSEMBLY AND REASSEMBLY

M1233002500151

AK301044AC

1

2

3

45

6

7

8

9

10


Disassembly steps1. Stopper plate

>>B>A>A

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PLANETARY CARRIER ASSEMBLYAUTOMATIC TRANSMISSION OVERHAUL 23B-47

REASSEMBLY SERVICE POINTS>>A>B

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LOW-REVERSE BRAKEAUTOMATIC TRANSMISSION OVERHAUL23B-48

LOW-REVERSE BRAKEDISASSEMBLY AND REASSEMBLY

M1233003700170

REASSEMBLY SERVICE POINTS>>A>A>A

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SECOND BRAKEAUTOMATIC TRANSMISSION OVERHAUL 23B-49

SECOND BRAKEDISASSEMBLY AND REASSEMBLY

M1233021800117

REASSEMBLY SERVICE POINT>>A>A>A

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OUTPUT SHAFTAUTOMATIC TRANSMISSION OVERHAUL23B-50

OUTPUT SHAFTDISASSEMBLY AND REASSEMBLY

M1233022100081

DISASSEMBLY SERVICE POINTS TRANSFER DRIVEN GEAR REMOVAL

Use the special tool Bearing remover (MD998917) toremove the transfer driven gear.

AK301036AC

1

2

3

4

5


Disassembly steps >>C>B>A

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OUTPUT SHAFTAUTOMATIC TRANSMISSION OVERHAUL 23B-51

TAPER ROLLER BEARING REMOVAL

Use the special tool Bearing remover (MD998801) toremove the taper roller bearing.

REASSEMBLY SERVICE POINTS>>A>B>C

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DIFFERENTIALAUTOMATIC TRANSMISSION OVERHAUL23B-52

DIFFERENTIALDISASSEMBLY AND REASSEMBLY

M1233003100219

DISASSEMBLY SERVICE POINTS BALL BEARING REMOVAL

Use the special tool Bearing remover (MD998801) toremove the ball bearings.

AK301282A


135 ± 5 N

1

2

86

5

3

4

7

5

6

8

9

2

Disassembly steps>>D>C>B>A>A>A>A>A

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DIFFERENTIALAUTOMATIC TRANSMISSION OVERHAUL 23B-53

REASSEMBLY SERVICE POINTS>>A>BC>D

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VALVE BODYAUTOMATIC TRANSMISSION OVERHAUL23B-54

VALVE BODYDISASSEMBLY AND REASSEMBLY

M1233005500202

AK300515AC

1

2

3

4

5

6

1

7

8

910

11

11

12

13

1415

1617

1819 20

6.0 ± 1.0 N

6.0 ± 1.0 N ·m

6.0 ± 1.0 N ·m

11 ± 1 N ·m

11 ± 1 N ·m

Apply automatictransmission fluidto all moving parts

before installation.

Disassembly steps1. Solenoid valve support

>>C>C>C>C>C>B>B>A>A>A>A>A>A

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VALVE BODYAUTOMATIC TRANSMISSION OVERHAUL 23B-55

AK300510 AC

21

22

23

24

2526

27

28

2930

31

3233

3435

36

3741

38

39

40

4243

44

45

4647

48

49

5051

52

535455

56

5758

59

60

61


Disassembly steps21. Roller22. Damper clutch control valve sleeve23. Damper clutch control valve24. Damper clutch control valve spring25. Plate26. Screw27. Regulator valve spring28. Regulator valve29. Plate30. Fail-safe valve A sleeve31. Fail-safe valve A232. Fail-safe valve A spring33. Fail-safe valve A134. Plate35. Plug36. Torque converter valve37. Torque converter valve spring38. Plate39. Fail-safe valve B sleeve40. Fail-safe valve B41. Inside valve body42. Roller

43. Overdrive pressure control valvesleeve

44. Overdrive pressure control valve45. Overdrive pressure control valve

spring46. Roller47. Low-reverse pressure control valve

sleeve48. Low-reverse pressure control valve49. Low-reverse pressure control valve

spring50. Plate51. Plug52. Switch valve53. Roller54. Underdrive pressure control valve

sleeve55. Underdrive pressure control valve56. Underdrive pressure control valve

spring57. Roller

Disassembly steps (Continued)

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VALVE BODYAUTOMATIC TRANSMISSION OVERHAUL23B-56

DISASSEMBLY SERVICE POINT SOLENOID VALVE REMOVAL

Mark each solenoid valve with white paint to identifyits location.

REASSEMBLY SERVICE POINTS>>A>B>C

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DRIVE SHAFT OIL SEALAUTOMATIC TRANSMISSION OVERHAUL 23B-57

DRIVE SHAFT OIL SEALDISASSEMBLY AND REASSEMBLY

M1233004300131

REASSEMBLY SERVICE POINT>>A>B>A>B

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Documents

GR00003800-23B.pdf